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MX-15i Surveillance System

Operations & Maintenance Manual

TM00358 Rev. A

This document contains information proprietary to L-3 WESCAM.

Unauthorized reproduction or disclosure - in whole or in part - without the

prior written consent of L-3 WESCAM is strictly prohibited.

Summary of Contents for MX-15i

Page 1: ...rations Maintenance Manual TM00358 Rev A This document contains information proprietary to L 3 WESCAM Unauthorized reproduction or disclosure in whole or in part without the prior written consent of L 3 WESCAM is strictly prohibited ...

Page 2: ...nt s Intended Use Functionality Description Features and functionality of the system are dependent upon the turret s payload logic processors and the overall system configuration Some documented functions may not work in your configuration as these may be optional features or unconfigured functions Copyright 2007 Wescam Inc All rights reserved MX MX Day Night Spotter Wescam and Wisard are register...

Page 3: ... Wescam 649 North Service Road Burlington Ontario L7P 5B9 Canada Tel 905 633 4000 Fax 905 633 4100 N A Toll Free 1 888 593 7226 or 1 888 5 WESCAM Outside N A Long Distance 1 905 633 4175 wescam com Rev Description Release Date Initial Release ECO1645 2007 07 13 A Revised per ECR 1715 ECO2464 2007 10 16 ...

Page 5: ...ea or to protect worn nickel plating The turret s interface plate and the aircraft s mounting plate must provide a conductive path to electrically ground out the turret WARNING TURRET IS A HEAVY ITEM USE ONLY APPROVED EQUIPMENT AND PROCEDURES FOR UNPACKING AND LIFTING THE TURRET WARNING SUPPLIED MOUNTING SCREWS FOR SERVICE STAND ONLY DO NOT USE SERVICE STAND MOUNTING SCREWS FOR INSTALLING THE TURR...

Page 6: ...ve sufficient time to follow all steps or while you are completing other maintenance tasks Caution Do not scrape bonded particles that cannot be removed with compressed air Soak the particles and allow them to loosen WARNING ALTHOUGH INERT THE NITROGEN GAS YOU WILL BE HANDLING IS COMPRESSED AND THEREFORE SHOULD BE TREATED WITH THE CARE ANY COMPRESSED GAS REQUIRES REVIEW ALL MATERIAL SAFETY DATA SH...

Page 7: ...esiccant material does not spill out Caution Do not over fill or pack the desiccant material Room must be left for the filler port to seat properly Caution Store and pack the turret by following the procedures defined in Chapter 4 of this manual When shipping items it is the customer s responsibility to correctly pack and obtain insurance L 3 Wescam is not liable for any damage that occurs during ...

Page 9: ...ry Switch Controls 10 2 1 2 Hand Controller Secondary Button Controls 14 2 1 3 Slew Transducer Turret Steering 16 2 2 VIDEO STATUS OVERLAYS 18 2 2 1 Tracking Orientation Graphics 18 2 2 2 Messaging Graphics 20 2 2 3 Target and Aircraft Status Graphics 21 2 2 4 North Indicator 23 2 2 5 System and Sensor Status Graphics 24 2 3 USER MENU NAVIGATION 27 2 3 1 Menu Components 27 2 4 SYSTEM STATUS MENU 3...

Page 10: ...4 2 TURRET SERVICE STAND INSTALLATION 72 4 3 TURRET AIRCRAFT INSTALLATION 75 4 3 1 Step 1 Corrosion Inspection 76 4 3 2 Step 2 Surface Preparation and Jointing Compound Application 77 4 3 3 Step 3 Installation and Mechanical Fastening 78 4 4 TURRET REMOVAL 80 4 4 1 Special Handling Instructions for Damaged Turrets 81 4 4 2 Removing the Turret from the Aircraft 82 4 5 HAND CONTROLLER INSTALLATION 8...

Page 11: ...nmental Considerations 101 6 3 TURRET PURGING 103 6 4 PURGE VALVE REPLACEMENT 106 6 5 REMOVING REPLACING THE DESICCANT ASSEMBLY 108 6 5 1 Remove and Replace the Desiccant Assembly 108 6 5 2 Removing Refilling and Reinstalling the Desiccant Assembly 109 6 6 LRU RETURN TO VENDOR PROCEDURE 112 6 6 1 L 3 Wescam Customer Service Contact Information 113 Appendix Acronyms and Abbreviations 115 ...

Page 13: ...3 Figure 2 13 Measurement Modes and Changes to Target Coordinate Data 23 Figure 2 14 North Arrow Graphic 23 Figure 2 15 MX 15i System Video Overlay 24 Figure 2 16 Steering Mode with ZMULTI Enabled 25 Figure 2 17 VIC Status Indicator in a Dual Display Configuration 25 Figure 2 18 Geo Focus Status Indicator 26 Figure 2 19 Menu Structure 27 Figure 2 20 Typical Menu Dialog 28 Figure 2 21 Level 1 Syste...

Page 14: ...for Installation 76 Figure 4 5 Bolt Sealant Application Areas 77 Figure 4 6 Turret Connectors 78 Figure 4 7 6 Bolt Tightening Pattern 78 Figure 4 8 MX 15i Turret Removal and Shipping Case Packing 80 Chapter 5 Failure Diagnosis Figure 5 1 Example of a Major BIT Failure in the System Status Menu 86 Figure 5 2 Alarms Page 88 Figure 5 3 Fault Diagnostic Tree for Power Loss 97 Figure 5 4 Fault Diagnost...

Page 15: ...s in the Level 2 Video I O Menu 39 Table 2 11 Status Information and Controls in the Level 2 Operator Gimbal Menu 40 Table 2 12 Status Information and Controls in the Level 2 Operator Payload Menu 42 Table 2 13 Status Information and Controls in the Level 2 Mission Menu 44 Table 2 14 Status Information and Controls in the Level 2 Overlay Menus 46 Chapter 3 Technical Description Table 3 1 EOW Lens ...

