GENII FRDS Maintenance and Troubleshooting Manual

Page 1 of 56 Document# 9001-0011 TROTTER CONTROLS, INC.

Revision F, 06/16/2010 FORT WORTH, TX

GENII FRDS Maintenance and Troubleshooting Manual __________________________________________________________________

Trotter Controls, Inc. Document# 9001-0011

Revision F, 06/16/2010

____________________________________________________________________________________________________

TROTTER CONTROLS, INC. Document# 9001-0011 Page 2 of 56

FORT WORTH, TX Revision F, 06/16/2010



Table of Contents REVISIONS ...............................................................................................................................................................................6

OVERVIEW...............................................................................................................................................................................7

INTRODUCTION ........................................................................................................................................................................7 GEN II FRDS FEATURES.........................................................................................................................................................7

Accurate and dependable coverage delivery......................................................................................................................7 Highly reliable specific purpose control system – Reliability FIRST.................................................................................7 Redundant Systems to Insure Door Opening......................................................................................................................8 Hydraulic system refinements ............................................................................................................................................8 Benefits...............................................................................................................................................................................8

CONSTANT FLOW RATE VERSUS CONSTANT GATE ANGLE ......................................................................................................9 Constant Gate Angle Delivery Systems ..............................................................................................................................9 Constant Flow Rate Delivery Systems................................................................................................................................9

SYSTEM DESCRIPTION ...........................................................................................................................................................10 MODES OF OPERATION ..........................................................................................................................................................12

PILOT INTERFACE DETAILS ............................................................................................................................................13

FOAM GALLONS DISPLAY ................................................................................................................................................14

AUTO MODE OPERATION .................................................................................................................................................14

SWITCH FUNCTIONS IN AUTO/TIMER MODE ......................................................................................................................14 DUAL ARMED LIGHT FUNCTIONALITY (AUTO/TIMER MODES) ..........................................................................................15

TIMER MODE OPERATION ...............................................................................................................................................18

SPECIAL USES OF PANEL SWITCHES (AUTO/TIMER MODES)...............................................................................20

LAMP TEST switch ..........................................................................................................................................................20 NO switch .........................................................................................................................................................................20 RUN PUMP switch ..........................................................................................................................................................20

SPECIAL MODES OF OPERATION (AUTO/TIMER) .....................................................................................................20

FUEL FERRY MODE................................................................................................................................................................20 PILOT INTERFACE “MIRROR” MODE.......................................................................................................................................21

Enabling/Disabling Mirror Mode ....................................................................................................................................21 Activating Mirror Mode ...................................................................................................................................................22 De-activating Mirror Mode..............................................................................................................................................22

BRIGHTNESS ADJUST MODE ...................................................................................................................................................22 FOAM INJECTION ...................................................................................................................................................................22

MANUAL MODE OPERATION...........................................................................................................................................23

SALVO SYSTEM ACTIVATION .........................................................................................................................................23

AUTOMATIC SALVO ACTIVATION ..........................................................................................................................................24 PILOT ACTIVATED SALVO......................................................................................................................................................24 AUTO SUPERVISOR ACTIVATED SALVO .................................................................................................................................24 MAN SYSTEM ACTIVATED SALVO ........................................................................................................................................25 RECOVERY FROM AN AUTOMATIC SALVO CONDITION ..........................................................................................................25

SYSTEM TESTS .....................................................................................................................................................................26

SYSTEM SELF DIAGNOSTIC TESTS – SYSTEST MENU .............................................................................................26

PILOT (NO DOORS) – SYSTEM TEST ........................................................................................................................................27 PILOT (ALL) – SYSTEM TEST ................................................................................................................................................27 AUTO SALVO – SYSTEM TEST................................................................................................................................................28 MAN SALVO – SYSTEM TEST .................................................................................................................................................28



MAINT SYSTEST – MAINTENANCE PERSONNEL – SYSTEM TEST............................................................................................28 SALVO BUTTON TEST ............................................................................................................................................................29 SYSTEM TEST PERSISTENT ERRORS .......................................................................................................................................30

Clearing Persistent SysTest Errors ..................................................................................................................................30 MENU SYSTEM.......................................................................................................................................................................31

