FAST Cockpit Controller MANUAL - SEI Industries LTD.€¦ · The cockpit controller records and...

FAST Cockpit

Controller MANUAL

2014 VERSION A

2014 FAST Bucket Cockpit Controller Manual (Version A)We Engineer Solutions

FAST Bucket Cockpit Controller Manual - Version A

Issue Date: NOVEMBER 2014

PLEASE READ BEFORE USING.

SEI INDUSTRIES LTD.7400 Wilson AvenueDelta, B.C. Canada

V4G 1E5

Phone: (604) 946-3131Fax: (604) 940-9566

E-Mail: [email protected]: www.sei-ind.com

COPYRIGHT © 2014 SEI INDUSTRIES LTD. ALL RIGHTS RESERVED

PRINTED IN CANADA

2014 FAST Bucket Cockpit Controller Manual (Version A)We Engineer Solutions

Table of Contents

Section 1: Cockpit Controller Overview 1System Description .......................................................................................................1

Introduction .....................................................................................................1Cockpit Controller Features ............................................................................2Optional GPS ..................................................................................................2

Section 2: Controller Installation 3Electrical Installation Instructions ..................................................................................3

Helicopter Wiring Diagram ..............................................................................4Helicopter Wiring Schematic ..........................................................................5

Software Installation .....................................................................................................6DataTrack Installation .....................................................................................6

Section 3: Pre-Flight 7Pre-Flight Tests ............................................................................................................7Controller Menu ............................................................................................................9

Section 4: Operations 10Using the FAST Cockpit Controller .............................................................................10

Automatic Volume Control ............................................................................11Release and Split Drops ...............................................................................12

Using FAST DataTrack ...............................................................................................13Viewing Records ...........................................................................................13Downloading Records ..................................................................................13Saving and Printing Records ........................................................................14

Using FAST Foam ......................................................................................................15Pre-Flight ......................................................................................................15Injecting Foam ..............................................................................................15

Using FAST FILL ........................................................................................................16External Pump ..............................................................................................16Internal Pump ...............................................................................................16Filling with FAST FILL ..................................................................................16FAST FILL Wiring Diagram ..........................................................................17

Section 5: Troubleshooting 18Troubleshooting Charts ..............................................................................................18

Section 1: Cockpit Controller Overview System Description

2014 FAST Bucket Cockpit Controller Manual (Version A) 1We Engineer Solutions

Section 1: Cockpit Controller Overview

System Description

Introduction

The FAST Bucket is a helicopter-borne self-contained retardant delivery system that permits cockpitselectable fill volume, multiple (split) drops from a single load and variable water release rates, in manual orautomatic versions.

The optional cockpit controller automatically releases the bucket by pre-selecting the desired level on thecontroller from 40% up to 100% of bucket capacity. By controlling when the release valve is fully closedduring the fill, the cockpit controller automatically attains the selected volume based on the signal from apressure transducer installed in the actuator. The actuator only uses 1.2 amps of 24 volt DC power.

In addition, the cockpit controller also records a variety of data including volume of water lifted, date andtime of lift and number of drops performed. This information can be downloaded to a PC through theMicrosoft Windows-based download software supplied with the system.

Important Note

The cockpit controller is no longer available with FAST buckets. This manual is supplied to assist existing customers who already have this accessory.

Section 1: Cockpit Controller Overview System Description


Cockpit Controller Features

• Automatic volume control (pre-select 40% to full)

• Split drop selection (manual, 1, 2 or 3 drops)

• Automatic foam injection control

• Drop rate selection

• Slow = approximately 8-14 seconds to empty (bucket size dependant)

• Fast = approximately 4 seconds to empty

• Data recording: summary stats on controller and detailed stats available for download to a PC include:

• Total water volume lifted and dropped including drops per lift

• Foam injected per bucket fill including injected percentage

• Time and date of each event

Optional GPS

Some cockpit controllers may feature a GPS option which allows the cockpit controller to be connected tothe helicopter’s existing AFF system. This allows GPS coordinates to be recorded against each recorded filland drop and be downloaded as a complete record to a PC. This same information can also be transmittedvia the AFF to the customer’s AFF website.

Section 2: Controller Installation Electrical Installation Instructions


Section 2: Controller Installation

Electrical Installation Instructions

• The cockpit controller is sensitive to high temperatures and should not be left in the sun on hot days.

• The cockpit controller should be located where it will not be easily damaged and within easy view and access of the operator.

