mcmurdo Fastfind User manual

Fastfind PLB
(including Max, MaxG and Plus versions)
Service Manual
mcmurdo
mcmurdomcmurdo
mcmurdo

Table of Contents
1. Introduction.................................................................................................................... 1
1.1. Scope....................................................................................................................... 1
1.2. Applicability .............................................................................................................. 1
1.3. Servicing equipment ................................................................................................ 2
1.4. Safety notices .......................................................................................................... 2
1.5. False alarms ............................................................................................................ 4
2. ssessment.................................................................................................................... 5
2.1. aintenance tasks ................................................................................................... 5
2.2. Routine testing ......................................................................................................... 5
2.3. GPS upgrade ........................................................................................................... 5
2.4. Assessment ............................................................................................................. 5
3. Maintenance procedures............................................................................................... 8
3.1. Inspection................................................................................................................. 8
3.2. Functional tests........................................................................................................ 9
3.3. essage read ........................................................................................................ 11
3.4. Internal inspection.................................................................................................. 13
3.5. Disassembly........................................................................................................... 13
3.6. Leak testing............................................................................................................ 13
3.7. Battery replacement............................................................................................... 13
3.8. Antenna rewinding ................................................................................................. 15
3.9. Programming ......................................................................................................... 18
4. Fault Finding ................................................................................................................ 20
5. Repair Procedures....................................................................................................... 20
6. Spares........................................................................................................................... 21
ppendix 1 : Specification.................................................................................................. 22

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PLB service manual Issue 4 Page
1
1. INTRODUCTION
The Personal Location Beacon (PLB) is a device used to transmit an alert in the event of an
emergency. Power is supplied by a Lithium Battery.
The Fastfind range of PLB contains these functions:
406 Hz transmitter A powerful (5 Watt) transmission encoded with
a unique serial number identifying the owner.
This signal is relayed via satellite to the
rescue centre.
The frequency of transmission is determined by the
product:
ax/G 406.037 Hz
Fastfind/Plus 406.028 Hz
121.5 Hz transmitter A low power transmission which acts as
a homing beacon.
Buzzer Audible alarm/indicator.
The Fastfind Plus and ax G PLBs also contain a GPS (Global Positioning System) receiver,
enabling it to determine its position and to include this information in the 406 Hz
transmission.
1.1. Scope
This manual provides the complete instructions issued to maintenance providers to enable
routine and emergency servicing of the PLB equipment listed below. This manual represents
the original equipment manufacturer’s (OE ) service documentation applicable to these
products.
1.2. pplicability
This manual applies to the following 406 Hz PLBs:
• c urdo Fastfind – all variants
• c urdo Fastfind Plus – all variants
• c urdo ax and ax G – all variants
NOTE: The method of distinguishing the various versions of PLB is by serial number. This is
located on the label underneath the battery pack and also in the User anual supplied with
the unit.
Serial Number Type Battery class Notes
600-XXXXXX Fastfind 1 or 2
630-XXXXXX Fastfind orse coding 1 or 2 USA only
500-XXXXXX Fastfind Plus 1 or 2 GPS
530-XXXXXX Fastfind Plus orse coding 1 or 2 USA only GPS
800-XXXXXXX Fastfind ax G 2 GPS
810-XXXXXXX Fastfind ax 2
NOTE: There are 2 variants of battery;
Class1 (-40 to +55C) or Class 2 (-20 to +55C)
W RNING: The orse-coded variants (530 and 630) cannot be converted to
standard coding, and vice versa. At this time, orse-coded variants may only be
registered in the United States.