Main Menu...................................................................................................................................................................................... 31 Maint Menu .................................................................................................................................................................................... 31 Config Menu................................................................................................................................................................................... 32 SysTest Menu ................................................................................................................................................................................. 32 Error History................................................................................................................................................................................... 32 Digital Inputs .................................................................................................................................................................................. 32 Digital Input Map............................................................................................................................................................................ 33 Digital Outputs................................................................................................................................................................................ 33 Digital Output Map......................................................................................................................................................................... 34 Analog Inputs.................................................................................................................................................................................. 34 Analog Calibrate ............................................................................................................................................................................. 34 Err Msg Index/Counts..................................................................................................................................................................... 35 Clear Errors..................................................................................................................................................................................... 35 Clear Err Counts ............................................................................................................................................................................. 35 Clear ErrHistory.............................................................................................................................................................................. 35 System Reset................................................................................................................................................................................... 35 Save Memory.................................................................................................................................................................................. 35 Read EEprom.................................................................................................................................................................................. 36 Compare RAM/EE.......................................................................................................................................................................... 36 Logo/Version .................................................................................................................................................................................. 37 Leakage Table................................................................................................................................................................................. 37 System Operation Parameters (Tweak)........................................................................................................................................... 38 FRDS Menu Tree............................................................................................................................................................................ 41

ERROR OVERVIEW .................................................................................................................................................................42 Reduced Accuracy .......................................................................................................................................................................... 42

Error Code Displayed: 112_Accuracy Loss.............................................................................................................................. 42 Reduced Redundancy (AUTO/TIMER mode only)........................................................................................................................ 43

Error Code Displayed: 114_Redundancy Loss .......................................................................................................................... 43 Reduced Accuracy & Redundancy (AUTO/TIMER mode only).................................................................................................... 43

Error Code Displayed: 113_Accur+Redun Loss....................................................................................................................... 43 Clearing Pump Errors ..................................................................................................................................................................... 43

SETTING SYSTEM PREFERENCES ..................................................................................................................................44

MAINTENANCE.....................................................................................................................................................................44

FUSE, RELAY, & STATUS LED LOCATION AND FUNCTION ....................................................................................................44 PREVENTATIVE MAINTENANCE SCHEDULE ...........................................................................................................................52 CALIBRATION & SETUP .........................................................................................................................................................53 MEMORY MANAGEMENT .......................................................................................................................................................53 UPDATING SYSTEM FIRMWARE .............................................................................................................................................53

REFERENCE DOCUMENTS................................................................................................................................................54

MANUALS ..............................................................................................................................................................................54 9001-0012 ~ GEN II FRDS Operators Manual, Trotter Controls, Inc. ......................................................................................54

TECHNICAL PUBLICATIONS & TEST SPECIFICATIONS ............................................................................................................54 TP-1000 ~ Constant Flow Rate vs. Constant Gate Angle, Trotter Controls, Inc..........................................................................54 TP-1002 ~ GEN II FRDS System Description, Trotter Controls, Inc. ........................................................................................54 TS-0005 ~ GEN II FRDS Maintenance System Tests, Trotter Controls, Inc................................................................................54

ENGINEERING REPORTS .........................................................................................................................................................54 ER-0074 ~ GEN II FRDS System Operation Parameters, Trotter Controls, Inc..........................................................................54 ER-0075 ~ GEN II FRDS System Error Codes and Resolution, Trotter Controls, Inc..................................................................54 ER-0077 ~ Preventative Maintenance Schedule, Trotter Controls, Inc. .....................................................................................54

PROCESS SPECIFICATIONS......................................................................................................................................................54 PS-0030 ~ GEN II FRDS– Pressure Relief Valve Adjustment, Trotter Controls, Inc. ..................................................................54



PS-0031 ~ Hopper Contents and Gatebox Sensor Adjustment, Trotter Controls, Inc. ..................................................................54 PS-0032 ~ Calibration Dumping Matrix, Trotter Controls, Inc.................................................................................................54 PS-0033 ~ Hydraulic Flushing Procedure, Trotter Controls, Inc. .............................................................................................54 PS-0035 ~ GEN II FRDS– Memory Management, Trotter Controls, Inc. ...................................................................................54

PRODUCT DATASHEETS .........................................................................................................................................................54 DS-0001 Datasheet ~ Pilot Interface (VFD) FRDS GENII, Trotter Controls, Inc. ......................................................................54 DS-0002 Datasheet ~ Relay Enclosure FRDS GENII, Trotter Controls, Inc. ..............................................................................54 DS-0003 Datasheet ~ Side Loader Gage (VFD) FRDS GENII, Trotter Controls, Inc. .................................................................54 DS-0015 Datasheet ~ Side Loader Gage (LCD) FRDS GENII, Trotter Controls, Inc. .................................................................54 DS-0023 Datasheet ~ Pilot Interface (LCD) FRDS GENII, Trotter Controls, Inc. ......................................................................54

