MAINTENANCE Manual

CRASH POSITION INDICATOR SYSTEM

type 15-503-134

Issue 38 - 13.01.22
CN 18689
HRS1032-04-04
 Preface

This manual is a controlled document, and as such is subject to amendment. It is in the interest of the
User to register this manual with Techtest Limited to ensure receipt of any amendments.
Amendments subsequent to the Initial Issue will bear the number of the amendment with which it was
issued. Changes of technical import within each new or revised leaf will be identified by a marginal
indicator. Such indicators will be omitted when the leaf is next re-issued. When the whole of the Chapter
is so changed or reoriented that the inclusion of amendment indicators would be impracticable, the
words “(Completely Revised)” will appear at the head of the relevant Chapter.

Any queries regarding this manual must be addressed to:

Product Support
Techtest Limited
Street Court
Kingsland
Leominster
Herefordshire
HR6 9QA
U.K.

Tel. +44 (0) 1568 708 744

Fax. +44 (0) 1568 708 713
Email: productsupport@hr-smith.com

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 AMENDMENT AUTHORISATION SHEET

Checked by: ……………………………………...............................

Mechanical Engineering

Checked by: ……………………………………...............................

Electrical Engineering

Checked by: ……………………………………...............................

Commercial

AMENDMENT RECORD

Issue number Changed by Date/ CN Reference Pages Affected

For previous Issues refer to Archives

31 S. Prescott 04.12.18 / 13213 17
32 S. Prescott 12.02.19 / 13477 9
33 S. Prescott 16.05.19 / 13917 4
34 S. Prescott 23.12.19 / 12835 2, 11
35 F. Moles 21.07.20 / 15718 Completely Revised
36 S. Prescott 13.04.21 / 17100 10
37 S. Prescott 02.12.21 / 18527 7
38 S. Prescott 13.01.22 / 18689 10, 20

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 Contents

PREFACE 1
AMENDMENT PAGE 2
CONTENTS 3~4
ABBREVIATIONS 5
1. SYSTEM DESCRIPTION 6
2. MAINTENANCE GUIDELINES 7
2.1 General 7
2.2 Required Equipment 7
2.3 System Test 8
3. MAINTENANCE PROCEDURE 8
3.1 CPI Beacon 8
3.2 Remove The Beacon 8
3.3 Install The Beacon 9
3.4 Scheduled Maintenance 10
3.5 On Condition Maintenance 10
3.6 Aircraft ID Configuration Unit (ICU): 503-40 11
3.7 System Interface Unit (SIU): 503-42 Series 11
3.8 Beacon Deployment Control (BDC): 503-41 13
3.9 Beacon Release Unit (BRU): 503-21 Series 13
3.10 Water Activated Switch (WAS): 503-23-2 13
3.11 Cockpit Control Unit (CCU): 503-22 Series 13
4. POST MAINTENANCE TEST 14
4.1 General Maintenance 14
4.2 LRU Maintenance 15
4.3 BIT Failure 15
4.4 Diagnostic BIT 16
5. Diagnostic Procedure following CPI Deployment 17
5.1 Scope 17
5.2 Objectives 17
6. Illustrated Parts Catalogue 18

List of Tables
1. Required Equipment 7
2. BIT Faults 16

List of Figures
1. System Schematic 6
2. BIT Indications 15
3. Diagnostic Procedure Flowchart 17
(to be continued)

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 Contents (Continued)

Page
List of Figures - Illustrated Parts catalogue

1. Beacon 503-16 MOD 4, 503-16-LMD MOD 2, 503-16HT, 503-16GPS MOD 1,

503-16-MM MOD 1, 503-16GPS-243, 503-16-LMD, 503-16-HUMS & 503-16
(Class 1) 19
2. Beacon 503-16 MOD 5+, 503-16-LMD MOD 3, 503-16HT MOD 3+, 503-16GPS
MOD 2+, 503-16GPS-LMD MOD 1, 503-16GPS-243 MOD 1+, 503-16-HUMS
MOD 1+, 503-16MM MOD 2+, 503-16 (Class 1) MOD 1,503-16-25 MOD 1
& 503-16-25BLK 20
3. Aircraft ID Configuration Unit 503-40 21
4. Beacon Deployment Control 503-41 Series 21
5. System Interface Unit 503-42 Series 22
6. System Interface Unit 503-42-G Series 23
7. Beacon Release Unit 503-21 & 503-21-MM 24
8. Water Activated Switch 503-23-2 25
9. Cockpit Control Unit 503-22 Series 25

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 ABBREVIATIONS

BIT Built In Test

BDC Beacon Deployment Control
BRU Beacon Release Unit
CCU Cockpit Control Unit
Cospas-Sarsat International Satellite System for Search And Rescue
CPI Crash Position Indicator
ELT Emergency Locator Transmitter
GPS Global Positioning System
ICU ID Configuration Unit
LED Light Emitting Diode
LRU Line Replaceable Unit
PLB Personal Locator Beacon
MM Memory Module
PBIT Power-up BIT
SIU System Interface Unit
SAR Search And Rescue
WAS Water Activated Switch