• The relay box should be located in a suitable location. As there is a fixed length wire which attaches the relay box to the cockpit controller, the relay box must be located within reach for this cable to connect. This location should also be readily accessible to facilitate maintenance and allow observation of the valve-signal LEDs during trouble-shooting. The relay box can also be temporarily mounted using Velcro.

• A water release switch, if not already installed, must be installed in the aircraft cockpit on the cyclic or collective.

• A controller by-pass switch, which allows the operator to activate the water release valve if the cockpit controller loses power or is otherwise inactive, must also be installed. This switch should be installed in a location that is easily accessible but also offers minimal chance for unintended activation. When choosing a suitable location, ensure that the switches are not so close to the cargo release switch that the operator could inadvertently activate the cargo release switch when attempting to activate the water release switch or the controller by-pass switch.

• The electrical wire installation is a permanent installation. The aircraft must have a spe-cific set of wires installed to connect the 10 pin mil-spec connector at the relay box to a 9 pin mil-spec connector at the belly hook of the aircraft. As well, the water release switch and the by-pass switch must be connected electrically to the relay box 10 pin mil-spec connector. Lastly, a continuous supply of aircraft 28V DC power must be connected to the relay box 10 pin connector.

• The appropriate 10 pin and 9 pin connectors are provided with the cockpit controller kit.

Important Note

Sealing of electrical connectors is very important as liquid inside any of the connections can cause short circuits to occur which will in turn cause erratic operation of the bucket.



Helicopter Wiring Diagram



Helicopter Wiring Schematic

Section 2: Controller Installation Software Installation


Software Installation

The cockpit controller records and stores data regarding the fills and drops performed during a fire fightingmission. As an added option, the cockpit controller can be connected to an AFF (Automated FlightFollowing) or GPS unit. This allows the data recording to include the GPS coordinates with each drop andfill recorded. This information can be exported to Google Earth for a graphical representation of themission.

Recorded information includes date, time, event (fill, drop or no sensor detected), foam percent, call sign,volume (drop or fill), latitude, longitude, height, course and speed. The positional information is onlyrecorded if the optional AFF/GPS system is purchased and the cockpit controller is attached to an AFF orGPS through the appropriate communications port.

DataTrack Installation

FAST DataTrack is the PC software which allows downloading of all the records in the cockpit controller.This software was included on a CD and is designed to be run on a Windows-based computer. Instructionsfor installing this software are also located on this CD.

The FAST cockpit controller requires that a specific driver is installed to create a com port using the USBconnection. Please follow the instructions below to install the proper driver onto your computer.

1. Connect the controller to the laptop or PC with a standard USB cable (this type of cable is oftenused to connect printers to computers).

2. Power up the cockpit controller. This will launch the "Windows Found New Hardware" wizard.

3. Do NOT allow Windows to connect to Windows Update to search for software!

4. Select "Install from a list or specific location (Advanced)."

5. Select "Search for the best driver in these locations." and include the path to the installationdirectory (typically C:\Program Files\...) and hit Next.

6. The driver should now install.

Once the driver is installed your computer should create a new serial port whenever the controller isconnected and powered on. If your system does not create a port, or the above installation procedure fails,you may need a different driver for your operating system.

These drivers are located at the FTDI chip website at:

• http://www.ftdichip.com/FTDrivers.htm

Installation instructions are found at:

• http://www.ftdichip.com/Documents/InstallGuides.htm

Section 3: Pre-Flight Pre-Flight Tests


Section 3: Pre-Flight

Pre-Flight Tests

1. When the cockpit controller is turned on, it will display "StormTank/Absolute Fire" followed bythe firmware version and then the time and date. Next, the controller screen will display "SensorTest Passed" if the pressure transducer is connected and functioning correctly. Once the test iscomplete, the screen will display as seen below indicating that the automatic volume control is setat 95% of max load, there is currently no water load in the bucket and drops will occur at a fastdrop rate.

2. If "Sensor Test FAILED" appears instead during the test, the display will read "Level = No Signal"and the controller will continue to operate but in manual mode. To correct the problem, proceed tothe Troubleshooting section of this manual. Once the problem is rectified and the pressuretransducer signal comes back into its proper range, the display will switch back to normal.

WARNING

Inadvertent or unintentional operation of the cargo release switch with the FAST Bucket attachedcould result in damage to the FAST Bucket assemblies and/or injury to persons on the ground.