DRAWINGS.............................................................................................................................................................................55 51625 SH.12 & 13 ~ Instrument Installation – Upper Panel (802F), Snow Engineering Co.........................................................55 52650 SH.1 ~ Instrument Installation – Upper Panel (1002F), Snow Engineering Co.................................................................55 60513 ~ Assy – Gatebox Electrical, Snow Engineering Co. ............................................................................................................55 60441 SH.10 ~ Control System Wiring Schematic (802F), Snow Engineering Co. ......................................................................55 60441 SH.21 ~ Control System Wiring Schematic (1002F), Snow Engineering Co. ....................................................................55 61566 SH.1 ~ Installation - Relay Box – FRDS (1002F), Snow Engineering Co. ........................................................................55 61566 SH.2 ~ Installation - Relay Box – FRDS (802F), Snow Engineering Co. ..........................................................................55 61567 SH.1 ~ Installation - Multibox – FRDS (1002F), Snow Engineering Co. ..........................................................................55 61567 SH.2 ~ Installation - Multibox – FRDS (802F), Snow Engineering Co.............................................................................55 61572 SH.1 ~ Assy - Relay Box – FRDS (802F & 1002F), Snow Engineering Co. ......................................................................55 61574 ~ Cable Assy. – Valve to Multibox, Snow Engineering Co...................................................................................................55 61587 ~ Pilot Interface – GEN II FRDS, Snow Engineering Co................................................................................................55 80442 SH.4 ~ Float Installation – Hopper (802F), Snow Engineering Co..................................................................................55 80493 SH.4 ~ Assy - Gatebox Actuator, Snow Engineering Co. ......................................................................................................55 80504 SH.10 ~ Hydraulic Schematic (802F), Snow Engineering Co. ........................................................................................55 80504 SH.21 ~ Hydraulic Schematic (1002F), Snow Engineering Co........................................................................................55 80577 SH.13 & 14 ~ Hydraulic System Installation (802F), Snow Engineering Co.....................................................................55 80577 SH.21 & 22 ~ Hydraulic System Installation (1002F), Snow Engineering Co. ..................................................................55 80628 SH.2 ~ Installation – Hopper Fill Gauge (1002F), Snow Engineering Co. .......................................................................55 80628 SH.3 ~ Installation – Hopper Fill Gauge (802F), Snow Engineering Co. .........................................................................55 81424, SH.2 ~ Installation-Hydraulic Manifold-802, Snow Engineering Co. ......................................................................................55 81759 ~ Fitting Assy, Hydraulic Tank, Snow Engineering Co. ........................................................................................................55 83056 SH.2 ~ Installation – Gatebox Actuator (Sensor Assy) (1002F) , Snow Engineering Co.....................................................55 83118 ~ Float Installation – Hopper (1002F), Snow Engineering Co........................................................................................55 83222 SH.1 ~ Hydraulic Manifold Assy Fire Gate (802F), Snow Engineering Co. ..............................................................................55 83222 SH.21 ~ Hydraulic Manifold Assy Fire Gate (1002F), Snow Engineering Co. ..................................................................55 83224 ~ Assy, Hydraulic Pump, Snow Engineering Co..................................................................................................................56 83230 ~ Filter Assy, Hydraulic System, Snow Engineering Co. .......................................................................................................56



Revisions

Revision C: 6/1/2009

€ Added revisions section to track changes made

€ Updated AUTO/MAN cheat sheet photos € Added additional drawings to include references included in TC document

ER-0077 € Added section for setting Power On preferences for AUTO / TIMER mode

Revision D: 9/24/2009

€ Foam Injection: Pushing the selector knob (to exit) does NOT terminate the foam injection operation, but allows it to continue during the AUTO or TIMER

display screen € SYSTEST – removed all “wait for Save Memory to complete” warnings, as

this no longer applies € Changed switch references of “TEST LAMPS” to “LAMP TEST”

€ Changed switch references of “Open Door” to “Open Gate” € Changed switch references of “Close Door” to “Close Gate”

€ Rewrote section describing switch function for YES / NO / FOAM / MENU

switches € Added SALVO pushbutton switch test

Revision E: 05/04/2010

€ Added note for Pilot Interface display change software version 2.02 and newer

€ Updated system overview graphics to include foam function € Added FRDS menu tree

€ Added warning about Armed switch and Emergency dump lever

Revision F: 06/16/2010 € Removed ER-0093 and updated Table of Contents page

€ Updated process specification PS-0035, GEN II FRDS Memory Management € Updated data sheet DS-0003, IP67 Remote Vacuum Fluorescent Display

€ Corrected Drawings reference list for 80493, 83056 & 83118



Overview

This document includes maintenance, troubleshooting, and other information in addition to

items needed for basic operation of the system.

A list of the reference documents used to support this manual is included at the end of the

manual and in the table of contents.

The reader is encouraged to refer to Trotter Controls Document# 9001-0012 for condensed

FRDS system operation instructions.