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1. System Description
The Techtest Crash Position Indicator (CPI) System is a primary radio location aid to alert Search And
Rescue (SAR) Authorities and assist location in the event of an Aircraft Distress Situation. The System
is designed for installation on Helicopters and fixed wing Aircraft and features a Locator Beacon
containing the Transmitter and Antenna. The Beacon, which can be both manually and automatically
activated, is deployed in the event of a crash, providing full Emergency Frequency Operation at 121.5
MHz, 243.0 MHz (optional) and 406.0 MHz.
The programmed Cospas-Sarsat Message is determined by the Cospas-Sarsat Authority of the Country
where the CPI is to be registered. It must be noted, that a User LOCATION Protocol Message
only encodes Positional Information with a resolution of four minutes. The NATIONAL-LOCATION and
STANDARD-LOCATION Protocol Message formats encode Positional Information with a resolution
of four seconds. It is strongly recommended for Systems that include Positional Information (Global
Positioning System (GPS)), a STANDARD-LOCATION or a NATIONAL-LOCATION Protocol Message
is chosen.
‘winBeacon’ (QA-00-120) is a Software Package supplied by Techtest that can be used to Encode or
Decode Cospas-Sarsat Messages. This is a stand-alone Software Package that does not connect to
any hardware.

Refer to Figure 1. The CPI System has a Beacon (1), an Aircraft ID Configuration Unit (ICU) (2), a
System Interface Unit (SIU) (3), a Beacon Deployment Control (BDC) (4), a Beacon Release Unit
(BRU) (5), a Water Activated Switch (WAS) (6) and a Cockpit Control Unit (CCU) (7).

Note: A drawing of each Line Replaceable Unit (LRU) can be found in the Illustrated Parts
Catalogue, Section 6.

7
2

1. Beacon (503-16 Series)

2. Aircraft ID Configuration Unit (503-40) 5
3. System Interface Unit (503-42 Series)
4. Beacon Deployment Control (503-41)
5. Beacon Release Unit (503-21 Series)
6. Water Activated Switch (503-23-2)
7. Cockpit Control Unit (503-22 Series)

Figure 1. System Schematic

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2. Maintenance Guidelines

Caution: In order to maintain a safe working environment, you must obey the guidelines that
follow when working on the CPI System.
2.1 General
All Maintenance work, as detailed in this Publication, must be done by suitably Qualified Personnel. In
the absence of suitably Qualified Personnel, the Equipment can be returned to Techtest Ltd for any
Maintenance Work.
The ARM Switch, on the SIU, should be set to the OFF position whenever the Aircraft or CPI System is
not in use.
Before Maintenance Work is started, the CPI System must be isolated (eg. remove circuit breaker), and
powered down. Set the SIU ARM Switch to the OFF position. The System must be left for at least five
seconds, to fully disable, before work starts (15 minutes for systems equipped with a 503-21-1)
If at any time the Beacon is removed from the BRU, a Protective Cover Plate (0881) (Refer to the IPC
Figure 7) must be attached to the BRU and remain in place until the Beacon is installed again.

2.2 Required Equipment

Refer to Table 1. If Maintenance is to be done by the Operator or a Third Party, the Test Equipment
listed in Table 1 is recommended to make sure that the System is fully serviceable.

Table 1. Required Equipment

Equipment Techtest Part No.

Programming Test Set (optional) 12-503-5 or 12-503-31
Portable Sarsat Beacon Test Set 12-503-26
CPI Programming Adaptor - USB Port (optional) 12-503-14-USB
CPI Beacon Activation Test Set 12-503-16* or 12-503-34
CPI Beacon Reader 12-503-23
CPI Programming Kit 12-503-22
Battery Conditioning Unit 99-15

* 12-503-16 is no longer manufactured

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2.3 System Test

The CPI System has a Built In Test (BIT) which can be used to assess the System’s integrity. If there is
a fault in the System it will also indicate the location, so correct Maintenance work can be done (Refer to
Section 4).