Page 16: ...able 6 3 Turret Purging Parts and Support Equipment 103 Table 6 4 Turret Purging Consumables 103 Table 6 5 Purge Valve Replacement Parts 106 Table 6 6 Purge Valve Replacement Tools 107 Table 6 7 Purge Valve Replacement Bulk Items 107 Table 6 8 Desiccant Removal Parts 108 Table 6 9 Desiccant Removal Tools 109 Table 6 10 Desiccant Refill Consumables 109 Table 6 11 Desiccant Refill Tools 110 ...

Page 17: ...Overview L 3 WESCAM October 2007 All Rights Reserved 1 System Overview This chapter provides a system overview and details various component specifications Chapter Contents System Configuration 2 System LRU Component Specifications 6 ...

Page 18: ...ns a video switching matrix that manages output to external display monitors video tape recorders VTR and other associated video equipment Graphical overlays on top of the displayed video provide the primary method for viewing system status information Infrequently used status information and other control parameters are viewed through user menus Figure 1 1 System Configuration P3 P1 P2 Aircraft 2...

Page 19: ...ystem Components Equipment Product Name Supplier Part Number Qty Turret MX 15i containing a payload of EOW Daylight Zoom Camera with continuous zoom lens IR Thermal camera with stepped zoom lens EON MX Day Night Spotter with a fixed focal length lens Features Gen 3 0 IR Video Processing circuit card assembly Moving Map and NightSun Communication interfaces enabled NTSC video format L 3 Wescam 4239...

Page 20: ...ns are distributed amongst multiple microprocessors 1 1 3 Video Switch Matrix A video switch matrix manages analog video inputs from all imaging sensors The video switch matrix also manages routing of all analog video outputs Prior to output to an external display the switch matrix applies graphical overlay annotations to the sensor video The MX 15i features an 8x8 S Video matrix with 3 overlay an...

Page 21: ...he captured video or as on screen user menu displays with no sensor video The annotations are applied by the video switch matrix before outputting to display Video Sync Detection A built in video sync detector monitors for potential video signal loss from the turret If video from the turret is lost a BIT message will be displayed to report the failure IR 3 EOW 2 EON 1 DCE Video 1 S Video Overlay 1...

Page 22: ...ad Sensors Payload Sensor 1 EOW Daylight Camera with continuous zoom lens Focal Length Optical 2 4 60 mm Digital 60 180 mm Field of View Optical 47 18 2 0 Digital 2 0 0 67 Payload Sensor 2 IR Thermal Camera with stepped zoom lens Focal Lengths 27 mm 135 mm 675 mm 2024 mm Fields of View 26 67 5 43 1 09 0 36 Note Optical focal length is 1012 mm Apparent focal length achieves 2024 mm when a 2x electr...

Page 23: ...Dimensions 11 4 cm w x 21 8 cm h x 7 6 cm d 4 5 w x 8 6 h x 3 d Attached cable length is customer specified Input Power 28 VDC Derived from Turret connection Environmental Operating Temperature 40 C to 55 C 40 F to 131 F Storage Temperature 55 C to 85 C 67 F to 185 F Max Altitude 3353m 11 000 ft above sea level Limit for a non pressurized environment only Table 1 5 GPS Antenna LRU Specification It...

Page 24: ...58 Rev A October 2007 L 3 WESCAM 8 All Rights Reserved Storage Temperature 55 C to 85 C 67 F to 185 F Max Altitude 30m and 16 764m above sea level 100 and 55 000 ft above sea level Table 1 5 GPS Antenna LRU Specification Continued Item Description Notes ...

Page 25: ...roller and navigate through the system s user menus and controls Chapter Contents Hand Controller Controls 10 Video Status Overlays 18 User Menu Navigation 27 System Status Menu 30 Gimbal Menu 32 EOW Menu 33 IR Menu 35 EON Menu 37 Video I O Menu 39 Operator Gimbal Menu 40 Operator Payload Menu 42 Mission Menu 44 Overlay Menus 46 Profiles Menu 48 Recommended Operator Mission Tasks 50 ...

Page 26: ...used for the most common operator functions All operator control descriptions assume default settings of the Level 2 Operator Gimbal Menu A number of parameters in the Level 2 Operator Gimbal Menu can be used to tailor operation of the Hand Controller however tailoring is optional and not normally required Figure 2 1 Hand Controller 2 1 1 Hand Controller Primary Switch Controls Figure 2 2 Hand Con...

Page 27: ...to select an AVT tracking algorithm 4 AUTO switch Click up to enable an Auto Geo Position steering mode MANUAL switch Click down to enable a Rate Manual steering mode Note Excluding Stow this selection will cancel all other disabled assisted or automated steering modes 5 AID switch When operating in a Rate Manual steering mode click up to enable a Rate Aid steering mode When operating in an Auto s...

Page 28: ...ither enable or disable system power 10 OFFSET switch IR Sensor When in Manual Sensitivity mode click up to increase the IR temperature offset When in Manual Sensitivity mode click down to decrease the IR temperature offset EOW EON Sensors Click up to increase the video s black level Click down to decrease the video s black level Note Offset sensitivity is similar to the contrast control on a tele...

Page 29: ...g Map Deadman lever Pull in to allow arming of the Laser Illuminator Release to disarm the Laser Illuminator STATUS LIGHTS 15 ARMED status light Lit LED indicates that the Laser Illuminator is armed Unlit LED indicates that the Laser Illuminator is disarmed 16 ACTIVE status light Lit LED indicates that the Laser Illuminator is firing Unlit LED indicates that the Laser Illuminator not firing 17 ON ...

Page 30: ...ill only fire when all arming conditions are met 3 GEO FOCUS button Press to enable or disable sensor Geo Focus Push and hold for 2 seconds to enable Geo Focus Trim mode Use the focus wheel to adjust the sensor s focus When in Trim mode press once to return to Geo Focus with trim settings applied Note In Geo focus mode all sensors are auto focused to a distance set by the range to target value Not...