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1.3. Servicing equipment
All agents are obliged to possess specialised equipment to ensure that PLBs are serviced
correctly. A message reader (ARG5410 or equivalent) is mandatory.
Equipment:
essage reader
PLB programming kit (FPROG – c urdo P/N 85-923/924)
Thermometer (required for leak testing)
Hand tools:
Antenna rewind key ( c urdo P/N 85-753)
Flat blade torque screwdriver
Posidrive #1 torque screwdriver
NOTE: A 121.5 Hz monitor should be available (as a general surveillance instrument for all
product servicing). This will detect the homing transmission and raise an alarm if the PLB is
accidentally activated outside the screened enclosure.
1.4. Safety notices
Please read the following information for your safety:
This product has been assessed as presenting negligible hazard in a sealed serviceable
state.
Safety analysis
The following table summarises the nature of the hazard which may be present when the unit
is opened or serviced; each hazard is discussed at greater length in the detailed sections.
Hazard cause Hazard identification Precautions
Lithium battery Explosive risk, corrosive fumes,
fire, biological hazard
Handle appropriately, avoid
contact
Radio frequency
radiation
Physiological hazard Avoid close or prolonged
exposure. Do not touch the
antenna during 406 Hz
transmissions
Adhesives Skin irritation, fumes Avoid contact, ventilate well
IPA (propanol) Irritation, highly flammable Avoid contact, ventilate well

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Lithium batteries
Hazardous chemicals Wear gloves
The batteries used in these products contain Lithium (Li). Lithium is inflammable, reacts
violently with water and constitutes a biological hazard. These batteries are HAZARDOUS if
short-circuited, punctured, incinerated or deformed. Lithium batteries must not be short
circuited.
Lithium batteries must be handled, transported and disposed of using appropriate safety
precautions and in accordance with applicable transportation regulations. The -20 °C battery
contains 7 grams of Lithium, the –40 °C battery contains 4.8 grams.
In the event of leakage of the battery electrolyte (which can be recognised by a pungent
odour), take care to avoid contact, particularly with open wounds; do not ingest the material.
Do not attempt to discharge a leaking battery – remove it using appropriate handling
materials and seal in a plastic bag, then dispose of it through an approved environmental
disposal agent, or in accordance with local regulations.
Radio frequency radiation
A PLB produces radio frequency radiation when it is activated. The radiated
level is below 5 W with a duty cycle of 1%. Due to the low duty cycle this is
not considered to be a hazard; however, it is advisable to avoid touching the
antenna of a transmitting PLB.
General precautions for chemical agents (adhesives, greases, IP )
Observe all safety precautions relevant to the country of operation. As a general rule,
protective overalls, gloves and goggles should be worn when handling these chemical
agents, but different countries may have additional requirements which must be observed.
Ensure that all chemical agents are handled in accordance with the manufacturer's
instructions, and that suitable protective clothing is worn.
ake sure that the working area is well ventilated, and that chemical substances are not left
exposed. Observe good hygiene practices; do not eat, drink or smoke when handling
chemicals.
Read the manufacturer's instructions before using any chemical agent.
Wear goggles Wear overalls Wash hands Wear gloves
Radio frequency
radiation

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1.5. False alarms
Every care must be taken to avoid the generation of false alarms.
For test purposes the PLB may be operated in the following ways without generating a false
alarm:
1. Self test mode (but avoid repetitive self tests)
2. Live mode for less than 120 seconds (after 120 s a live transmission is made)
3. Live mode in a screened enclosure
If for any reason the PLB is activated outside a screened enclosure (other than as a self test
and for less than 120 seconds), it must be assumed that a false alarm has been generated. It
is not sufficient to de-activate the PLB immediately – once the transmission has been made
the alert has been generated.
The rescue services must be informed immediately that there has been a false alarm. Use
any means available to contact the nearest Rescue Coordination Centre (RCC); state that
there has probably been a false alarm, identify the location of the PLB and if possible give
the PLB ID.
De-activating a live PLB
Press and hold the OFF/Test button; wait for the red LED to extinguish.
If the LED does not extinguish, remove the battery (refer to section 3.8) and return the PLB to
c urdo for investigation.

