86-924N Issue 5 SART S4 Service Manual
86-924N Issue 5 SART S4 Service Manual
86-924N Issue 5 SART S4 Service Manual
Service Manual
Commercial in confidence
mcmurdo
Contents
1. Introduction ......................................................................................................................... 1
1.1. Scope ........................................................................................................................... 1
1.2. Applicability ................................................................................................................... 1
1.3. Revision history............................................................................................................. 1
1.4. Servicing equipment...................................................................................................... 2
1.5. Safety notices ............................................................................................................... 3
2. Assessment ........................................................................................................................ 5
2.1. Maintenance tasks ........................................................................................................ 5
2.2. Routine testing .............................................................................................................. 5
2.3. Assessment .................................................................................................................. 5
3. Maintenance procedures.................................................................................................... 8
3.1. Mechanical inspection ................................................................................................... 8
3.2. Self test procedure ........................................................................................................ 8
3.3. Functional testing .......................................................................................................... 9
3.4. Frequency testing ......................................................................................................... 9
3.5. Leak testing ................................................................................................................ 12
3.6. Battery replacement .................................................................................................... 13
4. Fault finding ...................................................................................................................... 17
5. Repair procedures ............................................................................................................ 18
5.1. Replace O-ring ............................................................................................................ 18
5.2. Replace PCB .............................................................................................................. 18
5.3. Re-tune PCB............................................................................................................... 19
5.4. Factory return procedure ............................................................................................. 19
6. Spares ............................................................................................................................... 20
Appendix 1: Specification ........................................................................................................ 21
7. Product Warranty.............................................................................................................. 22
8. End of Life Statement ....................................................................................................... 23
8.1. Battery Removal ......................................................................................................... 23
8.2. Disposal ...................................................................................................................... 23
This document is Orolia Ltd copyright (©) and contains proprietary owned intellectual property rights and confidential data. All
rights are strictly reserved. The information must not be used except for the agreed purpose. Unauthorized use, reproduction
or issue to any third party is not permitted without the prior written authority of Orolia Ltd. This document is to be returned to
Orolia Ltd when the agreed purpose is fulfilled.
1.1. Scope
This manual represents the original equipment manufacturer’s (OEM) documentation applicable
to the SART equipment listed below. The manual provides complete instructions for shore-based
maintenance (SBM) providers to enable routine servicing of these products.
1.2. Applicability
This information applies to the following SART models. All of these are “badged” versions of the
basic S4 SART.
i McMurdo S4 RESCUE
i SAILOR SART II
i SKANTI SART II
i RFD S4 RESCUE
i KANNAD MARINE RESCUER 2 SART
From serial number 23500 the PCB was modified to stop possible +5V leakage current.
Ref C3800.
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1.4. Servicing equipment
Detailed SART servicing requires specialist equipment, including a microwave pulse generator
and a spectrum analyser. To reduce equipment costs a dedicated SART tester (ARG 5420) was
developed – this was discontinued when SARTs were not included in the IMO regulations for
Shore Based Maintenance. A lower level of routine SART servicing has become normal. This just
requires access to a marine X-band radar to trigger the SART and view its response on the radar
screen. For many service agents located near a harbour this facility can be arranged with local
boat owners. The level of equipment required can thus be broken into two categories:
Antistatic precautions
The electronics section of the SART is sensitive to electrostatic discharge (ESD). ESD can cause
immediate or hidden long term damage. It is important that the PCBs are only handled under
suitable antistatic conditions.
Ideally, a fully grounded workstation which has conductive surfaces to avoid the build up of static
charge should be used. As a minimum, the operator must be connected to a good earth point
through a resistance of 1Mohm. This is usually achieved by wearing a suitable wrist strap.
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1.5. Safety notices
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.
Lithium batteries
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 be handled, transported and disposed of using appropriate safety
precautions. The use of rubber gloves as a routine precaution is recommended.
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.
During SART testing, ensure compliance with Health & Safety instructions when working in close
proximity to the ship’s radar.
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General precautions for chemical agents (adhesives, greases, IPA)
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.
Make 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.
Cyanoacrylate adhesives bond instantly on contact. If skin is bonded, it can usually be released
by a gentle peeling action; above all, do not panic and avoid direct pulling on bonded skin.
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2. ASSESSMENT
Service agents (Shore Based Maintenance (SBM) providers) are reminded that it is their
responsibility to ensure that good common practice and the procedures herein are followed and
that only Orolia Ltd approved parts are fitted.