Page 31: ...N Sensors Press to change scene type to compensate for high or low image contrast IR Sensor Press to change scene type to compensate for high or low image contrast Note Scene will provide new parameters for video correction after a 1 Point calibration is initiated Press the IR CAL button after pressing the SCENE button 9 IR CAL button For the IR sensor press to initiate a 1 Point calibration 10 PO...

Page 32: ... MX 15i System Steering Modes Steering Mode Steering Control Overlay Label Slew Transducer Function Stow Disabled Fixed Position STOW System steers turret to its storage position Operator has no steering control of turret Slew transducer disabled Forward Disabled Fixed Position FWD System steers turret to a fixed forward pointing position Operator has no steering control of turret Slew transducer ...

Page 33: ...l length wide FOV the turret will speed steering response Slew Automated AUTO System steers turret to fixed coordinates supplied by radar moving map or other external source Operator has no steering control of turret Slew transducer disabled until turret reaches position Autoscan Automated SCAN System steers turret in a defined sweep pattern Operator has no steering control of turret Slew transduc...

Page 34: ...hics for optional functions that are not present Figure 2 4 Typical MX 15i Video Overlay Graphics 2 2 1 Tracking Orientation Graphics Tracking and orientation graphics are the primary overlay graphics an operator will use to assess image aiming turret orientation and zoom position There are four tracking and orientation graphics Center Reticle marker a reference point that denotes image center and...

Page 35: ...t Zoom Marker Indicates the next display area for a sensor with stepped zoom capability This graphic will not be displayed for sensors with a fixed focal length or when the sensor is at its maximum zoom setting Relative Zoom Status Bar A zoom utilization status bar that indicates the current FOV relative to the minimum and maximum viewing angles of the sensor A thick black bar indicates a wide FOV...

Page 36: ...ntil they are cleared by pressing the MENU button Messages will be displayed when a system BIT detects a failure an external system forwards a message for display Once cleared from the video display BIT alerts can be later retrieved from a user menu Alarms page where messages are retained until the system component s function is restored Wide FOV Narrow FOV Max FOV Min FOV Current FOV EOW 90 2X CO...

Page 37: ...ted or measured target slant range values The target is always assumed to be centered in the video Terrain elevation is presented at bottom center Note Display units for coordinates can be configured from the Mission menu Figure 2 9 Target and Aircraft Status Aircraft Coordinates Reports the aircraft s geographic location data lat long Display units can be configured by the operator Aircraft Headi...

Page 38: ... WGS84 For long range distances the calculation applies correction factors for the earth s curvature and atmospheric influences While accurate the calculation of target location cannot account for angular measurement errors inaccuracies in GPS position and altitude data or timing errors introduced by either extreme turret movement or from latent data updates For example viewing a subject at very n...

Page 39: ...he North Indicator arrow is located in the top left side of the display and the arrow s point indicates the direction of True North Operators would use the arrow as a universal point of reference for describing ground movements relative to an earth orientation rather than the aircraft s position The arrow provides a witness marker on the video so that the line of sight of the captured video can be...

Page 40: ...ng received If no GPS time code is being supplied this graphic will be displayed as USER Steering Modes Displays the current turret steering mode Possible values can be SCAN Autoscan mode MAN Rate Manual mode When ZMULTI is enabled the MAN graphic will be displayed in reverse video FWD Forward mode RAID Rate Aid mode AUTO Auto Track Geo Position or Geo Slew Auto Slew mode same status symbol for bo...

Page 41: ...atus Indicator in a Dual Display Configuration Focal Length Displays the current sensor s focal length Units are displayed in millimeters Digital E Zoom Displays the current IR sensor E Zoom setting There will be no graphic if E Zoom is disabled Possible values can be 2x 4x Filter Displays the selected optical filter that is supported by the current sensor The graphic will be blank if no filters a...

Page 42: ... at infinite focus For EON sensors which have a very narrow depth of field operators can compare the focus distance with the terrain elevation and use the offset as a relative indication for which direction to move the focus control Geo Focus Trim When the Geo Focus is enabled the operator can set a trim offset percentage between 0 and 99 Trim is a fine focus adjustment that compensates for errors...

Page 43: ...asured feedback information related to a sensor or system control These fields cannot be modified Value Fields configuration parameters the operator can modify to set new values These fields are identified by XinwardW pointing arrows Action Fields commands that operators execute to either initiate an action or display a new menu These fields are identified by WoutwardX pointing arrows SYSTEM STATU...

Page 44: ...ZOOM switch up or down to select a desired XvalueW or WactionX field 5 To access third level miscellaneous menus move the cursor to the MISC field at the bottom of the screen and press the MENU button 6 To exit a third level sub menu use the ZOOM switch to cursor down to DONE and then press the MENU button or press and hold the MENU button for two seconds 7 To exit a second level sub menu use the ...

Page 45: ...n to execute that field s action Changing the Value for a Value Field 1 If the System Status main menu is not displayed press the MENU button on the Hand Controller 2 Click the ZOOM switch up or down to select a desired menu option 3 Press the MENU button to display the sub menu option 4 Click the ZOOM switch up or down to select a desired menu option 5 Click the SENS switch to change the option s...

Page 46: ...L Displays the Gimbal menu EOW Displays the EOW menu IR Displays the IR menu EON Displays the EON menu VIDEO I O Displays the Video I O menu OPERATOR GIMBAL Displays the Operator Gimbal menu OPERATOR PAYLOAD Displays the Operator Payload menu MISSION Displays the Mission menu OVERLAY EOW Displays the Overlay menu for the EOW OVERLAY IR Displays the Overlay menu for the IR OVERLAY EON Displays the ...

Page 47: ...in a fully functioning state None OK STOWED Turret is operational but in the Stow position Steer turret to Forward or manual position to establish video MINOR OPERATIONAL Component BIT test failed but still functional Component capabilities are out of tolerance e g focus position exceeded tolerance set point Review BIT from the Alarms page MAJOR OPERATIONAL Component BIT test failed but still func...