Level Control (scroll in menus)

Desired Fill Volume Actual Water in Bucket

Split Drop Menu Manual, Auto (1, 2, 3)

Fast / Slow Drop Selection

Inject foam or hold two seconds for setup menu which includes Time, Setup, Units, Foam, Call Sign, Stats, Off, AFF/GPS

Section 3: Pre-Flight Pre-Flight Tests


3. Rotate the volume dial. The level should change in increments of 5. Press and release all thebuttons to ensure they are functioning correctly.

4. To test the actuator, put the controller into manual mode by pressing the 'Split Drops' button. Inthe split drop menu, turn the volume dial counter-clockwise until it reads 'Manual'. Press the OKbutton to accept.

5. Making sure you can see the LEDs on the relay box, press the water release switch and observethem. The relay box LEDs should illuminate as follows:

• Yellow (normally closed valve) briefly - ½ second if in fast drop.

• Red (normally open valve) - ON as long as water release is held.

6. While observing the LEDs again, press and hold the by-pass switch. The relay box LEDs shouldilluminate as follows:

• Yellow (normally closed valve) - ON as long as by-pass switch is held.

• Red (normally open valve) - ON as long as by-pass switch is held.

7. Extend the actuator's water release rod fully bypulling on it (you may have to give it a slight twistat first). The rod should retract smoothly whenreleased. While the rod is retracting, activate thewater release switch. Observe that the rod stopsmoving while the switch is held on. If the rod doesnot stop moving or does not fully retract again whenthe switch is released, proceed to thetroubleshooting section for recommended actions.

Important Note

The pressure transducer is continuously monitored. If the reading falls outside of the expected range (<0% or >125%) for more than eight seconds then Level = No Signal is displayed and the controller will continue to operate but in manual fill and drop mode. Foam dispensing will be disabled.

Important Note

When powering up, the controller will always display the last settings used. This facilitates setup for the next fire fighting cycle.

Section 3: Pre-Flight Controller Menu


Controller Menu

Hold the SETUP button for two seconds to access the setup menu. Use the VOLUME dial to rotate throughthe following options.

Time Allows time and date entry – use the dial to change time or date values and ‘Accept’ button to confirm.

Setup Allows parameters specific to the performance of the bucket to be adjusted.

Units Select alternate units including US gallons or liters for main display. Standard display is in percent. Use dial to change to desired option then press ‘Ok’ to confirm.

Stats Shows total number and volume (USG only) of fills and drops performed. If there are a number of records stored on the controller then there will be a delay entering the Stats option.

Foam

Allows setting whether the foam option is available on the main screen, the mix percentage desired, and the longline length. Selecting the foam option as ‘Off’ will remove the ‘FOAM’ option from the Main screen. The mix percentage is typically what is requested by the forestry officials overseeing the fire. 1% would mean that 1 USG would be pumped into the FAST bucket water for every 100 USG it is carrying. The longline length is required so the cockpit controller foam pump timer can be adjusted to compensate for voltage loss down the long wire which slows the pump.

Call Sign

Allows entry of helicopter call sign or pilot name. This is recorded with each fill or drop record saved in the controller and downloaded to the PC with FAST DataTrack. Change the characters using the dial and then press ‘Next’ to proceed to the next letter in the call sign. The full alphabet in both upper and lower case plus numerics are available options – simply rotate the volume dial past the end of the current alphabet and the next set of characters starts.

Off Turns LCD screen off. Press any button to turn on again.

AFF

Allows selection of Auto Flight Following or GPS system for communications between FAST controller and AFF. Once connected, GPS coordinates are recorded for each fill or drop. Data records will be downloaded to AFF web site. A specific code must be entered in the controller to enable this function.

Section 4: Operations Using the FAST Cockpit Controller


Section 4: Operations

Using the FAST Cockpit Controller

The cockpit controller operates in two modes; automatic and manual fill volume control as well as automaticand manual water release mode.

• Manual volume control can be done if level is set to "FULL." This means that no auto-matic volume control will occur and the FAST Bucket will fill to 100% unless the water release switch is pressed.

• To manually adjust the water volume, press "Split Drop" then turn the volume dial until manual is displayed, followed by the OK button. The water release switch can now be depressed as the FAST bucket is lifted from the water, allowing water to drain from the bucket until the desired level is reached. (Tip: For finer control use the "Slow" drop rate.)