Introduction

The Fire Retardant Delivery System or FRDS enhances the capability of the aircraft to fight

grass fires and forest fires by providing computer control over the release of fire retardant

agent from the hopper. The FRDS allows the pilot to select the most effective concentration

or coverage of agent over the ground, which varies with the type and size of fire. It also

lets the pilot select the volume of agent released during a dump. This enables “split load”

operations.

A second generation FRDS or GEN II system is now available and is being installed in AT-

802/802A aircraft. The GEN II system is an advancement of the original GEN I FRDS and

provides improved delivery accuracy, increased component reliability, and hydraulic system

refinements.

GEN II FRDS Features

Based on over 15 years of field experience with the first generation FRDS system, Air

Tractor has developed a completely new FRDS system designed from the ground up for

reliability, performance, and maintainability.

The focus of the GEN II FRDS ground up re-design was to eliminate failures due to

vibration, humidity, and hydraulic system failures as well as the provide state of the art

built in diagnostic features.

Some of the enhancements over the first generation FRDS product are described below.

Accurate and dependable coverage delivery

� Improved flow control and delivered gallonage accuracy

� Improved door speed

� New advanced leakage compensation algorithms delivers ACCURATE split load

operation

Highly reliable specific purpose control system – Reliability

FIRST

� Hardened against vibration and humidity

� Dual microprocessor (µP) and electro-mechanical backup automatic salvo systems

o Redundant Automatic Salvo system ensures door opening

� Fully sealed digital side loader displays sealed to IP67



� New non-contact hopper contents sensor

� New non-contact gatebox position sensor

� Water proof connectors with IP67 rating

� Pilot and Maintenance Friendly

� “Black Box” or cable change out/swap program

� Sunlight readable Liquid Crystal or Advanced Vacuum Fluorescent Text/Graphics

Display

� Built in system status, diagnostics & messaging

o Stuck valve detection

o Bad switch detection

o Broken wire detection

o Open or missing valve coil detection

o Bad sensor detection

o Blown fuse detection

o Voltage monitoring

o Built in test / diagnostics feature

Redundant Systems to Insure Door Opening

� Three independent systems are provided to ensure the doors open when

expected.

Hydraulic system refinements

� Hydraulic pump package – Highly

reliable

o Dual head 93% efficient

hydraulic pump

o Lower electrical current

requirements than GENI systems

o Heavy duty DC motor

o Inlet filter on pump eliminates

contaminates

o Tested for over 10,000 flight

hours in a 160F controlled

environment with no failure

� No servo valve – three, low-cost, dirt tolerant directional valves are used.

� Three valves offer three levels of redundancy when opening doors

� Independent pressure switch (electro-mechanical system) and pressure

sensor (µP system) are used to control the pump for added mission

reliability

Benefits

� System is highly reliable

� System is highly repeatable

� System offers three modes of operation

� System has three levels of redundancy on door opening command

� System is very easy to install and set up

� System is easy to operate

� Lower cost of ownership

� System is self diagnosing

� “Black Box” swap out

� Minimal training required for troubleshooting and maintenance



Constant Gate Angle Vs. Constant Flow Control (Coverage Level 2.0)

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

0.0 100.0 200.0 300.0 400.0 500.0 600.0

Ground Line (feet)

Co

vera

ge L

evel (g

als

/100

SF

T)

Constant Gate Angle Constant Flow Control

Constant Flow Rate versus Constant Gate Angle The flow rate of retardant from the hoppers has been shown to be proportional to

the coverage level seen on the ground pattern. It follows that the primary goal of

the retardant delivery system is to maintain a constant flow rate from the hoppers

throughout the delivery.

Constant angle and constant flow delivery operation are briefly discussed in the

following sections.

Trotter Controls Document# TP-1000 (included in the reference materials) provides

details regarding the clear advantages of constant flow (coverage) retardant delivery

as opposed to the less accurate constant gate angle delivery method used on less

sophisticated systems.

Constant Gate Angle Delivery Systems

Some retardant delivery systems open the gatebox doors to a fixed angle throughout

the delivery then close when a preset amount of time has elapsed. These systems

allow split load operation and a coarse method of delivering the retardant at different

flow rates.

Constant gate angle systems are simple to design and construct since the only

requirement is to open the door to a

fixed angle for a given amount of

time. This method is inexpensive to

engineer and produce but does not

have the ability to accurately control

the flow rate produced by the system

as the level of liquid retardant and

acceleration forces on the aircraft

vary during the delivery process.

Typically one timer is used to control

how wide the doors open (a crude coverage control), and another timer is used to

control how long the doors remain open (controls the amount of retardant

delivered).

Constant gate angle systems will produce a ground pattern that is too heavy at the

onset of retardant delivery and is too light at the end of the delivery.

These systems do not use retardant nearly as effectively as constant flow rate

delivery systems.