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2. SSESSMENT
2.1. Maintenance tasks
Servicing agents are reminded that it is their responsibility to ensure that the procedures are
followed, that only c urdo approved parts are fitted, and that good practice is observed.
False alarms caused by inadvertent activation must be avoided. We recommend that PLB
testing is only done in self-test mode to avoid false alarms.
The functions which can be performed by servicing agents are:
• Routine testing
• Reprogramming
• essage reading and verification
• Battery replacement
• Leak testing if required
• Antenna rewind
2.2. Routine testing
Every PLB should be tested monthly by its owner to ensure functionality. Wherever possible
the PLB should also be inspected for mechanical damage.
Whatever the reason for the return of a PLB to a maintenance agent, the PLB must be
subjected to a full assessment before any other action is taken. The agent has a
responsibility to ensure the PLB is completely serviceable and is fit for its purpose.
2.3. GPS upgrade
A product improvement was implemented on the Fastfind Plus PLB. Upgraded PLBs are
easily recognized by the warning on top of the PLB. If an original Fastfind Plus is received,
every effort should be made to have the PLB upgraded – contact
[e-mail] for advice.
2.4. ssessment
Every PLB returned for servicing, of whatever nature, must be fully assessed to determine its
operational status.
ssessment form
The flowchart and assessment form, shown on the next pages, are essential tools in
performing diagnosis.
The assessment form (or equivalent) must accompany any warranty return to the
manufacturer, and may be used to support customer billing. The first section of the form
records the customer, the PLB and the reason for return (as 'Customer comments'). It is
essential to record the identity details from the PLB rear label, as these will be necessary for
comparison with the transmitted data. The expiry date must be noted; if less than 6 months
life remains, a battery change should be recommended to the customer. Procedures for the
rest of the form are detailed in section 3.
Warning notice on
upgraded Fastfind Plus

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ssessment and service flowchart
RECEIPT
ssessment
Inspect
Self test
essage read
Verify self test
Verify
message read
Program
Print forms & labels
Rewind
Fit tamper cover
Fit seal
Return
to
customer
ntenna
deployed
Programming
required
Return
to
factory
Fit battery
Test
only
Battery
expiry
Forms
OK Fault found
Fit labels Replace battery
if necessary
Remove battery
Fit battery
Leak test

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PLB SSESSMENT Ref No Date
Customer Address
Type an. Serial No Battery
expiry date
Country ID Battery part no. 85-720 85-740
Customer comments
Warranty
claim YES/NO
INSPECTION
PLB
Tamper seal intact 
Flip lid present 
Plastic/Gasket OK 
Upgraded 
Battery pins OK 
Battery within date 
Battery voltage
Identity clear 
Switches clean 
Lanyard OK 
Antenna undamaged 
(if deployed)
Comments
FUNCTION L TEST
Self test
Red LED ON 
Green LED flash 3 
Buzz 3 times 
Live mode
Red LED stays on 
Buzzer sounds 
Comments
MESS GE RE D ID
121 sweep heard  Country
406 frequency OK  an Serial No
GPS (if Fastfind Plus)
GPS detected by Reader 
Lat (XXXXX) 
Long (XXXXX) 
Comments
Conclusions
Assessed by Signed Date
New Parts Fitted
Tamper seal 
Battery kit 
Antenna rewind 
Flip lid 
O rings 
Pass Fail