Page 48: ...cement for monitoring turret humidity indicator VOLTAGE DC Voltage Displays the supply voltage at the turret AZIMUTH STABILIZATION µRad Estimated stabilization in units of micro radians Typical value is 2 3 May give incorrect value under significant steering acceleration ELEVATION STABILIZATION µRad Estimated stabilization in units of micro radians Typical value is 2 3 May give incorrect value und...

Page 49: ... 67 Current horizontal FOV in degrees FOCAL LENGTH Optical 2 4 60 mm Digital 60 180 mm Current focal length in millimeters FOCUS 1 m to Infinity Focus position expressed as an estimated distance to the object that sensor is focused upon Units are in meters Note Do not use number for reporting target distance this is a very crude distance estimation SENSITIVITY AUTO System has been enabled for auto...

Page 50: ...US WARMING UP COOLING Sensor disabled because internal operational temperature is above or below limits OK Sensor at operational temperature FILTER COL Color filter NIR Near infrared filter Table 2 7 Status Information and Controls in the Level 2 EOW Menu Continued Field Values Description ...

Page 51: ...oom At 1x zoom the video s field of view the optical field of view At 2x zoom the video s field of view of optical field of view At 4x zoom the video s field of view of optical field of view Note The 4x option is only available on some IR sensors and not available on the VNFOV CALIBRATION 1 POINT Selects a 1 Point calibration option to remove of common video artifacts and reset dynamic range of th...

Page 52: ...the object that sensor is focused on Units meters Note This is a very crude calibration and therefore should not be taken as a target distance SENSITIVITY AUTO System has been enabled for automatic control of image brightness MAN Current value for manual sensitivity Operators can increment the sensitivity to control image brightness from the Hand Controller LEVEL AUTO System has been enabled for a...

Page 53: ...GH Optimizes camera for high contrast scenes LOW Optimizes camera for low contrast scenes ACTION FIELDS MISC Displays Miscellaneous menu ALARMS Displays Alarms page with BIT test results for the EON sensor BIT Initiates an EON BIT DONE Exits menu STATUS INDICATORS FOV Daylight 0 28 Lowlight 0 30 Current horizontal FOV in degrees FOCAL LENGTH 1000 mm Current focal length in millimeters LEVEL 2 EON ...

Page 54: ...ue for manual sensitivity Operators can increment the sensitivity to control image brightness from the Hand Controller TEMP STATUS WARMING UP COOLING Sensor disabled because internal operational temperature is above or below limits OK Sensor at operational temperature FILTER LP XLP COL Displays the current filter selection From the Hand Controller operators can select between the daylight camera C...

Page 55: ...vel 2 Video I O Menu Table 2 10 Status Information and Controls in the Level 2 Video I O Menu Field Values Description VALUE FIELDS VIDEO OUTPUTS Source Sets the source and assigns a sensor to a video output channel Overlay Enables or disables display of overlay graphics in video distributed to the output channel ACTION FIELDS FACTORY DFLT Resets all user configured value fields to factory default...

Page 56: ...toscan feature For example Autoscan is useful in search and rescue missions where the plane is flying a search grid To ensure complete video capture Autoscan can be set up for a turret sweep that overlaps the previous flight corridor Figure 2 27 Level 2 Operator Gimbal Menu Table 2 11 Status Information and Controls in the Level 2 Operator Gimbal Menu Field Values Description VALUE FIELDS AZIMUTH ...

Page 57: ...on is set to 90 ELEVATION FWD 90 Sets the vertical angle when the turret is in the Forward position STEERING FLTR 0 to 100 Increases or decreases the responsiveness of steering controls 75 is the recommended setting Note A value of 100 will disable steering AUTOSCAN ON OFF Initiates an Autoscan steering mode using the configured steering position sweep margins and sweep rate parameters AUTOSCAN AZ...

Page 58: ... the lens Figure 2 28 Level 2 Operator Payload Menu Table 2 12 Status Information and Controls in the Level 2 Operator Payload Menu Field Values Description VALUE FIELDS ZOOM SENSE NORM Sets the direction of zoom travel on the user control Upward pressure on ZOOM switch increases zoom Downward pressure on ZOOM switch decreases zoom REV Reverse the normal zoom directions ZOOM GAIN 0 to 100 Sets the...

Page 59: ...p zoom position within the focal length INIT FILTER Various Sets the startup default lens filter ACTION FIELDS FACTORY DFLT Resets all user configured value fields to factory default settings DONE Exits menu Table 2 12 Status Information and Controls in the Level 2 Operator Payload Menu Continued Field Values Description ...

Page 60: ...TC OFFSET 16 Sets the Greenwich Mean Time regional differential value in hour increments AIRCRAFT LOCATION TARGET LOCATION Decimal Degs Degs Min Min Degs Min Secs MGRS Sets the display format for location data to one of three degrees options Military Grid Reference Survey AIRCRAFT ALTITUDE Feet Meters Sets the display units for altitude data TERRAIN ALTITUDE Feet Meters Sets the display units for ...

Page 61: ...ng external navigational equipment this field dynamically displays the updated values of the terrain altitude When manual the operator can enter a static value ACTION FIELDS SET TIME Saves the configured time settings FACTORY DFLT Resets all user configured options to factory default settings DONE Exits menu Table 2 13 Status Information and Controls in the Level 2 Mission Menu Field Values Descri...

Page 62: ...D INTENSITY 0 to 100 Sets color intensity of reverse video characters 100 is white while 0 is black LOS RETICLE ON OFF Enables or disables display of the LOS Reticle FL GRAPHICS ON OFF Enables or disables display of the focal length relative zoom graphic AZ EL SCALES ON OFF Enables or disables display of the azimuth elevation scales SENSOR ON OFF Enables or disables display of the system and senso...

Page 63: ...INDICATOR ON OFF Enables or disables display of the north indicator graphic ACTION FIELDS FACTORY DFLT Resets all user configured value fields to factory default settings DONE Exits menu Table 2 14 Status Information and Controls in the Level 2 Overlay Menus Continued Field Values Description ...