• Automatic volume control mode is active when the level selected is between 40% and 95%. To change the level setting, simply rotate the volume dial. The level will change in 5% increments.

• The volume control system within the FAST Bucket operates with input from a very accurate pressure transducer.

WARNING

The volume control system is not a certified aviation weight/load indicating system. Operatorsshould follow all operating procedures for safe aircraft operation without reference or reliance onthis system. Normal in-flight external and sling load precautions and procedures must be followedat all times to ensure the safety of the aircraft and crew.

Important Note

With split drops set to 1, 2 or 3, the FAST Bucket will remain open following the last drop to reduce drag. Following the final drop, the cockpit controller screen will display "Press Drop Before Filling." The water release switch must be pressed prior to entering the water to allow the release valve to close. DO NOT PRESS THE SWITCH REPEATEDLY! The controller will go to the normal operations screen and display the volume and drop rate once reset has been achieved.



Before the FAST Bucket is lowered into the water source, select the appropriate volume, using the rotaryselector on the cockpit controller (40-95%). After filling, the FAST Bucket must be lifted smoothly andpositively from the water source allowing the volume control system to react as loading increases smoothly.When the volume in the bucket exceeds the set level, the water release valve will open to reduce the watervolume until it reaches the target level. A smooth and consistent increase in power will ensure best weightcontrol results.

Automatic Volume Control

In automatic mode, the volume control system is deactivated six seconds after a volume control adjustmenthas been performed in order to prevent inadvertent releases of water through momentary G fluctuations thatmay be experienced in turbulent conditions.

The volume control system is locked out 10 seconds after the volume exceeds 80% of the level setting tostop unexpected releases of water if turbulent conditions cause the bucket to bounce and appear heavier thanit actually is. For example, with the level set to 90% while filling the bucket from a shallow river, if only85% water has been obtained, a timer is initiated and if no volume control correction occurs within 10seconds then it is locked out.

The volume correction occurs while the bucket is being lifted from the water source; consequently the pre-selected volume is achieved as the bucket clears the water with little or no time delay.

Important Note

The volume control system requires a positive continuous loading to function effectively. If the FAST Bucket is unloaded repeatedly as it is being lifted from the water, the volume control system will not function accurately.

CAUTION

The FAST Bucket must be lifted smoothly and positively from the water to ensure the system has timeto operate properly and help ensure the longevity of the system components.

WARNING

During filling of the bucket, if the desired volume of water cannot be lifted within the safety marginsof the helicopter, the water should be released and the level on the controller set lower before anotherattempt is made to fill the bucket.



In flight, if the level setting is reduced, the FAST Bucket will immediately release water to adjust to the newvolume level.

Release and Split Drops

With the FAST Bucket, there are a number of selectable options on the cockpit controller including the rateof release (fast or slow) and the number of drops. For example, a slow drop rate may be used for a grassfire, wetting a relatively large area. A fast drop rate may be used for heavy timber or spot drops requiringmaximum impact.

Automatic Mode: Press the split drop button then use the volume dial to set 1, 2 or 3 auto split drops. Pressand release the water release switch. Water will drain to the next split point. Auto split drops are availableas follows according to the load in the bucket:

• FULL…….......3 drops possible (525 US gallon or greater)

• 75%-100%......2 drops possible (all sizes)

• Below 75%.....1 drop (system will drop all water)

In automatic mode, the water release switch must not be held to achieve the drop. Simply pressing andreleasing the switch tells the cockpit controller to drop the desired amount. For example, with a 90% loadand two drops selected, each time the water release switch is depressed, approximately 45% of the capacityof the FAST Bucket will be dropped on the target area.

Manual Mode: Press the split drop button then use the volume dial to select "Manual" mode. Press and holdthe water release switch for water drop. Water will drain until the switch is released.

In manual mode, the volume of water released is determined by the drop rate selected (fast or slow) and thelength of time the operator holds the water release switch. Selecting a "SLOW" exit rate will allow forgreater control of each split and more split drops with each load of water.

With the controller in manual drop mode, it is still possible to dial in a desired level and have the load in thebucket automatically controlled and yet still be able to drop the water manually.

As mentioned previously, with split drops set to 1, 2 or 3, the FAST Bucket will remain open following thelast drop in order to reduce drag on the bucket. Following the final release of water, the cockpit controllerscreen will display "Press Drop Before Filling." The release valve will not close until the water releaseswitch has been depressed and released once; the FAST Bucket cannot be filled until this occurs.