3. Maintenance Procedure
Cautions:
1. For Systems that operate with a BRU (503-21-1): The BRU is designed to remain functional
for up to 15 minutes after the SIU is disarmed. After 15 minutes the Automatic Power-Down
switches the BRU to OFF.
2. It takes 15 minutes after the SIU (503-42 Series) has been disarmed before the BRU Water
Sensors are deactivated and On-Aircraft Maintenance (e.g. Wash-Down, BRU disconnection)
can be carried out.
3. The System has a chargable back-up Battery. If the Battery is charged and the Circuit
Breaker is removed on the Aircraft, the System remains active.
Before any Maintenance work is started, the CPI System must be isolated. Set the SIU ARM Switch
to the OFF position. The System must be left for at least five seconds, to disable, before any work is
started.
Servicing: It is recommended that the Beacon Special Bolt (0862/1) (Refer to the IPC Figure 1)
and Helicoil (ND-00-045)* are inspected for damage during Heavy Maintenance Visits / ’D’ checks
and / or upon Beacon removal.
*Note: The Helicoil is not a field replaceable item.
3.1 CPI Beacon
3.1.1 Cleaning
At regular Service Intervals, and when removed for Maintenance, a Beacon must be cleaned to remove
surface contamination because of exhaust gas residue. This is to prevent damage to the surface lacquer
or underlying moulding. The recommended cleaning agent is Methylated Spirit.
3.2 Remove The Beacon
Note: Refer to the IPC Figure 7. The Protective Cover Plate (0881) must be installed to the BRU with
two M5x30 Pan Head Screws and must remain in place until the Beacon is installed.

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3.2.1 503-16 MOD 4 & above and all other variants MOD 0 & above
Before any Maintenance can be carried out on the Beacon, it must be removed from the BRU as follows:

3.2.1.1 Refer to the IPC Figure 1 and Figure 2. Remove the M6 Special Bolt (0862/1) and Lock Plate (01505)
which sit in the recess on the front of the Beacon. When removed the Beacon will not be fixed to the
BRU. Care must be taken to support the Beacon to prevent it from falling. The Beacon can be carefully
removed from the BRU.

3.2.1.2 Install the Protective Cover Plate (0881) to the BRU

3.2.1.3 Install the two M5x30 Pan head screws that hold the Protective Cover Plate (0881) to the BRU

3.3 Install The Beacon

3.3.1 Install the Beacon as follows:

3.3.1.1 Refer to the IPC Figure 7. Remove the two M5x30 Pan head screws that hold the Protective Cover Plate
(0881) to the BRU

3.3.1.2 Remove the Protective Cover Plate (0881) from the BRU

3.3.1.3 Inspect the Sealing Gasket (0921) in accordance with Step 3.9.2

3.3.1.4 Locate the Beacon Connector Guide Pins to the BRU Floating Connector. The Beacon can then be
pressed into position.

3.3.1.5 Install the Beacon to the BRU

3.3.1.6 While the Beacon is supported in place, install, and hand tighten, the M6 Special Bolt (0862/1) lubricated
with MoS2 or Cu Grease together with the Lock Plate (01505)

3.3.1.7 Torque tighten the M6 Special Bolt (0862/1) to 30 ~ 32 lbf in (3.4 ~ 3.6 Nm).

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3.4 Scheduled Maintenance
3.4.1 Battery
3.4.1.1 The 503-16 Series Beacon has an internal LiS02 Battery Pack which must be replaced every five years.
The 503-16-LMD Beacon has an internal LiMn02 Battery Pack which must also be replaced every five
years. This interval for Battery replacement is dependent on the Beacon (a) not been Deployed or (b)
not set to Transmit at any point during the Battery’s installed life. If the Beacon has been one of the two
conditions, the Battery must be replaced immediately.
Notes:
1. The BIT is not regarded as either of these actions.
2. The Beacon Battery cannot be replaced by the Operator / End User. The Beacon must be returned
to Techtest Ltd. for Battery replacement and certification.
3. The CPI Beacon Battery has a recommended BIT frequency of once per month. Each use of the
BIT will deplete the Battery. If used more than once per month the Battery will not last for the
specified 24 / 48 hours at the end of its five year life.

3.4.2 Special Bolt

(Refer to the IPC Figure 1). The Special Bolt (0862/1) has a five year life from installation, after which it
must be replaced.

3.5 On Condition Maintenance

Caution: Electrical bonding must be ensured in accordance with the Installation Manual, as
electrical bond failure can cause inadvertent deployment and/or failure to transmit.
• Periodic inspections must be made of the electrical bonding.
Note: If, at any time, the Beacon has been deployed, it must be returned to Techtest Ltd for inspection.
3.5.1 CPI Beacon
• Inspection of the external Gasket A01763 should be made periodically. The gasket is a replaceable
part using Instruction Manual HRS1301-01-22
3.5.1.1 Deployment when the cause is unknown
In the event of an accidental deployment the Beacon (503-16 Series) and ICU must be quarantined from
the CPI System at the earliest opportunity. The Beacon (503-16 Series) and ICU contain Memory
Modules (MM) which store the reason for last known activation. Any System activation, post accidental
deployment, will overwrite this MM Data. After safe removal, contact:
Product Support
HR Smith Group of Companies
Street Court
Kingsland
Leominster
Herefordshire
HR6 9QA
England
Tel: +44(0)1568 708744
Fax: +44(0)1568 708713
productsupport@hr-smith.com
3.5.2 Reporting of False Alarms
3.5.2.1 If there is, for any reason, an accidental activation or false alarm of the CPI System, it must be reported
to the nearest (SAR) authority. The information that must be reported includes (a) Emergency Locator
Transmitter (ELT) / Aircraft Identification Code, (b) Date, (c) Time, (d) Duration and Cause of Activation
as well as (e) location.