When the MODE switch is set to TIMER, the GEN II FRDS unit offers constant gate

angle. The main advantage of this mode is that almost no sensors are using during

TIMER mode operation thus allowing FRDS operation in the event of a hardware

failure that prevents operation in AUTO mode.

Constant Flow Rate Delivery Systems

Constant flow rate delivery systems are more expensive to design and construct

since the system must monitor various parameters during the retardant delivery and

control the gatebox doors in a way to maintain constant flow rate.



These systems control the position of the gatebox doors to effectively maintain

constant flow rate during retardant delivery operations.

Constant flow rate delivery systems will produce a superior ground pattern that is

consistent throughout the delivery. These systems optimize the use of retardant

during delivery operations and assure that the correct coverage level is maintained

until just before the retardant tanks are empty.

The GEN II FRDS unit operates in constant flow mode when the mode switch is in the

AUTO position.

Trotter Controls Document# TP-1000 shows that the constant gate angle system’s

(CGA) retardant utilization efficiency is only 65% as efficient as the more

sophisticated constant flow rate delivery system for a 2.0 coverage delivery. At a

coverage level of 0.5, the constant gate angle system is only 53.6% as efficient as

the constant flow system.

The bottom line is that the constant flow system will deliver longer ground line for a

given amount of retardant delivered.

CONSTANT FLOW = MAXIMUM GROUND LINE PER GALLON OF RETARDANT

Utilization of constant flow rate delivery systems drastically improves the ability of a

given aircraft and pilot to suppress fires due to the constant coverage delivered and

longer ground lines that can be produced with a given amount of available retardant.

System Description

The GEN II FRDS is comprised of the basic primary elements:

� A hydraulic actuator to open and close the gatebox doors used to meter

retardant flow rate.

� Hydraulic valves to control the flow of oil to and from the actuator.

� Sensors to sense various parameters needed by the control system.

� A relay enclosure to provide high power relays and drivers needed to operate

the hydraulic valves and provide various voltages. This enclosure also houses

a redundant electro-mechanical system.

� A pilot interface containing a graphic/text display, switches, accelerometers,

and the primary microprocessor used to control the system. This is the

primary interface for the pilot to control and interact with the system.

The reader is encouraged to refer to Trotter Controls Document#TP-1002 for a

detailed description of the system. The electrical schematic (Snow Engineering

drawing 60441) and the hydraulic schematic (Snow Engineering Drawing 80504)

provide specific details on the how the system is connected.

The GEN II FRDS Operator’s Manual (Trotter Controls Document #9001-0012)

provides an abbreviated description and operation details from the pilot’s

perspective.

An overview of the system is shown in Figure 1.



Figure 1 ~ GEN II FRDS overview.



Modes of Operation

There are several modes of operation for the GEN II FRDS. The operation mode is selected

using the MODE switch on the pilot interface. There is a hydraulic power switch (HYD PWR)

and a separate mode switch with three positions (AUTO, TIMER, MAN).

The various operation modes for the system are listed below.

� Automatic Mode (AUTO) – In this mode, the microprocessor controlled primary

system automatically controls the flow rate and quantity delivered using various

sensors and valves.

� Timer Mode (TIMER) – In this mode, two timers and minimal sensors and valves are

used to control the doors. One timer adjusts how long the doors move towards the

open position (adjusts door angle) and a second timer adjusts how long the doors

remain in a fixed position before closing. The doors are maintained in fixed position

throughout the delivery.

� Manual Mode (MAN) – In this mode, the backup manual system (separate from the

primary AUTO system) opens and closes the gatebox doors using simple directional

valves. The flow rate and quantity captured are not controlled. This mode is used to

manually operate the gatebox doors and as a backup system for the AUTO system.

The doors are opened to full open or full closed in this mode using directional control

valves.

The operation mode is selected using the MODE switch on the pilot interface. The various

modes for the system are shown in Table 1.



Table 1 ~ FRDS Operation Modes during normal operation.

Power

Sw

Armed

Sw

Mode

Sw

System State / Mode

OFF X X Display Active, No pressure available to hydraulics, no pressure in

system

ON OFF X Display active, pressure available to hydraulics, no power available to

valves to cause actuator motion, pressing fire switch has no effect

ON ON AUTO Automatic control, power to hydraulics, depressing fire switch initiates

delivery

€ Constant flow rate

€ Microprocessor Auto Salvo and Electro-mechanical Auto Salvo

Active

€ The gatebox door position is controlled in a way to maintain

constant retardant flow rate during delivery

€ Pump is controlled by the primary auto system and hydraulic

pressure sensor

ON ON TIMER Timer based control of doors, power to hydraulics, depressing fire

switch initiates delivery

€ Microprocessor Auto Salvo and Electro-Mechanical Auto Salvo

Active

€ Timer settings control the gatebox door position during delivery

€ Pump is controlled by the primary auto system and hydraulic

pressure sensor

€ No sensors except pressure sensor required for operation

€ The AUTO SALVO system uses the gate open sensors

ON ON MAN Electro-mechanical control, power to hydraulics, depressing fire switch

initiates delivery

€ Electro-Mechanical Auto Salvo Active Only

€ Pressure Switch Controls Pump

€ Doors @ full open or full close only

€ Gatebox door position is not automatically controlled by the

system during delivery

€ Pump is controlled by a pressure switch and relay. Pump

operation cannot be disabled by the system in the event of an

error in this mode.