Page 64: ... select the modified profile name Note Make sure you have selected the correct CURRENT PROFILE before saving All previous settings for the selected CURRENT PROFILE will be replaced by the new settings 2 With the profile selected move the cursor down to SAVE at the bottom of the screen and press the MENU button This action will save the current system settings and a screen prompt will appear asking...

Page 65: ...Restore Factory Default Settings 1 If the System Status main menu is not displayed press the MENU button 2 Using the ZOOM switch move the cursor to the PROFILES option 3 Press the MENU button 4 Using the ZOOM switch select FACTORY DFLT at the bottom of the screen 5 Push the MENU button ...

Page 66: ...e to complete a turret purge or clean the sensor windows if necessary When the humidity in the turret is above the flight limit 1 2 hours is necessary to purge the turret Do all other operator mission tasks at or during flight time Figure 2 32 Sample Operator Maintenance Task Timeline Performing a Pre Flight Inspection 1 Remove power from the turret system 2 Make sure that the upper quadrants of t...

Page 67: ...ecord and playback correctly 13 From the Hand Controller press the STOW button to automatically steer the turret to the Stow position 14 Do the steps that follow to prepare the turret system for INS alignment 14a Make sure that the GPS is connected and functions correctly 14b Make sure that the Aircraft position shows on the overlay 14c Make sure that the Pilot is aware of the speeds and maneuvers...

Page 69: ...tion L 3 WESCAM October 2007 All Rights Reserved 53 Technical Description This chapter describes components and features of the MX 15i system Chapter Contents Turret 54 Payload Sensors 57 Turret Environmental Protection 63 Software Features 65 ...

Page 70: ...izes and steers a sensor platform measures the line of sight and protects the internal payload from the environment Figure 3 1 MX 15i Turret 3 1 1 Lid The turret s lid attaches to the aircraft and contains the major electronics used to control the turret and sensors The lid assembly contains the following components Gimbal electronics Mounting interface to the aircraft Installation locator pins Mo...

Page 71: ...ents The yoke also contains the following components Turret humidity indicator Desiccant assembly and humidity indicator A turret humidity indicator measures the internal humidity of the turret Do not confuse the turret humidity indicator with the desiccant humidity indicator which is also found in the yoke Despite the fact that the turret is a sealed unit with protective measures moisture levels ...

Page 72: ...3 1 3 Gimbal The gimbal is the outer dome that electro mechanically steers and stabilizes an internal sensor payload The major functions of the gimbal are to Stabilize sensors Measure the optical bench s line of sight Align the INS Protect the payload from environmental exposure ...

Page 73: ...S reticle over a subject They might zoom into the maximum capabilities of the EOW lens For a more detailed investigation operators would switch to the higher magnification capabilities of the EON sensor to examine the subject If the subject moves out of the EON sensor s view the operator would switch back to the EOW sensor to re acquire the subject Operating Temperature Limits The EOW sensor is ex...

Page 74: ...n least sensitivity i e smallest iris opening shortest shutter speed and minimum electronic gain most sensitivity i e largest iris opening longest shutter speed and maximum electronic gain Filters Selects range of light wavelength to extend viewing into a near infrared range There are two filter positions COL restrictive pass filter to transmit visible spectrum only NIR all pass filter to transmit...

Page 75: ...es of photodiodes where each represents an image pixel the focal plane array converts infrared light into electrical signals where the measured energy is assigned a grayscale tone The combination of numerous grayscale pixels creates the overall monochromatic video image The focal plane array is contained within a vacuum sealed dewar assembly and is cryogenically cooled During system startup the ho...

Page 76: ...trol on a television or monitor To control exposure operators can utilize either an Auto or Manual mode In Auto mode the system automatically controls image brightness to maintain video quality over a range of thermal levels In Manual mode operators can manually change brightness by making stepped adjustments to the sensitivity increment Offset Sets the temperature offset value for the image and s...

Page 77: ... any laser illuminated subjects In haze conditions operators would select the XLP filter to restrict the view to a wavelength band of 840 to 1000 nm This filter minimizes the impacts of haze and improves the performance of long range viewing Operating Temperature Limits The EON sensor is exposed to temperature fluctuations that occur inside the gimbal The system monitors the sensor s temperature a...

Page 78: ...st iris opening shortest shutter speed and minimum electronic gain most sensitivity i e largest iris opening longest shutter speed and maximum electronic gain Level Sets the pedestal black level and similar to the contrast control on a television or monitor Operators can adjust the cutoff point for black to pull greater detail in deep shadows Scene Setup Controls exposure of the entire video image...

Page 79: ... or moisture 3 3 2 Turret Desiccant Assembly The desiccant assembly is designed to allow the turret to breath and exchange air This movement of air is a passive action designed to minimize pressure impacts from changes in altitude Specifically the desiccant assembly functions to Inlet outside air into the turret and equalize pressure Dry incoming air of any moisture or suspended salts If moisture ...

Page 80: ...he turret is a sealed unit with the protection of the desiccant assembly moisture levels can increase in the turret When the upper quadrants 30 40 of the turret humidity indicator are lavender pink use nitrogen to purge the turret You can find the purge valve on the rear door There is no regular or scheduled interval for these maintenance actions The replacement of the desiccant assembly and purgi...

Page 81: ...e Video In Control The reference focal length for zoom multiplier scaling is 40 mm on the EOW sensor Figure 3 5 Slew Force Interpretation Note Do not enable the zoom multiplier when attempting to manually track a high crossing rate target with a long focal length 3 4 2 Functions Related to Target Geographic Location The target geo location functions assume a spherical Earth with radius of 6366 7 k...

Page 82: ...digital to analog signal The IR sensor outputs raw thermal image data over a HotLink digital interface The IR video processor optimizes the raw image data in three phases To balance the thermal quality of the image the first optimization applies pixel uniformity correction stored in a software Non Uniformity Correction NUC table that is defined by either a 1 Point or 2 Point calibration of the IR ...