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3.5.2.2 To report a False Alarms in the United States, contact any of the Agencies as follows:
• United States Air Force Rescue Coordination Centre Tel: (800) 851-3051
• Atlantic Ocean / Gulf of Mexico USCG Atlantic Area Command Centre Tel: (757) 398-6390
• Pacific Ocean Area Tel: (510) 437-3700
• From Any Location: USCG HQ Command Centre Tel (800) 323-7233
• To Report False Alarms Worldwide Contact your National Authority.
3.6 Aircraft ID Configuration Unit (ICU): 503-40

The ICU is not maintained by the end User. In the event of failure, the ICU must be returned to Tech
test Ltd for repair / replacement as deemed necessary.

3.7 System Interface Unit (SIU): 503-42 Series

Scheduled Maintenance
With the exception of the Battery, the SIU is not maintained by the end User. In the event of failure, the
SIU must be returned to Techtest Ltd for repair / replacement as deemed necessary.
3.7.1 Battery
SIU battery (A01011).
The average number of charge cycles to maintain performance (two hour operation) is usually 650. If
the System is cycled once per day, every five in seven days, then 650 cycles occur over a thirty month
period. It is recommended that the Battery Packs are replaced at not more than thirty month intervals.
If the Battery is exposed to extended periods of temperature extremes, then a shorter replacement
period must be used, for example one year.
Note: The Battery has a total life of five years.
3.7.2 Battery Replacement
3.7.2.1 Refer to the IPC Figure 5 and Figure 6. Replace the Battery as follows:
3.7.2.1.1 Remove the six M3x8 Pan Head Screws (NA-00-408), Spring Washers (NC-00-163) and Washers
(NC-00-040) from the Battery Cover (01005)
3.7.2.1.2 Remove the Battery Cover (01005) and Gasket (01643) from the SIU
Note: A Battery Removal Tool (0716) is supplied with the replacement Battery.
3.7.2.1.3 Insert the Battery Removal Tool (0716) into the slot between the Battery and the SIU housing until it
clicks into position.
3.7.2.1.4 Pull the Battery out of its housing, and safely discard
3.7.2.1.5 Remove and discard the Battery ‘O’ ring (OR-00-011)
3.7.2.1.6 Install the new Battery, together with its ‘O’ ring, into the Battery housing until it locates with an
audible click
3.7.2.1.7 Install the gasket (01643) and Battery Cover (01005)
3.7.2.1.8 Loosely install the six M3x8 Pan Head Screws (NA-00-408), Spring Washers (NC-00-163) and
Washers (NC-00-040) to the Battery Cover (01005)
3.7.2.1.9 Torque tighten the six M3x8 Pan Head Screws (NA-00-408) to 3.5 ~ 4.4 lbf in (0.4 ~ 0.5 Nm).

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3.7.3 On Condition Maintenance
Periodic inspection of the Battery Cover Gasket (01643) must be done. If there are any noticeable
signs of deterioration of the Gasket that will effect its sealing properties, it must be replaced.
3.7.3.1 Refer to the IPC Figure 5 and Figure 6. Replace the Battery Cover Gasket (01643) as follows:
3.7.3.1.1 Remove the six M3x8 Pan Head Screws (NA-00-408), Spring Washers (NC-00-163) and Washers
(NC-00-040) from the Battery Cover (01005)
3.7.3.1.2 Remove the Battery Cover (01005)
3.7.3.1.3 Remove and discard the Gasket (01643)
3.7.3.1.4 Install a new Gasket (01643)
Note: Make sure that all the Gasket holes are aligned.
3.7.3.1.5 Install the Battery Cover (01005)
3.7.3.1.6 Loosely install the six M3x8 Pan Head Screws (NA-00-408), Spring Washers (NC-00-163) and
Washers (NC-00-040) to the Battery Cover (01005)
3.7.3.1.7 Torque tighten the six M3x8 Pan Head Screws (NA-00-408) to 3.5 ~ 4.4 lbf in (0.4 ~ 0.5 Nm).
3.7.4 Charge procedure for the built-in Battery (off-Aircraft)
The back-up Battery (A01011) can be conditioned / charged externally from the CPI System with
the (optional) Battery Conditioning Unit (99-15).
3.7.5 Charge procedure for the built-in Battery (on-Aircraft)
In accordance with the Aircraft manufacturer and Platform Specific Requirements, it may be
necessary to charge the built-in Battery on-Aircraft before setting the SIU to the ARM position.
Note: The procedure to charge the Battery is done after the SIU has been installed, and in
accordance with the Aircraft Manufacturer Platform Specific Operational Requirements.
3.7.5.1 Charge the built-in Battery (on-Aircraft) as follows:
3.7.5.1.1 Make sure that the SIU is set to OFF
3.7.5.1.2 Disconnect Connector J2 from the SIU
3.7.5.1.3 Connect Connector J1 to the SIU
3.7.5.1.4 Apply 28 V DC to the Aircraft
3.7.5.1.5 Set the SIU to ARM
3.7.5.1.6 Charge the built-in Battery for approximately 15 minutes
3.7.5.1.7 Set the SIU to OFF
3.7.5.1.8 Remove 28 V DC from the Aircraft
3.7.5.1.9 Disconnect Connector J1 from the SIU
3.7.5.1.10 Connect Connector J2 to the SIU.