CAUTION

The volume control system will react immediately to a decrease in the level setting in flight.Operators should ensure that in any in-flight adjustments are made gradually and only when the areabelow the bucket is clear.

Section 4: Operations Using FAST DataTrack


Using FAST DataTrack

Viewing Records

The cockpit controller can store 600 records in its memory. This is enough to store approximately 2-3 daysof information depending on the length of daily fire fighting missions. When the memory is full, the oldestrecords are removed from memory as new records are added so it’s important to download the data everyday or two.

The cockpit controller also has a method of viewing summary results of the recorded data. By pressing andholding the setup button for more than two seconds, the setup menu will appear. Choose "Stats" then pressOK. If there are a number of records stored in the controller then it may take up to 15 seconds to displaythe results.

The stats will show four successive screens including total daily records, total records in memory, totalnumber of fill records and associated US Gallons, followed by total number of drop records and associatedUS Gallons.

The last stats display allows the operator to clear the memory of all data records or exit.

Downloading Records

• To download the records from the cockpit controller, ensure that the FAST DataTrack software is properly installed including the driver for the USB/serial port. Do not con-nect the cockpit controller to the PC yet.

• Locate and run the FAST DataTrack program. It will be either on the PC desktop or in the install location (typically C:\Program Files\Absolute Fire Solutions). On the down-load tab, locate and click the com port drop-down arrow and make a note of the current com ports available for selection.

• Turn on the cockpit controller and plug the USB cable into both the controller and PC. After a few seconds, this will create a new COM port on the computer. Make sure to leave the controller on its main screen.

• In DataTrack, switch to the events or summary tab and then back to the download tab. This will refresh the com port list.

WARNING

Do NOT clear the records if they have not yet been downloaded to a computer using the FASTDataTrack. If the data is cleared at this point, these records are lost permanently and CANNOT bedownloaded using FAST DataTrack!

Section 4: Operations Using FAST DataTrack


• Once again in the download tab page, locate the com port drop-down and select the com port which was created for the controller connection. It will be the one that is new to the list; usually the last one.

Downloaded records are kept in a 'Project' file which should be defined before downloading any records. Ifa project file is not defined then a default project is created. If a project file was defined during a previoussession then this becomes the project file for all new records downloaded. If a separate project file accordingto pilot, day, fire location, etc. is required, this is the time to define that.

• Choose File-New and type in a project name. A folder and files for that project name will be created automatically.

• Now click either Download All or Download New depending on your needs. Download All will take longer if you have previously downloaded records.

• The PC will automatically communicate with the controller and download the records as requested. This may take up to 30 seconds but you can observe the progress in the status display area.

• Once the download is complete you have the option of viewing the records or going to the events or summary pages to get the complete list of all records downloaded or the summary totals of all these records.

Saving and Printing Records

There are three options available on the download tab and three on the events tab as follows:

Print: This option allows printing of the downloaded records only or all of the records appearing on theevents page, depending on which tab is active when print is clicked.

Export: Allows the export of either downloaded or events (all) records to either KML or CSV format. KMLis the format which can be read by Google Earth. CSV is a basic data format that can be read by manyprograms including MS Excel. After clicking the export button, a dialog box will pop up asking for a filename and type for the export; choose CSV or KML. Click Save. After the save has occurred, a new dialogbox will appear allowing the option to open the folder where the exported files are kept. Select 'Open Folder'and, when the folder opens, simply double clicking on the files saved will open the appropriate program toview the data. In the case of the KML file, Google Earth will open and zoom into the cluster of locationscontained in the KML file.

Import: This option allows the importing of records from other project files into the events screen. Clickon Import then navigate to the desired 'Raw Data' directory and click on the raw data file to import.

Clear: This option clears the records which show in the download tab. This only clears the records in thisscreen. They are still stored in the database file on the PC as well as in the cockpit controller. To clear thecontroller records, hold down the setup button on the controller for more than two seconds and then scrollto Stats and press 'OK'. Click 'Next' until the 'Recs in Memory' page appears. Press 'Exit' if the records areto be left in memory. Press 'Clear' to permanently erase the records currently stored in the controller.

Section 4: Operations Using FAST Foam


Using FAST Foam

FAST FOAM adds the ability to inject foam retardant concentrate into a bucket of water. An internal pumpmeters the concentrate under the control of the cockpit controller.