Page 83: ...C Table Application Pixel Interpolation Image Sharpening Raw Data with Sensor Artifacts Resolution Enhancement Pixel Thermal Mapping Data Conversion Histogram Tonal Equalization Analog Conversion Input Image Optimization Routing Artifact Removal 16 Bit HotLink Video NTSC or PAL Output IR Sensor Monitor Video Switch Matrix Image Processing ...

Page 85: ... Reserved 69 Installation Instructions This chapter describes the installation and removal procedures for system LRUs Chapter Contents Turret Shipping Cases Storage 70 Turret Service Stand Installation 72 Turret Aircraft Installation 75 Turret Removal 80 Hand Controller Installation 83 ...

Page 86: ... metal that are joined together and retained by spring loaded latches Cut urethane foam inside the case provides shock and vibration protection to the turret However the turret shipping case is not waterproof and it is intended to be stored indoors only The urethane foam will retain moisture and may degrade the material All other LRUs are shipped in packaging that protects to best commercial stand...

Page 87: ...spect each part as you remove it from the case Report any damage to your supervisor immediately Table 4 1 Turret Shipping Case LRU Packaging Packaging Contents Part Number Qty Notes Turret Shipping Case Shipping case 41179 1 Case weighs approximately 125 kg 276 lbs Turret 42390 1 Service stand assembly 42626 1 Service stand top plate 25705 1 Service stand mounting screws CSNAS1514CA 6 6 Cap screws...

Page 88: ...ile performing routine maintenance or testing tasks While the turret is installed in the service stand no additional weight should be placed on the service stand as the service stand is only designed to hold the weight of the turret alone The turret may be stored temporarily in the L 3 Wescam supplied service stand for maintenance or testing purposes For long term storage L 3 Wescam recommends sto...

Page 89: ...s shipping case to an open area with a flat surface 2 Make sure that the This Side Up Arrow is pointing upwards 3 Undo the latches on the sides of the shipping case and remove the lid section 4 Remove the top foam layer 5 Lift the service stand top plate from the shipping case 6 Remove the middle foam layer service stand mounting screws and cap covers 7 Inspect all foam pieces for water retention ...

Page 90: ...cond screw that is opposite to the first screw 8 Tighten a screw that is 90 from the first screw set followed by the opposite screw 9 Tighten all remaining opposite screw sets Note 3 persons are necessary for the subsequent 6 steps 10 Use 2 persons to lift the top plate and turret assembly out of the case 11 Use a third person to put one of the legs into its respective mounting hole on the service...

Page 91: ... Equipment that must conform to NAS 1351 4 Screw length is installation specific Make sure screw length extends 1 cm 3 8 below the mating surface Torque screws to 100 10 in lbs 11 Nm 1 1 Nm Table 4 3 Turret Installation Consumables Description Part Number Manufacturer Notes Joint compound non chromate corrosion inhibitive CA 1000 PRC DeSoto International Consult manufacturer s Technical Data Sheet...

Page 92: ...pping case to an open area with a flat surface 2 Make sure that the This Side Up Arrow is pointing upwards 3 Undo the latches on the sides of the shipping case and remove the lid section 4 Remove the top foam layer 5 Lift the service stand top plate from the shipping case 6 Remove the middle foam layer service stand mounting screws and cap covers 7 Inspect all foam pieces for water retention or ma...

Page 93: ...st cases you will receive written approval to proceed with installation For severe corrosion less common you will receive written notice to take the turret out of operation and prepare for repair 4 3 2 Step 2 Surface Preparation and Jointing Compound Application All mounting surfaces and fasteners must be cleaned with a solvent before applying the CA 1000 joint compound Use a progressive cleaning ...

Page 94: ... solvent on a new lint free cloth 10 Clean each mounting screw one at a time 11 Before the solvent evaporates wipe the cleaned area with a second clean cloth 12 Apply CA 1000 sealant to the mounting screw s thread 4 3 3 Step 3 Installation and Mechanical Fastening The turret s lid has locating pins that guide its orientation into the interface plate When raising the turret to mate with the interfa...

Page 95: ...he cable connector to align the guide keys and then push in to complete the connection 7 Tighten the power MIL C 38999 threaded lock ring to the J1 connector of the turret lid Stop when you cannot see the red line on the threads 8 Put the communication cable into the J2 connector of the turret lid and tighten the MIL C 38999 threaded lock ring Stop when you cannot see the red line on the threads 9...

Page 96: ... in its shipping case for service or storage performing other maintenance tasks that require access to the turret s lid Regardless of the task it is good practice to have the shipping case ready to hold the turret when not installed Figure 4 8 MX 15i Turret Removal and Shipping Case Packing Table 4 5 Turret Removal Parts Description Part Number Number of Piece Notes Turret shipping case 41179 1 1 ...

Page 97: ...RESENTS NO HAZARD TO PERSONNEL IN THE NORMAL USE MAINTENANCE TRANSPORTATION OR STORAGE OF THE SURVEILLANCE SUBSYSTEM HOWEVER SHOULD THE INFRARED LENS BECOME DAMAGED OR BROKEN THE MATERIAL MUST BE HANDLED AND WASTE DISPOSED OF IN ACCORDANCE WITH STATE AND OR FEDERAL REGULATIONS IN THE EVENT OF A BROKEN OR DAMAGED INFRARED TELESCOPE ASSEMBLY THE FOLLOWING PROCEDURES MUST BE FOLLOWED WEAR EYE PROTECT...

Page 98: ...legs and the top two foam layers 4 Locate the bottom portion of the shipping case under the turret 5 Hoist up the shipping case to take the weight of the turret 6 Unfasten the mounting screws 7 Lower the turret to within 30 cm 12 of the aircraft s interface plate 8 Slacken all turret cables 9 Disconnect the power MIL C 38999 threaded lock ring to the turret s J1 connector 10 Disconnect the signal ...