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3.8 Beacon Deployment Control (BDC): 503-41
3.8.1 Scheduled Maintenance
Note: The BDC contains components with an operational life of seven years. After seven years of
operation the BDC must be returned to Techtest Ltd for replacement.
3.9 Beacon Release Unit (BRU): 503-21 Series
Refer to the IPC Figure 7. If the BRU is removed from the installed System for shipping, storage etc.
the Protective Cover Plate (0881) must be installed, and remain in place until the BRU is installed.

3.9.1 Scheduled Maintenance

Actuator
The Actuator, contained in the BRU, has a total life of 10 years from date of manufacture, or one
deployment firing.
3.9.2 On Condition Maintenance
Sealing Gasket
Periodic inspections must be made to the Sealing Gasket (0921) located between the BRU and the
CPI Beacon. If there are any noticeable signs of deterioration of the Sealing Gasket, that could affect
its operating performance and ability to maintain a water tight seal, it must be replaced.
3.9.2.1 Replace the BRU Sealing Gasket as follows:
3.9.2.1.1 Remove the CPI Beacon from its installed location as detailed in Section 3.2
Note: The BRU’s four countersunk Mounting Screws will have to be loosened to allow the Sealing
Gasket to be released.
3.9.2.1.2 Remove and discard the Sealing Gasket (0921) from the edge of the BRU
3.9.2.1.3 Install a new Sealing Gasket (0921) to the BRU
3.9.2.1.4 Torgue tighten the four countersunk Mounting Screws to 18~22 lbf in (2.0~2.5 Nm)
3.9.2.1.5 Install the CPI Beacon as detailed in section 3.3.

3.10 Water Activated Switch (WAS): 503-23-2

The WAS is not maintained by the end User. In the event of failure, the WAS must be returned to
Techtest Ltd for repair / replacement as deemed necessary.
3.11 Cockpit Control Unit (CCU): 503-22 Series
The CCU is not maintainable by the end User. In the event of failure, the CCU must be returned
to Techtest Ltd for repair / replacement as deemed necessary.

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4.0 Post Maintenance Test

4.1 General Maintenance

4.1.1 General Maintenance work includes Battery and Gasket replacement or any work that does not require
any LRU to be disconnected from the CPI System. This does not include the removal of the Beacon
from the BRU. When the Maintenance work has been completed, and LRU(s) are replaced, do a Built
In Test (BIT)
BIT
4.1.2 Do the BIT as follows:
Notes:
1. The BIT takes place through the CCU.
2. A Portable Cospas-Sarsat Beacon Test Set, (12-503-26) can be used to decode the Message from
the Beacon while the BIT is being done. Refer to the (12-503-26) User Manual for Operating
Instructions.
4.1.2.1 Refer to Figure 2 and the IPC Figure 9. Before a BIT can be started, switch the System to ARM on
the SIU (Figure 2 (a))
4.1.2.2 Press the TEST/RESET Button (Figure 2 (b)). Both the TX/TEST and BEACON GONE Light Emitting
Diode (LEDs) will illuminate (Figure 2 (c))
Note: The TX/TEST LED WILL flash at the same frequency of the Swept Tone (Fig 2 (d)).

4.1.2.3 Make sure that both the LEDs remain illuminated for three seconds (Figure 2 (e)) then extinguish
(Figure 2 (f)), to show that the System has passed the BIT correctly
4.1.2.4 If the BIT passes, the reading taken by the (12-503-26) must be cross checked against the Aircraft
information. If there is a difference in the information, the ICU can be programmed again with the
Programming Test Set (12-503-5 or 12-503-31) or CPI Programming Adapter (12-503-14-USB) or CPI
Programming Kit (12-503-22).
Note: If the LEDs remain illuminated (Figure 2 (e)) for more than three seconds and six beeps are
heard from the CCU, the BIT has failed.
4.1.2.5 Press the TEST/RESET Button on the CCU (Figure 2 (b)), to do the BIT again to possibly overcome
Battery Passivation.
4.1.2.6 If the BIT has been done three times and the LEDs remain illuminated, the BIT has failed (Refer to
Section 4.3).
Note: It is recommended that a test of the System must be kept to a minimum, since the BIT
decreases the Battery capacity. Refer to HRS Technical Report TR655 CPI Battery Lifetime.