The FAST FOAM injection system incorporates a storage tank and pump system to efficiently handle theinjection of various foam retardants. The storage tank is a bladder made from similar material to the FASTBucket shell and hangs inside the upper area of the FAST Bucket.

Pre-Flight

Before leaving on a mission, the pilot simply navigates into the setup menu, chooses 'Foam' and selects thedesired mix ratio (0.1 - 1.5%) followed by the length of longline being used (0 - 250 feet), if any. The foambag must also be filled with foam concentrate. Foam bags are sized to complement each size of FASTBucket so there is a sufficient amount of foam concentrate to allow the aircraft to fly roughly a two hourmission before having to refill the foam concentrate. This will vary depending on the mix ratio required,amount of water being loaded each time and flight time from water source to fire.

Injecting Foam

To inject foam, the pilot simply loads the FAST Bucket with the desired amount of water then waits for thevolume of water in the bucket to stabilize for a minimum of 10 seconds. The pilot then simply presses thefoam button on the cockpit controller, answers 'Yes' to 'Inject Foam' and the cockpit controller automaticallydispenses the correct amount of foam concentrate into the bucket. Once at the fire, the pilot simply releasesthe water/foam mix according to normal water release methods

If, for some reason during the foam injection, the pilot wishes to stop the injection process, simply press the'Abort' button on the cockpit controller and foam injection will cease immediately.

Section 4: Operations Using FAST FILL


Using FAST FILL

FAST FILL is a 28V DC-powered internal or external pump system which mounts to any of the FASTbuckets. Each of these requires only 12-14" of water depth to draw from.

Although pumps are used to fill the FAST Buckets, tipping the bucket over is still the fastest way to performa fill. As the pump does not interfere with this technique, a pump can be left installed in the bucket even ifit is not being used.

External Pump

The external pump is positioned lower than the internal pump and can draw from shallower water. Theexternal pump has a large bottom base and screen making it suitable for use where there are muddy bottomsor debris such as leaves and sticks.

The external pump assembly hangs off the bucket lanyards and has an elbow supported on the ring armassembly. The pump itself is suspended away from the base of the bucket through a wire rope or cableassembly. This method keeps the bucket and pump somewhat isolated from each other thus reducing impactdamage to the pump.

Internal Pump

The internal pump mounts easily to a flange intake on the flap where a V-band clamp holds the pump inplace. Although the V-band clamp has a spring loaded safety lock, it should be wired to itself to ensure thepump cannot come off inadvertently. There is also a cap included with the system that should be used whenthe pump is removed from the bucket. This cap is held in place with the same V-band clamp. Always ensurethat the O-ring is in place in the flange to ensure that the pump or the cap seals properly.

Filling with FAST FILL

CAUTION

Using the aircraft's hook weight measuring system or the cockpit controller’s 'actual' volume displayfor 'fill' reference will give artificially low volume indications as the bucket is supported by the watersource during pump filling operations.

Section 4: Operations Using FAST FILL


If the desired volume of water cannot be lifted within the safety margins of the helicopter, the water shouldbe released and the filling process restarted.

1. If using the cockpit controller, press the water release switch to cause the flap to close (if in autosplit mode); dial level up to FULL.

2. Set the FAST bucket down on the water surface to relieve the bucket weight off the actuator for 3-5 seconds. This allows the outer rods of the actuator to retract.

3. Lift the bucket up so it takes its usual shape but leave the bottom of the bucket in at least 12"(30cm) of water.

4. Press and hold the pump operating switch and allow the bucket to fill to the desired level. Do thisby observing the water level in the bucket, then release the fill switch.

FAST FILL Wiring Diagram

Section 5: Troubleshooting Troubleshooting Charts


Section 5: Troubleshooting

Troubleshooting Charts

Problem Troubleshooting Procedure

No power to cockpit controller (LED screen blank)

Press any button on the controller to make sure it isn’t in screen saver mode.

Check connections to the relay box and cockpit controller making sure they are tight and that there are no bent pins in either of the connectors. Also look for any short circuiting of wires in the whole system.

Check the fuse in the relay box.

Disconnect actuator, if attached, and check controller.

If problem persists, check for aircraft power at the relay box cable connector MS3476W12-10S between pin A (Ground) and pin E (24Vdc).

If the above checks positive, then check for power on the DB9 cable connector at the controller. Check between pin 3 (Ground) and pin 6 (between 16 and 24Vdc).

If the above check is positive and the problem persists, replace cockpit controller.