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3. M INTEN NCE PROCEDURES
3.1. Inspection
Tamper seal Check tamper seal is intact.
If seal is damaged or is non-standard in any respect, battery state
must be considered suspect.
Contact customer to confirm any history of PLB activation.
Plastic damage Check that the flip lid is present.
Check plastic body for signs of damage.
Check gasket for signs of wear or cracking. Slight damage not
extending beyond the edge of the plastic body is acceptable.
GPS For GPS-fitted units only, check that there is no metallic object, such
as a metallised label, in the vicinity of the GPS antenna
Battery expiry If the battery has less than 6 months before expiry, contact
customer and recommend replacement.
Battery Remove the battery and check that the battery pins are straight and
are not corroded. easure the open circuit battery voltage; this must
be greater than the appropriate limit in the table below, otherwise
reject the battery. Check that the ‘O’-rings are present and in good
condition. Ensure that the Identity information is clear. Refit the battery.
Battery voltage limits
85-720-004 (-20 °C Class 2) >12.0 V
85-740-004 (-40 °C Class 1) >11.8 V
Switches Check that the switches are clean and not masked by dirt
Lanyard Check that the lanyard has not suffered damage
Antenna damage If the antenna has been deployed, ensure that it is not creased
or cracked.
Unit identity While the battery is removed, check that the programmed information
on the rear label is clear and correct
GPS antenna is
under this area

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3.2. Functional tests
Self test
1. Slide a finger under the red anti-tamper cover, press and hold down the
OFF/Test button
2. The red LED should come on
3. After approximately 10 seconds the green light must flash 3 times and the buzzer
must sound three times to confirm self-test has passed.
NOTE: If the unit fails self test then:
a. Repeat the test but place the unit on a flat surface (do not hold it) - sometimes the
hand can cause changes in the RF matching of the antenna – consequently self test
may fail.
b. Check that the pin holding the antenna in position is made of black plastic (the early
units had stainless steel pins – these were found to sometimes change the RF
matching of the antenna). Replace steel pins with plastic.
Live test
NOTE: As the tamper cover must be removed for access to the ON button, this test should
only be performed if there is doubt about the result of a self-test.
1. Press the ON button for at least one second
2. The red LED lights continuously
3. Confirm the buzzer sounds regularly every few seconds
4. Without delay, press and hold the OFF button until the red LED extinguishes and
stays off (approx 3 seconds)
This must be done within 120 seconds to avoid a live transmission.
If the red LED starts to flash, a live transmission has occurred –
refer to Section 1.5 immediately

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GPS Test
The GPS system should be tested only when its operation is suspect.
Because of the time required to obtain a GPS position, it is necessary to operate the PLB in
the live transmission mode, and hence it must be contained in a screened enclosure for the
duration of this test. This in turn means that the GPS signal must be re-transmitted inside the
screened enclosure using a GPS repeater and internal antenna. The test may take up to 5
minutes and requires the external GPS antenna to have a view of at least 4 GPS satellites.
It is necessary to verify the content of the GPS position information transmitted by the PLB,
using a suitable message reader connected to an antenna inside the screened box.
Successful acquisition of a GPS position is indicated by the flashing green light on the PLB.
Equipment
Screened enclosure
essage reader (ARG5410 or equivalent)
GPS antenna, repeater and retransmitting antenna
Procedure
Switch on PLB and immediately place it inside the screened enclosure.
onitor the 406 Hz transmissions displayed by the message reader until positional
information is obtained.
If the positional information has not been obtained within 5 minutes, wait until immediately
after a 406 Hz transmission and switch off the PLB. Restart the test.
GPS
antenna
Power supply
12v 300mA
Screened
enclosure
Repeater
Internal
antenna
PLB under
test
50 ohm
screened
coax cable.
15 max
50 ohm
screened coax
cable. 1
10dB
attenuator
essage
reader