Routine service agents can provide:
i Assessment
i Functional test
i Leak test
i Battery replacement
Advanced service agents can also provide:
i Microwave testing
i Frequency adjustment
Every SART should be tested monthly by its owner to ensure its functionality.
Whenever possible the SART should be inspected for mechanical damage.
It is strongly recommended that the SART be functionally tested every year using a radar signal.
The SART should not be opened during this test. An approved service label showing the date of
test should be affixed to the outside of the SART.
Every time the batteries are replaced, the SART must receive a functional test and a leak test, as
shown in the table below.
Frequency of testing:
INTERVAL PERFORMED BY
Self test Function test Leak test
1 month ´ Customer
1 year ´ ´ Customer or SBM provider
Battery change ´ ´ ´ SBM provider
2.3. Assessment
Every SART returned for servicing, of whatever nature, must be fully assessed to determine its
operational status. The diagram shows the tasks which must be carried out for each servicing
situation. This must include a functional test and a leak test.
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Receipt
ASSESSMENT
Battery change Fault found
Inspect
Self test
Disassemble Disassemble
Reassemble Reassemble
Functional test
Return
Assessment form
The assessment form overleaf serves as a prompt to ensure no assessment steps are left out. It
may be used to support customer billing, and must accompany any warranty return to the
manufacturer.
It is important that as much information as possible is recorded on the form. Procedures for the
assessment are detailed in section 3.
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Inspection Remarks
Casing intact YES NO
Pole intact YES NO
Pole extends correctly YES NO
Lanyard OK YES NO
Frangible tab intact YES NO
Battery expiry date OK YES NO Date:
Self test
Un-triggered (sleep) state PASS FAIL
Triggered (active) state PASS FAIL
Conclusions
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3. MAINTENANCE PROCEDURES
3.1. Mechanical inspection
Casing Ensure there are no visible cracks or mechanical damage.
A cracked casing will lead to water ingress and is a serious fault.
Pole Confirm the pole is intact and in good condition. The pole
should be checked by removing the cap from the bottom of the pole tube
and checking that the sections can be extended smoothly, and that they
lock into position. Ensure that the pole is fully stowed after inspection, and
that the end cap is secure.
Lanyard The lanyard must be fully wound on the spool, such that only the ball
at the end is outside the casing.
Frangible tab A broken frangible tab means that the SART may have been activated.
If this is the case, fit a new battery.
Battery expiry Note the expiry date. If there is less than 6 months left contact
vessel and advise that they will need a new battery.
Testing requires a signal to trigger the SART out of sleep and into active/standby mode.
This can be supplied by:-
i An X-band marine radar operating nearby (within 3 miles)
i A dedicated SART tester (ARG 5420)
i A 9.35 GHz microwave pulse generator, set for 1 us pulse every 1 ms.
In addition, to prove that the SART returns to sleep mode, the signal must either be turned off
(SART tester or pulse generator) or the SART upper section (radome) can be covered with a
metal container – a can of suitable size works well.
Test procedure
TEST
Indicator
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3. Confirm SART indicates sleep mode as per table below
Sleep Standby/Transmit
LED flashes every 2 seconds LED is on continuously
Beeper off Beeper sounds every 2 seconds
NOTE: Without specialised equipment, it is not possible to differentiate between Standby and
Transmit modes.
Observations
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ARG 5420 SART tester
The Sartech/ARG 5420 portable SART tester is a hand-held instrument which triggers a SART
and measures the resulting response. The frequency spectrum, frequency limits, pulse length
and number of sweeps are measured and displayed. Test results may be stored for later recall or
they may be printed.
Procedure
Comprehensive instructions are given in the handbook provided with the equipment; this
summary only acts as a reminder to users who are familiar with the instrument.
1. Switch on 5420 and check display.
2. Press F4, press F1 twice.
3. Activate SART in Self-test mode.
4. Hold 5420 horizontal, about 300 mm (12") from top of SART.
5. Press and hold F1 on 5420 until a consistent spectrum is displayed.
6. De-activate SART.
7. Press F3 twice on 5420 to display PASS/FAIL listing.
8. Press F3 again, then F2 to save the result.
9. Press F4, then enter the SART serial number.
10. Press F4 to store.
At close range the signal from the SART is directional. Best results will be obtained when the
tester is positioned as shown. It may be necessary to rotate the SART to find the best signal
strength.