€ The AUTO SALVO systems are not active = NO

REDUNDANCY

Pilot Interface Details The pilot interface is comprised of graphics / text display and various switches used by the

pilot or maintenance crew to control system operation.



Foam Gallons Display The pilot interface displays the current gallons left in the foam reservoir. The gallons

displayed can range from 3 to 18 gallons. Due to the mechanical limitations of the foam

tank sensor, 3 gallons is the minimum that can be displayed.

Auto Mode Operation The functionality of the switches when the system is in AUTO or TIMER mode is summarized below.

Switch Functions in AUTO/TIMER Mode

Table 2 ~ Pilot interface switch functions when in AUTO/Timer mode.

Parameter Device

Type

Action Comments

Mode Switch Auto, Timer, Man

Switch

Set Mode to AUTO Changes the operation

mode. When set to AUTO,

primary microprocessor has

control.

Hyd Power Switch Turns on hydraulic

power

Energize EDUMP valves,

BLEED valve, pressurizes

hydraulic system

Fire switch Switch – 1 NO, 1 NC Open the doors when

pressed (if armed),

Close doors when

released

Located on flight stick

Armed Sw Switch Arms hydraulic

system directional

valves (hardware),

turn armed lamp on if

real time diagnostics

is OK

Display Armed & Ready on

Status, Light LED if all is

ready

Open Gate Sw Switch Open the doors at

1/8 speed, opening

door

Open doors manually using

the primary AUTO system

Close Gate Sw Switch Close the doors at

1/8 speed, closing

door

Close doors manually using

the primary AUTO system

Run Pump Sw Switch Turn on pump

output, running

pump

Run the pump using the

primary AUTO system.

Clears any detected pump

errors.

Lamp Test Sw Switch Test all lamps that

can be tested (see

LAMP TEST switch on

page 20)

This switch will not function

if the I2C serial diagnostics

bus is not active.

Menu / No Sw Switch Used to enter the

MENU system

Used for menu selection of

items in the maintenance

and configuration menus



Parameter Device

Type

Action Comments

Foam / Yes Sw Switch Used to inject foam

with the optional

foam injection pump

Pressing Foam from the

main AUTO or TIMER menu

displays the FOAM

INJECTION screen.

Coverage Level

(Delivery Parameter)

GENII – Data Wheel

The coverage level in

gallons per 100

square feet

AUTO MODE: Set the

retardant flow rate desired

TIMER MODE: Set time for

doors to move towards

open

Gals to Dump

(Delivery Parameter)

GENII – Data Wheel

Pilot, 200, 250, 300,

350, 400, 450, 500,

550, 600, 650, 700,

750, ALL

AUTO MODE: Set the

number of gallons to dump

TIMER MODE: Set time for

doors to remain open

Dual Armed Light Functionality (AUTO/TIMER Modes)

On GENII systems, two ARM indicator lights are provided. One ARM light indicates that the

microprocessor controlled AUTO system is armed while the second ARM light indicates that the

back-up electro-mechanical system is armed. Both ARM lights on indicates that both the primary

and backup manual system are armed and ready. GENII systems take any errors detected into

account before turning the AUTO armed LED on. The possible states of the GENII armed indicators

and their meanings are shown in the table below.

NOTE

While performing a dump in AUTO mode:

Software version 2.01 and prior: -Pilot Interface displays “DUMPING” while doors are open and “GATE CLOSED” once complete.

Software version 2.02 and newer: -Pilot Interface display does not change; ARMED indicator blinks rapidly until dump operation is complete. Remote ARMED indicator does not blink.



Table 3 ~ GENII Dual Armed Indicator Meaning (AUTO/TIMER modes)

MAN ARMED

LED

AUTO ARMED

LED

Indicated ARMED Status

ON ON FULL REDUNDANCY: The backup manual system is armed

and the primary AUTO system is armed. No errors are

detected for the AUTO system.

ON ON FLASHING REDUCED REDUNDANCY: The backup manual system is

armed and the primary AUTO system is armed. Errors are

detected for the AUTO system. The auto system may have

reduced accuracy or reduced redundancy. See status

message at the bottom of the alpha-numeric display.