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3.3. Message read
NOTE: When the antenna is not deployed, the transmission power is greatly reduced. The
essage Reader must be very close to the PLB to detect this weak signal.
Use a " essage Reader" to verify the unique ID. A typical instrument is the ARG5410, which
is used here to describe the process. For full details of the operation of the Reader, refer to
its handbook; only an outline is given here. The procedure is as follows:
1. On the Reader select RECV mode
2. Position the Reader approx. 1 m (3 feet) from the PLB if the antenna is deployed,
or as close as possible if the antenna is not deployed
ESSAGE
READER
ANTENNA
3. On the PLB press and hold the OFF/Test button
4. After about 4 seconds the Reader should emit three bursts of sound
This proves the 121.5 Hz homer is radiating and modulating correctly. If the ARG
5410 Reader is not used, then another suitable facility for detecting the 121.5 Hz
swept tone must be provided (an air band receiver for example).
5. The Reader should then beep and report S’TEST OK
6. The Reader will revert to its enu. Select VIEW mode
7. Use ← → keys to view the decoded 406 Hz message content
8. Confirm the frequency – Fastfind/Plus is 406.028 Hz and ax/G is 406.037 Hz.
This proves the 406 Hz transmitter is radiating within the correct frequency band. If
the ARG5410 Reader is not used, then another facility for measuring the 406 Hz
frequency must be provided (a spectrum analyser for example). Note that on some
older readers the frequency will be read as out of range.
9. Confirm the 15 digit ID agrees with PLB rear identity label UIN
(but see note on following page)
This proves the 406 Hz transmitter is modulating correctly and the PLB is
programmed with the correct identity. If the ARG5410 is not used then another facility
for message decoding must be provided (other message readers).
10. Confirm the Country is correct
11. If fitted, check that the GPS is identified and that the LAT and LONG are
displayed (as *****). Note: The ARG5411 will not perform this function.
Q
11:25
Mesg#11 S’TEST OK
ID: 9D0D071D3B00013
406.0257 MHz P SS
Typical screen

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Common problems with message read
Audio tone If not heard then reduce range from 1m to 0.3 m to
help.
Frequency If outside limits, repeat self-test several times to
provide a warm-up.
Bad frame/Data error/
Self test bad/
Unmodulated
This error message occurs if the Reader fails to
synchronize. It may also occur if the antenna is not
deployed, in which case reposition the Reader.
Repeat the test.
BCH2 Error A GPS PLB only transmits the first 112 bits of its
Long (144-bit) essage during self test. This may
cause some readers to report a checksum (BCH2)
error.
Incorrect data Early software versions of Readers may not be
capable of reading GPS long messages.
Note that an exhausted Reader battery can cause bad frames.

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Normal mode
It is possible to message read in live mode provided the PLB is in a screened enclosure. In
this case the Reader reports NOR AL OK and the first 3 bytes of the full hex message are
FF FE 2F… instead of the usual FF FE D0… for self test mode.
GPS fix information
It is important to understand that the Hex ID reported by the Reader may change (depending
on the reader) when the PLB acquires a GPS position. The first ID reported corresponds with
the ID printed on the PLB label (unless there is a fault or the PLB is wrongly identified);
however, this ID may then change and be reported differently after a GPS fix. These
examples should make this clear:
First ID reported 2DD4C026BF81FE0
Lat * * * * * *
Long * * * * * *
Subsequent ID reported 2DD4C0269966022
Lat 50N49.73
Long 1W3.4
3.4. Internal inspection
No internal inspection is permitted.
3.5. Disassembly
No disassembly of the PLB is permitted.
3.6. Leak testing
Leak testing is not required for routine servicing, but may be performed if the PLB sealing is
suspect.
Gross leak test
Use hot water at +60 + 5 ºC. Cooler water will not raise the internal
pressure enough, hotter water will damage the PLB.
The battery pack must be fitted for this test.
1. Remove the flip-top lid to avoid trapping air
2. Immerse the PLB in the hot water until it is just submerged
3. Dislodge ALL trapped air from the gasket and the tamper cover
4. For the next 5 minutes, rotate the PLB and check for any escaping bubbles around
the seal and switches
(NOTE: There will probably be air trapped under the battery pack)
5. If there is any sign of water ingress, remove PLB quickly
6. Remove PLB from water, wipe thoroughly dry.
7. Replace the flip-top lid
ny escape of bubbles indicates a fault. Return the PLB to c urdo for servicing.
3.7. Battery replacement
If the PLB has been activated, it is recommended that the battery is replaced regardless of
the duration of activation. The PLB battery has a shelf life of 5 years from date of
manufacture. The expiry date is shown on the battery label.
HOT