SART being
tested
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SART tester features
The SART tester displays the results of the tests in three ways:
1. During and after the test, it displays the response as a graph of amplitude against frequency
– the ‘spectrum analyser’ display. The position of the tester should be adjusted to produce
the optimum response – it is desirable to receive the greatest possible strength of signal, but
not to saturate the 5420 receiver.
2. Once the test is complete, pressing F3 on the tester displays the frequency response of the
SART against time, and so shows a series of frequency sweeps. A magnified view (press F1)
is shown – note that the SART being displayed sweeps down from 9.5 GHz to 9.2 GHz. Note
the exact limits of the frequency sweep – 9.53 and 9.16 GHz – are displayed on this and the
next screen.
3. Pressing F3 again displays the summary results with the PASS/WARN/FAIL classification.
Summary results
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3.5. Leak testing
Two alternative methods of leak testing are given. The gross leak test is preferred, as it causes a
greater pressure differential across the seals of the SART, and so is more likely to detect a leak.
Also, as this is a “positive pressure” test, there is less risk of a leaking SART filling with water.
If the immersion test is used, the accuracy and repeatability of the weighing scales is critical. A
SART weighs approximately 0.5 kg and the pass criterion is a weight gain of less than 1 g, hence
a repeatability of better than 0.1% is essential.
The SART floats, so it must be constrained to ensure that it stays submerged.
Provided that the water is clean and fresh, no damage should be sustained from a leak. Leaking
SARTs may be disassembled and dried in an oven (maximum 55 ºC), then re-assembled and re-
tested.
Any escape of bubbles must be considered a failure. If the unit fails then disassemble the SART.
If there is any evidence that water has entered the battery pack then it must be replaced. To
rectify the leak, it may be necessary to replace the ‘O’-ring.
This test checks for a gain in weight caused by the ingress of water.
Any escape of bubbles must be considered a failure. If the unit fails then disassemble the SART.
If there is any evidence that water has entered the battery pack then it must be replaced. To
rectify the leak, it may be necessary to replace the ‘O’-ring.
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3.6. Battery replacement
It is essential for safety and the reliability of the equipment that only the correct type of battery is
fitted. Use only Orolia Ltd approved parts.
All batteries carry a label showing the replacement battery part number.
Replacement procedure
CAUTION: Before undertaking any work, Service Agents are advised to carry out an inspection
of the SART to ensure that it is in a suitable condition to be returned to service after the battery
change.
Remove the three screws visible when viewing the underside of the SART. When the pole
bracket is fitted, its retaining screw is longer than the other two screws; when no bracket is fitted;
all screws are the same length. Discard the removed screws. Remove the pole bracket if fitted.
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Remove the lower section of the SART by rocking it gently from side to side until the three
battery connectors disengage.
Discard the complete battery section including the frangible tab. Take care to dispose of the
battery in accordance with applicable regulations.
Carefully pull off the switch actuation ring, taking care not to lose or damage the spring. Inspect
the ring to ensure that the magnet is in position.
Remove and discard the O-ring from the SART body. Do NOT use sharp tools; the
recommended method is to squeeze the O-ring between thumb and forefinger and push it until it
bulges clear of the groove (as shown above right), then to pull that part clear of the groove.
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Reassemble the switch ring and fit the spring according to the drawings below, ensuring that the
spring lies flat in the housing.
Fit the replacement battery section. Line up the switch ring groove with ‘O’, align the frangible tab
with this groove and ensure that the battery connectors are aligned. Push the two major parts
together.
Refit the pole bracket if applicable.
Fit the appropriate three screws and tighten to a torque of 1 Nm (100 cNm).
The SART is now fully assembled. Before it can be returned to service, it must be checked for
integrity and performance. Ensure that the SART is watertight by carrying out a leak test - refer to
Section 3.5. Perform a self-test.
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Disposal of batteries
Lithium battery packs should be discharged slowly, and then disposed of through an approved
environmental disposal agent, or in accordance with local regulations.
The rate of discharge must not exceed 100 mA. Resistors of 68 ohms (for the 6 V nominal
output) and 150 ohms (2 W rating) are satisfactory for the SART battery. UNDER NO
CIRCUMSTANCE MAY THE BATTERY BE SHORT-CIRCUITED.
If the battery shows signs of electrolyte leakage, do not attempt to discharge. Refer to section 1.5
for advice on correct handling.
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4. FAULT FINDING
Due to the nature of the SART fault finding is limited. The steps shown below should be sufficient
to trace the fault to a major sub-assembly, which can then be replaced.