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 Figure 2 (a) Figure 2 (b) Figure 2 (c)

Figure 2 (d) Figure 2 (e) Figure 2 (f)

Figure 2. BIT Indications

4.2 LRU Maintenance

4.2.1 LRU Maintenance includes any work which requires LRU’s to be replaced and / or returned to
Techtest Ltd for repair / replacement. After the System has been installed, make sure that the System
is serviceable and meets its Operational Performance requirements with the System Installation Test
Set, (12-503-16 or 12-503-34). Reference must be made to the (12-503-16 or 12-503-34) Operating
Manual in order to carry out these Tests.

4.3 BIT Failure

Power-up BIT (PBIT) Fail

4.3.1 When the System starts, it attempts to read the Distress Message and the G-Activation Levels for the
Aircraft from the ICU. If it fails to read the Message both CCU LEDs will illuminate momentarily. The
System will start again and attempt to read from the ICU. For a continuous fail, both LEDs flash
continually at a very slow rate.
If the System has Armed successfully, there will be two beeps, with no LEDs illuminated.
Note: Applicable to 503-42 Series up to MOD Strike 4 and 503-42-2 & 503-42-3 up to MOD Strike 5).
If the CPI System has not been in operation overnight (or for a similar period of time) without power
applied, then it may fail PBIT until the System has had sufficient time to charge. Thus, the System
must be allowed to charge with power applied for approximately 15 minutes before arming and running
the PBIT. The System must be declared unserviceable if it subsequently continues to fail the PBIT.

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4.4 Diagnostic BIT

4.4.1 In the event that the CPI System BIT shows a FAIL, a Diagnostic Test must be performed as follows.
4.4.1.1 Switch the System to OFF at the SIU
4.4.1.2 While depressing the TEST/RESET Button on the CCU, switch the SIU to ARM. The System will beep
once signalling that the Test has started
4.4.1.3 Release the TEST/RESET Button
4.4.1.4 The System will produce a Swept Tone of 121.5 MHz transmission, followed by a 406.0 MHz tone [1].
A string of beeps will follow, the number being dependent on the type of Fault. Use Table 2 to identify
the Fault.

Table 2. BIT Faults

Fault Beep Train Bleeps

A SIU access to Beacon Data Fail 2
B SIU Accelerometer 1 fail 3
C SIU Accelerometer 2 fail 4
D SIU Accelerometer 3 fail 5
E Beacon Battery fail 7
F Beacon RF fail 8
G Beacon Tests incomplete 9
H Sounder fail 10

Fault A
If Fault A is shown then the cables between the SIU and Beacon must be checked. Make sure that they
are attached and in good working order. If the Fault continues, contact Techtest Ltd.
Fault B, C, D
If any of these Faults are shown, the SIU is at fault and must be replaced or the System shut down
and Techtest Ltd informed.
Fault E
If Fault E is shown the Beacon’s Battery must be replaced by Techtest Ltd and the System tested again.
The BIT may have to be done up to three times to overcome possible Battery Passivation. If the Fault
continues, contact Techtest Ltd.
Fault F, G, H
If any of these Faults are shown the Beacon is at fault and Techtest Ltd must be contacted.
If any of these Faults are not immediately corrected the System must be set to OFF at the SIU, and
the Beacon removed from the Aircraft (Section 3.2) until the System is repaired.
Note: A working System will provide the following Sequence during Diagnostic Test:
• The System will beep once when the Test has started
• Release the TEST/RESET Button
• The System will supply a Swept Tone of 121.5 MHz transmission, followed by a 406.0 MHz
tone [1]
• The System will beep once to signal the end of Diagnostic BIT, followed by two beeps when
the System has ARMED.

[1]. The 406.0 MHz transmission will contain Test Data in the Message.

16 Issue 38 -13.01.22 - CN 18689

HRS 1032-04-04
5. Diagnostic Procedure following CPI Deployment
5.1 Scope
Refer to Figure 3. This Procedure is to be used by Maintenance Personnel that follows a Beacon
Deployment from a Techtest Ltd CPI System (15-503-134 Series), especially in cases where there is an
unknown reason for Deployment.
5.2 Objectives
The CPI System has built-in safeguards to reduce the risk of Inadvertent Deployment. There may be
unexpected internal or external conditions which occur while the System is Armed that will cause the
System to Deploy. The Procedure is designed to collect as much Diagnostic Information as possible in the
event of a Deployment. This will enable the reason for Deployment to be found quickly and for corrective
steps to then be put in place to stop a further incidents.
Preferred tools: 12-503-23 CPI Readout Kit

Beacon Deployed

Confirm Beacon Transmitting

on 121.5MHz

Recover Beacon and Press

reset on the Beacon to
cease transmission

Disarm SIU, and detach ident

config unit. Read activation
reason from ident using
12-503-23

Identified valid Yes

reason for
deployment

No

Read activation reason

from CPI beacon using
12-503-23

Identified valid Yes Record reason,

reason for complete and return
deployment CPI incident form

No

Complete and return CPI

Complete and return incident form. Return BRU,
CPI incident form Beacon and any other LRUs
Return entire system to identified as the cause of
Techtest Ltd activation by the read out to
investigation Techtest Ltd.