OFF ON NO REDUNDANCY: The backup manual system is not

armed and the primary AUTO system is armed. This

condition cannot exist unless there is a hardware problem

with the manual system.

OFF ON FLASHING NO REDUNDANCY: The backup manual system is not

armed and the primary AUTO system is armed but has

detected errors. This condition cannot exist unless there is

a hardware problem with the manual system. The AUTO

system should operate properly. However, there is

no redundancy should the AUTO system fail.

ON OFF NO REDUNDANCY: The backup manual system is armed.

The primary AUTO system is not armed. This condition

normally exists when the Pilot Interface MODE switch is set

to MAN. The AUTO system may or may not operate

properly. The system has reduced or no redundancy.

Dimly glowing OFF or ON On systems with a remote armed light, this indicates that

the remote light is disconnected or the bulb is burned out.

On systems without a remote armed light, the terminator

plug is not connected.

The pilot interface and its functionality when operated in AUTO mode are shown in Figure 2.



Figure 2 ~ Pilot Interface function when operated in AUTO mode (main AUTO menu shown).



Timer Mode Operation GENII systems also have a timer mode that allows operation of the system using minimal sensors

and valves. This mode is provided to allow operation in the event of a sensor or other hardware

failure that would prevent the AUTO mode from functioning properly. Trial and error adjustments

of the timer settings are required to provide the desired operation of the gatebox doors.

Note that timer mode provides constant door angle control similar to less capable systems

available on the market.

Timer mode is not recommended as the default operation mode since the quality of the ground

pattern and retardant usage is not as desirable as the pattern produced by the system when

operated in AUTO mode.

Timer mode operation is summarized below:

€ To enter Timer Mode, set the MODE switch on the GENII pilot interface to TIMER.

€ Use the selector knob to adjust the timer value in the COVERAGE window to control how

long the doors will slew towards the open position before stopping. This adjustment

controls the fixed gate angle used. Larger timer settings will result in a larger fixed door

opening.

€ Use the selector knob to adjust the timer value in the GALS TO DUMP window to control

how long the doors remain open before closing. This adjustment controls how much

retardant is delivered. If PILOT is selected for this value, the doors will close as soon as the

“FIRE” button is released during a delivery.

System drops and operation are identical for AUTO and TIMER (GENII only) mode except that the

retardant flow rate is not actively controlled in TIMER mode since the doors open to a fixed angle

and remain at this angle until they are closed.

The functionality of the pilot interfaces and switches when the system is operated in TIMER mode

are summarized in Figure 3 on the next page.



Figure 3 ~ Pilot Interface Functionality when operated in TIMER mode (main timer menu shown).



Special Uses of Panel Switches (AUTO/TIMER MODES) The panel switches are, for the most part, self-explanatory, and are described in detail in the AUTO

MODE and TIMER MODE operation sections. However, some of the panel switches have special

uses described below.

LAMP TEST switch

This switch tests the built-in panel indicator LED’s, with the EXCEPTION of the LED’s labeled “GATE

CLOSED” (two LED’s), “MAN SALVO”, and the left MAN “ARMED” LED. These LED’s are always

controlled by hardware and do not respond to the software controlled LAMP TEST function. The

remaining LED’s will respond to the LAMP TEST switch in normal operation. Failure of the LAMP

TEST could indicate a failure of the I2C communications buss within the pilot interface

and between the pilot interface and relay box.

NO switch

While in most menus and sub-menus, the NO switch can be used to immediately exit the menu

system and return to the main system display.

During system startup, holding the NO switch down will start the system with FACTORY VALUES

after a warning message is displayed. Note that the system will not operate properly using the

factory default leakage and analog calibration values. This option is provided as an intermediate

step required to recover specific calibration data for your aircraft in the event of a memory

problem.

While either an AUTO dump or TIMER dump is in progress, pressing the NO switch will ABORT the

dump and immediately close the gate doors.

RUN PUMP switch

Depressing this switch momentarily, will clear ANY active errors except for errors 021 and 105

reported by the system diagnostics performed by the pilot (SysTest, See System Tests on page

26), including errors that may have shut down the hydraulic pump. Note that even though all

errors are cleared, the fact that these errors have occurred are still indicated in both the Error

History table and the Error Counts table.

€ Pressing the Run Pump switch clears all current errors except for error 021 and 105.

€ Current hardware errors will return once they are detected again by the system.

€ Errors 021 and 105 detected during SysTest will persist even if power is removed from the

unit until the appropriate SysTest has been successfully performed to clear the error(s) (See

System Tests on page 26).