The FAST Bucket may be operated using the controller by-pass switch until new cockpit controller is received.

Relay box fuse blows on power up

The relay box fuse is solely as a protection against reverse polarity wiring to the relay box. If this fuse is blown, it means that the power and ground wires from the aircraft supply to the relay box are reversed. Check power at the relay box cable connector MS3476W12-10S between pin A (should be ground) and pin E (should be +24Vdc).

Helicopter breaker for bucket circuit blows when water release switch is pressed

On systems which utilize the AFS provided pre-made wiring harness for the aircraft, there are two wires which are normally connected to a 2-pin belly connector which provides the water release signal from the water release switch. These are polarity sensitive and, if wired backwards, will cause the main supply power breaker to trip

If the main supply breaker is greater than 5A then typically the breaker will not blow, but instead damage will occur to the spike protection in the relay box or actuator wiring harness or both. This will also be apparent by the fact that the ‘actual’ volume reading will not be available, therefore the main screen will read ‘Level=No sensor.’

This breaker may also blow if another aspect of the wiring is not done correctly of if any wiring is shorting to ground. Refer to the helicopter wiring schematic in the appendix to confirm correct wiring.



Troubleshooting Charts (continued)


When pressing and holding water release switch, both LEDs on relay box stay on

Check wiring from water release switch to ensure that it is not hooked up in parallel to the by-pass switch. The by-pass switch will cause both LEDs to come on for the duration of the ‘press.’

Also test at the relay box cable connector MS3476W12-10S between pin A and H for 24V and ensure 0V between pin A and J when water release switch is activated.

If problem persists, change out the relay box followed by the controller.

Cockpit controller reads ‘Level=No Sensor’ and it is not possible to dial 1, 2, or 3 for split drops

This indicates that the controller is not receiving a proper, in range (0-125%) signal from the pressure transducer. This can mean that there is either a break in the wires from the actuator to the controller or that the pressure transducer has failed. Check connections to FAST Bucket.

Ensure that the actuator and longline (if used) are all plugged in properly.

Restart the system and watch the controller through its initial test sequence. The screen will read “testing sensor” and then either “sensor fail” or “sensor pass.” Furthermore, when the main screen appears, the actual sensor volume feedback will show up inside the brackets (__).

If the sensor fails, first check all wiring from the pressure sensor in the actuator to the cockpit controller. If there is continuity, then a check can be performed to determine if the spike protection is damaged in the actuator wiring harness or simply replace the actuator harness and retest from step 1.

Go to ‘Setup’ and check if correct bucket size and parameters are entered for the bucket being used. If a smaller bucket is indicated in the controller, the ‘actual’ volume percentage will be too high and will appear as if the sensor failed.

If the above does not correct the problem, then a new transducer should be installed

If this does not correct the problem, then replace the cockpit controller followed by the relay box to determine which one is at fault.

The FAST Bucket may be operated in the manual mode and all features, except automatic weight control, automatic split drops and foam, will be functional.





Cockpit controller ‘actual’ volume shows value other than zero with no water in bucket

The auto volume control system uses the pressure in the actuator’s hydraulics to determine the water weight in the FAST bucket. As the actuator is a closed system, the pressure can vary with temperature especially if the actuator is left in the sun. Though it is not required, to return the ‘actual’ to zero while not flying, simply perform the pre-flight test – i.e. pull the water release rod of the actuator out and press the water release switch. This will allow the pressure to equalize.

If the ‘actual’ shows a number with the actuator electrically disconnected from the helicopter then a voltage signal is being applied falsely from somewhere. The most common reason is water or oil on the face of inside the back of the 9 pin MS connector at the hook. Clean the face of the connector thoroughly and remove the back shell and do the same. If the wire connections in the back of the connector are not waterproofed with water blocking compound, do this now.

Inspect all wiring from the belly plug to the relay box and controller looking for any possible wear points that may be shorting power to the pressure transducer wire.

Water release valve stays open after fill or opens in turbulence or turns

The automatic weight control system is calibrated to lock out weight adjustments approximately 10 seconds after exceeding 80% of the level setting or six seconds after the FAST Bucket does its final weight control operation. If water is being released after this point:

Ensure that the release valve is closed as the FAST Bucket is lowered into the water source (water release switch has been pressed after the last automatic split drop).

Check for obstructions in the release valve.