Figure 3. Diagnostic Procedure Flowchart

Issue 38 - 13.01.22 - CN 18689 17

HRS1032-04-04
6. Illustrated Parts Catalogue

Page
List of Figures
1. Beacon 503-16 MOD 4, 503-16-LMD MOD 2, 503-16HT, 503-16GPS MOD 1,
503-16-MM MOD 1, 503-16GPS-243, 503-16-LMD, 503-16-HUMS & 503-16
(Class 1) 19
2. Beacon 503-16 MOD 5+, 503-16-LMD MOD 3, 503-16HT MOD 3+,
503-16GPS MOD 2+, 503-16GPS-LMD MOD 1, 503-16GPS-243 MOD 1+,
503-16-HUMS MOD 1+, 503-16MM MOD 2+, 503-16 (Class 1) MOD 1,
503-16-25 MOD 1 & 503-16-25BLK 20
3. Aircraft ID Configuration Unit 503-40 21
4. Beacon Deployment Control 503-41 Series 21
5. System Interface Unit 503-42 Series 22
6. System Interface Unit 503-42-G Series 23
7. Beacon Release Unit 503-21 & 503-21-MM 24
8. Water Activated Switch 503-23-2 25
9. Cockpit Control Unit 503-22 Series 25

18 Issue 38 -13.01.22 - CN 18689

HRS 1032-04-04
 1 2 3

Beacon 503-16 MOD 4, 503-16-LMD MOD 2, 503-16HT, 503-16GPS MOD 1, 503-16-MM MOD 1, 503-16GPS-243,
503-16-LMD, 503-16-HUMS & 503-16(Class 1)
No. Description Part No. Qty.
1. Lock Plate 01505 1
2. M6 Spring Washer N/A 0
3. Special Bolt 0862/1 1

Figure 1.

Issue 38 - 13.01.22 - CN 18689 19

HRS1032-04-04
 1 2 3
4

Beacon 503-16 MOD 5+, 503-16-LMD MOD 3, 503-16HT MOD 3+, 503-16GPS MOD 2+, 503-16GPS-LMD MOD 1,
503-16GPS-243 MOD 1+, 503-16-HUMS MOD 1+, 503-16MM MOD 2+, 503-16(Class 1) MOD 1, 503-16-25 MOD 1
& 503-16-25BLK
No. Description Part No. Qty.
1. Lock Plate 01505 1
2. M6 Spring Washer N/A 0
3. Special Bolt 0862/1 1

4. Gasket A01763 1

Figure 2.

20 Issue 38 -13.01.22 - CN 18689

HRS 1032-04-04
 U 11
G tu 1 o D
O u 0 ri L D

AT x 10 xx
FI c 11 N N

N xx 10
C an 00 Se NG LT
N fa 0 al A

x
IO x/x 10
ID f M 10 0 E T
PI o 11 4 R S

IT
C ate 01 3- TE E

U re 01

N
D 00 50 S HT

61 X
U2 XX
01 I C
o No OM TE
N

de /X

5
Co XX
R
. N art LE

tu n.
ac io
uf ct
I.D P

an e

re
M sp
in

7 3 D
9 5
of

6 2 COR

10
te

8 4
Da

1 D RE
r
to

MO
ec
sp
In

Aircraft ID Configuration Unit 503-40

Figure 3.

Pa LeomTechtest
Serialrt number inster Ltd
Engla
Date of No 50 3-41 nd
CPI BE xx
ACON Manufac x
DEPLO tu
Dat YMENre xx/xxx
Manue of Inspec T CO
NTRO
x
facturer C tion L
.
ode U XX/XXX
Inspec 2615
tor
MOD
1 2 REC
6 OR
7 83 4 D
9 105

Beacon Deployment Control 503-41Series

Figure 4.

Issue 38 - 13.01.22 - CN 18689 21

HRS1032-04-04
 1.

2.

WA
R ATTERYRNIN
B
3. BA
UNITEMOVE
IN
G
D WMUST !
TTE STO HIL BE
CA BATCH No RY PA RAG ST
DO N UTION xxx Ex RT NO A E
OT DI : p Date 01
SPOSE xx/xx 011
OF IN
FIRE

4.

5.