The sequence given below requires that each part is completed satisfactorily before proceeding
to the next part. It is, for example, assumed that any faults found at a particular stage are
remedied before continuing.
The following table is applicable to all versions of SART.
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5. REPAIR PROCEDURES
SART repair is by replacement of major sub-assemblies only. No component level diagnostics
are provided. The following repairs are possible if required:
i Replace O-ring
i Replace PCB
i Re-tune PCB
All spares are provided as individual items. See section 6 for a full spares list.
If the sealing of a SART is suspect, it is recommended to replace the ‘O’-ring. Refer to section
3.6 for disassembly, replacement and reassembly instructions. Do not discard the battery pack
unless this is being replaced at the same time. Ensure that a leak test is performed after
replacing the ‘O’-ring.
If the PCB is suspect, it should be replaced. Refer to section 3.6 for disassembly and ‘O’-ring
replacement. It is essential that the ‘O’-ring is replaced.
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5.3. Re-tune PCB
Although it is possible to perform alignment of the PCB in the field, this is not a recommended
procedure because it requires specialised test equipment and suitably qualified technicians.
It is strongly recommended that PCBs are returned to Orolia Ltd for calibration.
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6. SPARES
The following items are available as spares:
Replacement parts/Options
S4-RT9 mounting conversion 86-484A Bulkhead bracket, mounting plate,
kit screws
Bulkhead bracket 86-415
Pole Assembly Kit 86-631A Pole, pole bracket, screw
User manuals
McMurdo S4 RESCUE 86-920-001
Sailor SART II 86-902-005
SKANTI SART II 86-902-008
Repair parts
O-ring 86-418
PCB module 86-510
Frangible tab 86-436
Spring 86-424
Magnet 86-462
Switch ring kit 86-461-001B Switch ring and magnet
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APPENDIX 1: SPECIFICATION
Frequency: 9.2 – 9.5 GHz
Polarisation: Horizontal
Antenna vertical beamwidth +2 dB: +12.5º minimum relative to the horizontal plane of
the transponder
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7. PRODUCT WARRANTY
For details of our full and specific warranties please see our website or user manuals.
In general we have a ‘back to base’ warranty. Any faulty items (which cannot be repaired
following procedures in this manual) will therefore need to be returned to us for repair.
Before returning please ensure that you email [email protected] with details of the
product, the fault and the customer.
We will then revert with a returns number. Please ensure that this is labelled clearly on the
packaging.
All enquiries relating to this warranty or Approved Service Agents should be sent to:
Orolia Ltd, Silver Point, Airport Service Road, Portsmouth, Hampshire, PO3 5PB UK
Telephone: Int + 44 (0) 23 9262 3900 Fax: Int + 44 (0) 23 9262 3998
Web: www.mcmurdomarine.com Email: [email protected]
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To disconnect the battery, turn the SART over and remove the three battery retaining screws
using a cross headed screwdriver. Gently prise the battery from the main unit; Note that this will
also release the ‘O’ ring seal. Cover the terminals of the battery pack with sticky tape to prevent
inadvertent short-circuiting.
8.2. Disposal
The Waste Electrical and Electronic Equipment (WEEE) Directive aims to minimise any adverse
impact of electronic equipment on the environment, both during the product lifetime and when it
becomes waste. Within the European Union this legislation is mandated by Directive
2002/96/EC, and there is similar legislation in most other continents. The directive applies to all
electronic products such as IT, household appliances, portable electronics etc., and imposes
requirements to collect, treat, recover and recycle each product at its end of life. Electronic end-
user products must also carry a WEEE label (as below) and recovery and recycling information
has to be provided to the recycler.
This SART product contains traces of lithium in the battery pack. In addition it may contain lead
and brominated flame retardants (BFRs), both in the housing material and circuit boards.
In keeping with the directive, Orolia Ltd strongly recommends that this SART product and its
battery pack be disposed of in a sensible and considerate manner. For example, do not simply
discard the product in the domestic waste. Instead take it to a civil recycling facility, or contact
Orolia Ltd for advice.
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Orolia Ltd
Silver Point, Airport Service Road, Portsmouth PO3 5PB, United Kingdom
Telephone: Int + 44 (0)23 9262 3900
Fax: Int + 44 (0)23 9262 3998
WebSite: www.mcmurdomarine.com
Email: [email protected]
86-924 Issue 5