If the release valve is clear, restart the controller by cycling power to it and ensure the sensor test passes and an acceptable ‘actual’ volume shows in the brackets on the main display. If the self-test indicates fail, go to troubleshooting step E.

Actual water volume does not match level selected on controller

The volume control system operates by monitoring the weight of water in the bucket and releasing water when the weight exceeds the level selected on the cockpit controller.

Ensure the bucket is pulled from the water source in one continuous, steady, fairly quick operation (about 5 seconds to clear water). If the desired load setting is too great for the helicopter to perform this, dial the volume control down slightly to ensure a smoother, faster transition out of the water

Confirm how many weight control releases are done to attain final level. One release is ideal and will typically give most accurate results. If two or more then typically the final volume will be lower by 5-10%.

If only one water release is occurring and the accuracy is still off by 5-10% then call for instructions on changing a parameter.





FAST Bucket does not fill or retain load when filling

The FAST Bucket release valve stays open after its last drop to allow smooth flight back to the water source. The water release switch must be depressed once prior to dropping the bucket into the water source to close the water release valve.

Ensure the water release switch is depressed once when reaching the water source. Check controller screen to ensure the message ‘Press drop before filling’ is no longer being displayed.

Check water release valve for obstructions. Ensure that the centre cable is free to move and not caught or wrapped around any other parts including lanyards, FASTFill or ring arm components

If possible, have an observer on the ground confirm that the actuator’s water release rod extends out from the bottom plate by approximately 6-8” with the flap closed (ensure the actuator’s bottom plate is fully retracted into the actuator housing when checking this). If this rod extends much further than this then call for instructions on checking center cable and lanyard lengths.

FAST Bucket leaking in flight

Check the shell for punctures.

Check the shell band clamp to ensure it is in the range of 12-15 ft-lbs torque ensuring as well that it is clamping the shell tightly to the base.

To ensure the problem is not due to automatic volume control, dial the level to FULL and split drops to manual and fill the bucket using manual release to attain the desired level. If the bucket does not leak then the problem lies with the auto volume control. Test for pressure transducer issues.

Water exit rate is too slow or does not fully empty on last split drop

Ensure that at least 35% water volume is in the bucket for the last drop. Anything less than this severely limits the effective operating capability of the actuator.

If split drops is set to manual, the water release switch must be held for the release valve to remain open.

Ensure that NOT more than three fast or five slow drops are performed per bucket load. Every water release performed causes the actuator outer rods to extend. Once the actuator outer rods are fully extended, it will not be possible to perform any more drops.





Water release is too slow or fast when on ‘slow’ drop rate or during a weight control

Perform the pre-flight and ensure the actuator water release rod retracts smoothly.

Have a ground observer confirm the center release cable is not slack when bucket is empty or filled.

There are timing parameters set in the cockpit controller which can be adjusted to vary these drop rates.

By-pass switch does not work

Confirm that the breaker providing power to the by-pass switch is on and providing power to it.

Observe the LED lights on the relay box while operating the by-pass switch. Both the NC valve (yellow) and NO valve (red) should come on while the by-pass switch is activated. If the lights come on, jump to ‘Check down line.’ If not, continue with next step.

Check connection to the relay box making sure it is tight and that there are no bent pins in the relay box connector. Also look for any short circuiting of wires in the whole system.

If problem persists, check at the relay box cable connector MS3476W12-10S between pin B (ground) and pin J (24Vdc) when holding the by-pass switch in the on position. If this does not check out then test for power on either side of the by-pass switch itself ensuring that there is good power to the switch and that the power travels through the switch when activated.

Disconnect the bucket actuator at the belly connector if attached and test for LED lights again.

If the LEDs do not light up, replace the relay box.

Check Down Line

If the LEDs in the relay box do light up properly then the problem exists between the relay box connector and the actuator.

Before connecting the actuator, test for power at the 9 pin belly connector. While someone cycles the by-pass switch on and off, check for power between pin B (ground) and pin F(24Vdc) and pin H(24Vdc). If either of these checks fail then check the wiring between the relay box and belly plug.

If a longline is typically used, plug it into the belly connector and perform the above check at the bottom of the longline. If this check fails then check the longline wiring.

If the above tests all pass then there is a problem with the actuator wiring harness or valves.

FAST Cockpit Controller MANUAL - SEI Industries LTD.€¦ · The cockpit controller records and...

Documents

Transcript of FAST Cockpit Controller MANUAL - SEI Industries LTD.€¦ · The cockpit controller records and...