6.
P
Se art n Le Te
Da rial N umb ominchte
CP te o o er ste st L
I SY f M
a xx 503-4r Engtd
EM nufa x
ST lan
2 d
INT cture
ER
1 2MO
D RE FAC xx/x
6 EU xx
7 3 CORD NIT x
8 4
9 1 5
0

.
X
X
X
/X 5
X
X 61
n. U2
tio e
ec od
sp C
In rer
of tu
e fac
at
D anu
M
r
to
ec
sp
In

System Interface Unit 503-42 Series

No. Part No. Qty. Description

1. NA-00-408 6 Screw, Pan Head

2. NC-00-163 6 Spring Washer

3. NC-00-040 6 Washer
4. 01005 1 Battery Cover
5. 01643 1 Gasket
6. A01011 1 Nickel Metal Hydride Battery

Figure 5.

22 Issue 38 -13.01.22 - CN 18689

HRS 1032-04-04
 1.

2.

WA
R ATTERYRNIN
B
3. BAT
UNITEMOVE
IN
G
D WMUST !
TE STO HIL BE
CA BATCH No RY PA RAG ST
DO N UTION xxx Ex RT NO A E
OT DI : p Date 01
SPOSE xx/xx 011
OF IN
FIRE

4.

5.

6.
P
Se art n Le Tec
Da rial N umb omin htes
er
CP te o o ste t Ltd
I SY f M
a xx 503- r En
EM nufa x
ST 42
INT cture
ER
1 2MO
D RE FAC xx /x
6 3 CORD EU x
7 4 NI
8
9 1 5
0

.
X
X
X
/X 5
X
X 61
. 2
tion e U
ec od
sp C
In rer
of tu
e fac
at
D anu
M
r
to
ec
sp
In

System Interface Unit 503-42-G Series

No. Part No. Qty. Description

1. NA-00-408 6 Screw, Pan Head

2. NC-00-163 6 Spring Washer
3. NC-00-040 6 Washer
4. 01005 1 Battery Cover
5. 01643 1 Gasket
6. A01011 1 Nickel Metal Hydride Battery

Figure 6.

Issue 38 - 13.01.22 - CN 18689 23

HRS1032-04-04
 1. 2.

3.

ER
LEOMINSTER ENGLAND

ING COV
Part No 503-21 Serial No xxx

RN ER
WA UND ION
Date of Manufacture xx/xxxx
Actuator Expiry Date xx/xxxx
TECHTEST LTD

RD ICE AT
A ZA DEV ACTIV RN NIT
H ING ON WO E U
CPI RELEASE UNIT

R E S
SP ULT T B EA
ED ES US EL
SS Y R S M .I. R
1 2 3 4 5
6 7 8 9 10

RE MA OR C.P
MO P URY TECT 3-21
MOD RECORD

C INJ RO . 50
R
VE
E P ED
EY LIMIT
TE
ST
N CO881 E
TE AI 0 C
CH
T O N
RERT NENA
PAAINTSES
O
R MRP
FO PU

Beacon Release Unit 503-21 & 503-21-MM

No Part No Qty. Description
1. 0921 1 Sealing Gasket
2. 0881 1 Protective Cover Plate

3. ND-00-045 1 Helicoil

Figure 7.

24 Issue 38 -13.01.22 - CN 18689

HRS 1032-04-04
 LTD AN
D
ST NGL
HTE R E
TECINSTE -23-2 xx
M 3 x/ x x ITCH
L E O 5 0x x c t u r e x T E D S W
x
r t N o l N o a n u f a A C T I VA
P a S e r ia o f M T E R
e
Dat WA
RD
RECO 4 5 0
CPI

MOD 2 3 8 9 1
1 7
6

S F W
W IT A
X

IT T Y
X/X 5

C ED U
H
. X U261

M TH
U IS
S
T
n

B
P
o

E
t i e
pec Cod
Ins ure
a t e o fu f a c t
D Man
DO
NO to r
T
pec
Ins
HO CO
LE VER
S
DO HO
NO LE
T CS
OV
ER

Water Activated Switch 503-23-2

Figure 8.

MOD RECO
6 1
7 28 39 4 RD
10 5 Part nu leomTe
DaSerial No mber inch
stetes
r t ltd
te of Ma
CPI CO xxx 503-22England
nufac
CKPIT CO ture xx/xx
NTRO L PANE xx
Date L
Manufacof Inspectio
ture Cod n. XX/XXX
Date of e U2615 X
Inspec
tion.
XX/XXX
X

TX/TE TEST/
ST RESET
TRANSMIT

BEAC
ON
GONE
DEPlOY

CPI
CO
NTR
Oll
ER

Cockpit Control Unit 503-22-Series

Figure 9.

Issue 38 - 13.01.22 - CN 18689 25

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 INTENTIONALLY LEFT BLANK

26 Issue 38 -13.01.22 - CN 18689

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