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Contents of kit
Battery pack –20 °C 85-720-004
or
Battery pack –40 °C 85-740-004
‘O’ ring 85-725 x 2
Screw 3x20 85-728
The replacement procedure is the same for both types of battery.
NOTE: Later –20 °C battery packs are larger than the original versions; this modification
enables the PLB to float when fitted with the later battery pack.
Method
1. Remove the battery retaining screw and detach the battery. Dispose of this battery in
accordance with local regulations.
2. Inspect the battery pins on the PLB to ensure they are not bent or corroded.
3. Fit the two ‘O’ rings to the battery connectors. It is recommended to fit these to the
pillars, rather than placing them in the recesses of the battery pack, but either method
may be used as desired.
4. Assemble the battery pack to the PLB, taking care that the ‘O’ rings stay in place.
5. Fit the securing tag attached to the lanyard. It is essential that this part is fitted, as
it forms part of the PLB sealing system.
6. Fit the screw to retain the battery pack. Tighten the screw to a torque of 25 cNm.
Alternative fitting methods for ‘O’ rings
All parts fitted, ready for tightening
NOTE:
For clarity, the lanyard
has been omitted from
these illustrations
Battery pins

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W RNING: The ‘O’ rings and lanyard must be fitted correctly, otherwise the PLB will
not be watertight.
Battery disposal
Hazardous chemicals Use gloves
Lithium battery packs should be discharged slowly, then disposed of through an approved
environmental disposal agent, or in accordance with local regulations.
The rate of discharge must not exceed 100 mA. It is recommended to discharge through a
resistance of a minimum value of 10 ohms per volt of the nominal battery voltage eg a
resistor of 120 ohms (2 W rating) is satisfactory for a 12 V battery.
UNDER NO CIRCU STANCE AY THE BATTERY BE SHORT-CIRCUITED.
If the battery shows signs of electrolyte leakage, do not attempt to discharge. Refer to the
Safety Notices (section 1.4) for advice on correct handling.
3.8. ntenna rewinding
This details the procedure used to refit the antenna after it has been unfurled. A specialized
tool, the antenna winding key (85-753), is required for this operation.
Contents of kit (85-765)
Tamper cover 85-727
Tamper cover seal 85-733
Tamper label 85-726
Screw 3x6 85-743
Antenna retaining pin 85-739
If the PLB has been activated, the best course of action is to measure the off-load battery
voltage. If this is less than the figure given in 3.1, it is recommended that the battery is
replaced. If the antenna has been deployed accidentally without activating the PLB,
replacement of the battery is not normally required.
NOTE:
Check that the pin holding the antenna in position is made of black plastic (the early units
had stainless steel pins – these were found to sometimes change the RF matching of the
antenna). Replace steel pins with plastic.

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PLB service manual Issue 4 Page 16
Rewinding the antenna
Once activated, the PLB has the antenna extended. The tamper cover, with seal and
retaining pin, is usually absent – in any case, a tamper cover should NOT be re-used.
Inspect the antenna for damage, such as cracks, creases or delamination of the coating.
Ensure that the antenna is fit for re-use.
If present, remove the screw which previously retained the tamper cover.
1. Fit the seal to the recess in
the tamper cover, then insert
the retaining pin into the hole
in the centre of the seal area.
2. The ball at the tip of the antenna has an off-centre
triangular hole which fits the shaft of the winding
key.
3. Insert the winding key through the hole in the
antenna housing and engage it in the hole in the
ball.
4. Rotate the key approximately 3 turns anti-clockwise to wind
the antenna into the housing. The antenna has a number of
holes along its length; when the antenna is correctly wound
these holes will line up.
Do NOT over-rotate, as the antenna may crease.
Seal
Retaining pin
Holes line up