Page 99: ...nection 3 Insert the Hand Controller s communication cable in the connector You many need to twist to align the guide keys and then push in to complete the connection 4 Tighten the Hand Controller s MIL C 38999 threaded lock ring to the connector Stop when the red line on the threads is no longer visible 5 Restore power to the turret The Hand Controller is now powered 6 From the Hand Controller li...

Page 101: ...ober 2007 All Rights Reserved 85 Failure Diagnosis This chapter describes steps to be followed when trying to isolate or repair system faults that have been issued as pop up alerts Chapter Contents Built In Tests 86 BIT Error Codes 89 LRU Fault Diagnosis 97 ...

Page 102: ...ent might still operate in a degraded state Operators are notified of Major BIT failures through pop up alerts on the video overlay Minor BIT Failures Minor failures indicate out of tolerance conditions For example a moving component has mechanical wear and the movement s timing takes longer than the stored design time Operators are notified of Minor BIT failures through pop up alerts on the video...

Page 103: ...tus Main Menu Status State Description Recommended Action OK MINOR MAJOR STARTUP Component Initializing Some components are warmed or cooled before they can be operated None N A Communication failure with component Review the Alarms page OK OPERATIONAL Component is in a fully functioning state None OK STOWED Turret is operational but in the Stow position Steer turret to Forward or manual position ...

Page 104: ...pter 5 Built In Tests TM00358 Rev A October 2007 L 3 WESCAM 88 All Rights Reserved Figure 5 2 Alarms Page Alarm Timestamp 18 52 Alarm Summary MAJOR EOW BIT Error Code 5 1 THERMAL SHUTDOWN Alarm Description ...

Page 105: ...x on page 96 5 2 1 Generic BIT Codes 1 x Table 5 2 Failure Descriptions for 1 x BIT Codes BIT Message Category Failure Description Recommended Action 1 1 Board Failure MAJOR Gimbal processor CCA failed to boot properly Replace turret 1 2 Battery Low MINOR Battery for NV ram and real time clock low on gimbal processor CCA No action Contact L 3 Wescam 1 3 Over Temperature Shutdown MAJOR Gimbal inter...

Page 106: ...power If failure persists replace turret 4 6 Pitch Startup Failure MAJOR Gimbal would not initialize No pitch motion detected No steering available Cycle power If failure persists replace turret 4 8 Inner Motor Failed MINOR One of the inner motors failed during startup May be caused by low voltage Check power at turret Contact L 3 Wescam 4 9 Inner Yaw Motor Overload MINOR Yaw motor exceeded absolu...

Page 107: ... MINOR Zoom elements failed to reach a specific position in a specific time Verify that EOW sensor focal length can still be adjusted If zoom control loss impacts mission replace turret 5 5 Zoom Failure MAJOR Zoom servo loop of EOW sensor not responding properly No zoom control available for EOW sensor Focal length will be approximately its value at time of failure Execute a BIT from the Level 2 E...

Page 108: ...Failed to communicate with EOW sensor Verify that EOW video is lost If the capability loss impacts mission replace turret 5 13 Thermal Sensor Failure MINOR Thermal protection sensor reading out of range Check turret temperature through the Level 2 Gimbal Menu If gimbal temperature is 75 C 167 F and EOW camera is still functional continue to use system If gimbal temperature is 75 C 167 F turn off t...

Page 109: ...t cycle the turret power and apply only a 1 Point calibration If problem persists replace turret 6 12 TEC Servo Failure MAJOR TEC servo loop of IR sensor not responding properly If mechanism is between positions or at the calibrate position it will not produce usable video If it is at the normal setting some focal lengths are available However a 2 Point calibration cannot be performed Execute a BI...

Page 110: ...ate Turn turret off and allow to cool 7 2 Focus Position Error MINOR Focus elements failed to reach a specific position in a specific time Verify that EON sensor focus can still be adjusted If focus control loss impacts mission replace turret 7 3 Focus Failure MAJOR Focus servo loop of EON sensor not responding properly No focus control available for EON sensor Execute a BIT from the Level 2 EON M...

Page 111: ...ents failed to reach a specific position in a specific time Verify that EON sensor focus can still be adjusted If focus control loss impacts mission replace turret 7 11 Secondary Focus Failure MAJOR Focus servo loop of EON sensor not responding properly No focus control available for EON sensor Execute a BIT from the Level 2 EON Menu If failure persists replace turret Table 5 7 Failure Description...

Page 112: ... 14 MX Pod Not Communicating MAJOR Turret not communicating with the MX Pod Check cabling then MX Pod power If the indication persists replace the MX Pod Table 5 8 Failure Descriptions for 20 x BIT Codes BIT Message Category Failure Description Recommended Action 20 1 Not Communicating MAJOR GPS not communicating with Turret Check GPS communications connections Cycle system power 20 2 Invalid Mess...

Page 113: ...ts It is assumed that the fault is caused by a single failure or malfunction The Fault Diagnosis Trees are in a logic diagram format Each action is followed by a question with a yes or no answer The answer gives either another question or a solution Do the necessary steps to isolate the cause of the fault Figure 5 3 Fault Diagnostic Tree for Power Loss Yes No Yes No Yes No Yes No Yes Yes No No No ...

Page 114: ...or Video Cables Replace Monitor Monitor Functional Slew Turret to Forward Position Replace Turret Video Cable Perform a System BIT Replace Turret Cycle Power Contact L 3 Wescam Customer Service Turret Operational Turret Moves Cable PIN Break Video Displays No Video Display on Monitor Press Menu SW Menu Displayed Set Sensor Sensitivity to Auto Check Continuity of Turret Video Cable Video Displays V...

Page 115: ...tion This chapter describes all of the procedures that are required to perform any maintenance on the MX 15i system Chapter Contents Maintenance Policy 100 Inspecting Cleaning Windows 101 Turret Purging 103 Purge Valve Replacement 106 Removing Replacing the Desiccant Assembly 108 LRU Return To Vendor Procedure 112 ...

Page 116: ... faulty LRUs L 3 Wescam or approved L 3 Wescam service depots repair faulty LRUs General maintenance activities have no scheduled intervals or duty cycles and customers are limited to the performing the following approved procedures Inspecting and cleaning turret windows Inspecting humidity indicators Purging the turret Removing and replacing the purge valve Removing and replacing the desiccant as...

Page 117: ...ators should make sure the turret is stored in the Stow position and instruct the deicing crew that they not spray de icing fluid onto the turret Maritime Environments When your turret is operating in a maritime environment moisture that collects on the turret windows during flight will contain dissolved salt particles When this moisture dries the salt particles will remain on the turret window an...

Page 118: ... have bonded to the window 3 Apply the detergent mixture to the window Allow time to soak but do not let the window dry The detergent will act on releasing bonded particles 4 Reapply the detergent mixture to the window 5 Use a dry cloth to wipe the window in a gentle circular motion Follow one direction only and do not move back and forth 6 As the window is washed apply rinse water and wipe dry im...

Page 119: ...d until all 4 quadrants return to a blue color prior to any further flight operations Purging should not take longer than 90 minutes If purging takes longer than 90 minutes ensure the following Nitrogen is flowing in and out of the turret Nitrogen is only escaping from the relief valve Figure 6 1 Humidity Indicator Table 6 3 Turret Purging Parts and Support Equipment Description Part Number Quanti...

Page 120: ...ces using other purge equipment 1 Steer the turret to a Forward position 2 Pull and tag the main breaker to disable power and steering control to the turret 3 By hand orient the turret to a position where you will have easy access to the purge valve and you can see the turret s humidity indicator easily 4 If stored in a carrying case remove the regulator assembly from the case 5 Turn the purge kit...

Page 121: ...urge for another 30 minutes 21b Otherwise all quadrants are blue and the turret is now purged 22 When the turret is confirmed to be fully purged turn the regulator counter clockwise and adjust hose pressure to 0 kg cm psi 23 Disconnect the air hose chuck from the valve extension 24 Disconnect the valve extension from the turret s purge valve and replace the cover cap 25 Reconnect the air hose chuc...

Page 122: ... the purge valve can be stem physically broken visible damage to the exterior threads or internal poppet valve turret s humidity indicator remains high despite purging for 2 hours when purging leak check applied to the valve bubbles Figure 6 3 Removing the Purge Valve from Rear Turret Door Table 6 5 Purge Valve Replacement Parts Item Nomenclature P N Qty Notes 1 Schrader valve TA322 2198 1 Drawing...

Page 123: ... 6 Purge Valve Replacement Tools Item Nomenclature P N Manufacturer Notes 1 Purge valve removal socket 5 8 13048 01 Wescam Part alternatives Machine down an impact socket deep 5 8 6 point to an outside diameter of 0 75 to a depth of 1 75 Needle nose 8 inch long fine pitch pliers However pad plier jaws with electrical tape to avoid stripping the purge valve 2 Impact socket deep 5 8 6 point SFS201 S...

Page 124: ...emove and Replace the Desiccant Assembly Removing and replacing the desiccant assembly involves unfastening 4 retention screws The desiccant assembly has captive fasteners held by a spring loaded retention pin rather than a threaded shaft Like a bayonet style the screw requires a 1 4 turn with inward pressure to release The turret includes a breather check valve that seals airflow when the desicca...

Page 125: ... Place the replacement desiccant assembly into position on the turret 11 Push inward until the breather check valves engage and the desiccant assembly sits flush 12 Fasten the retention screws 13 Restore power to the turret 6 5 2 Removing Refilling and Reinstalling the Desiccant Assembly Refilling the desiccant material involves removing a filler port The filler port is a bayonet style that can be...

Page 126: ...port to seat properly Removing Refilling Desiccant Material and Reinstalling 1 Orient the turret to the Stow position 2 Pull and tag the main breaker to disable power and steering control to the turret 3 Support the desiccant assembly with one hand 4 Locate a bottom retention screw that secures the desiccant assembly to the turret 5 Push the screw head in twist counter clockwise a 1 4 turn and the...

Page 127: ...material 14 Repeat steps 8 to 12 until The desiccant material is just below the black filler port ring Filler port seats properly 15 Install the desiccant filler port 16 Push the filler port in and turn clockwise until you hear a locking click 17 Place the desiccant assembly into position on the turret 18 Push inward until the breather check valves engage and the desiccant assembly sits flush 19 F...

Page 128: ...dor 1 Collect the following LRU asset and failure details LRU description part number and serial number Relevant fault information and symptoms of failure e g BIT error codes list of functionality loss and technician s repair recommendation Anticipated LRU shipment date Customer s contact information i e email address and fax number 2 Make sure you have discussed the repair with an L 3 Wescam Cust...

Page 129: ...mer Service representative of the shipment details Waybill number Tracking number Courier company s name Date of shipment 11 Await confirmation from an L 3 Wescam Customer Service representative that the LRU has been received L 3 Wescam will complete an LRU failure assessment and contact customer with service options 6 6 1 L 3 Wescam Customer Service Contact Information For additional assistance o...

Page 131: ...ZOOM Electronic Zoom F F Degrees Fahrenheit FL Focal Length FLIR Forward Looking Infrared FOD Foreign Object Damage FOG Fiber Optic Gyro FOR Field of Regard FOV Field of View FUL Full Passband FWD Forward G GHz Gigahertz GPS Global Positioning System H HCL Hand Controller HPU High Power Unit I IDCA Integrated Dewar Cooler Assembly IMU Inertial Measurement Unit INCR Increase INIT Initialization InS...

Page 132: ...ion S SBC Single Board Computer SCAN Autoscan SENS Sensitivity SNR Signal to Noise Ratio SP Short Pass SSD Static Sensitive Devices T TBD To Be Determined TCU Transmitter Control Unit TGT Target TRGT Target TXU Transmitter Unit V VAC Volts Alternating Current VDC Volts Direct Current VIC Video In Control VIS Visible VME Versa Module Eurocard VNFOV Very Narrow Field of View VTR Video Tape Recorder ...

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