Special Modes of Operation (AUTO/TIMER)

Fuel Ferry Mode This special mode of operation allows the airplane to be flown with the gate actuator hydraulically

locked in the closed position to ferry fuel in the hopper for long non-stop over-water flights. It can

also be used to ferry water or retardant to distant fires with the hydraulic pump remaining off to

preserve battery power, and insure that the gate doors are in a fail-safe mode and will not open. In

this mode, although the system is hydraulically locked, the hydraulic pump will remain off to

preserve battery power, and hydraulic pressure will NOT be maintained.



To enter this mode, perform the following steps:

� From the main AUTO or TIMER display press

the NO/MENU switch.

� The menu shown to the right should be

displayed.

� Use the selector knob to highlight FUEL FERRY

� Press the selector knob to enter FUEL FERRY

mode

� Turn the ARMED switch to the OFF position

� Turn the HYD POWER switch to the ON position

o The gate doors are now hydraulically locked and pump operation is disabled.

� This mode can be exited ONLY by switching “HYD POWER OFF TO EXIT”.

o No other switches or controls are operational to eliminate accidental exit from this

mode. The HYD POWER switch is a safety-locking switch and must be pulled out to

unlock it before it can be switched to the OFF position.

NOTE: The MAN SALVO button is active in this mode. Depressing the MAN SALVO button

regardless of ARMED or POWER switch setting will cause the pump to operate and the

gatebox doors to open slowly.

Pilot Interface “Mirror” mode A special mode has been incorporated to allow the same graphics and text displayed to the pilot to

be displayed or “mirrored” on the remote side loader gauges as well as any remote gages present

in the cockpit. This feature allows a remote display to be mounted in the rear cockpit for pilot

training purposes (or a more visible location in the front cockpit) and is useful during maintenance

of the system.

“Mirror” mode allows any remote display connected to the system (such as the remote hopper

gauges) to be used to display identical information as on the Pilot Interface display. For example,

you could monitor operation from just about anywhere as seen in the photo below.

The remote side loader gages display the same information as any “remote” displays located in the

cockpit. Be sure to set the MODE switch to MANUAL when loading the system with retardant so

that the side loaders display hopper gallons to ground personnel.

Enabling/Disabling Mirror

Mode

To enable mirror mode functionality, set the value of

system parameter (tweak) 94 to the value of 255 (the

default factory value).

To disable mirror mode functionality, set the value of

system parameter (tweak) 94 to the value of 0.

Refer to Trotter Controls Engineering Report 0074 for

details on how to edit system operation parameters.



Activating Mirror Mode

If the mirror mode system parameter has been enabled using system parameter 94 (the default),

and the MODE switch is in either AUTO or TIMER mode, mirror mode is activated.

In this mode, the hopper gauge (which normally shows gallons in hopper) will “mirror” the same

information as displayed on the main Pilot Interface display when the system is in AUTO or TIMER

mode.

When the mode switch is set to MANUAL mode, the hopper contents are displayed on the remote

displays present in the cockpit and on the side loaders.

De-activating Mirror Mode

Placing the MODE switch in the MAN position will return the hopper gauge to its normal function.

Any remote displays (cockpit or side loader) will display the gallons of retardant present in the

hopper.

Brightness Adjust mode When the main display is visible in AUTO or TIMER mode, Pressing and holding the selector knob

will enter Brightness Adjust mode.

Brightness values may range from 1 (dimmest) through 8 (brightest). Setting a value of zero will

allow the brightness to “auto-adjust” based on ambient light at the Pilot Interface.

On VFD units, the brightness setting controls both the display of the Pilot Interface (and any

“mirrored” VFD displays) as well as the brightness of any dimmable display lamps/LED’s on the

Pilot Interface.

On LCD units, the backlight brightness changes as well as the brightness of any dimmable display

lamps/LED’s on the Pilot Interface.

Foam Injection This feature (if installed) allows the operator to inject foam from the foam dispenser into the main

retardant hopper. This feature is selected by pressing “FOAM/YES” from the main AUTO or TIMER

screen.

Press the "FOAM/YES" from the main AUTO or TIMER screen.

� Turn "Hyd Power" switch on. o Note that the Hydraulic Pump will not operate in this mode.

� Use the twist knob to select the number of seconds (from 0 to 120) to run the injection

pump.

� Press "YES" to start the injection pump for the specified amount of time.

� The timer value can be changed at any time, or the "NO" switch can be used to turn off the

injection pump.

o A countdown timer at the bottom of the screen shows the number of seconds

remaining for the injection cycle, while the number displayed at the lower right indicates the gallons remaining in the foam tank.

� Pushing the selector knob exits FOAM INJECTION mode and displays the main AUTO or

TIMER screen. The injection pump will continue operation until the selected duration

expires. When FOAM INJECTION mode is exited, the Hydraulic Pump will again be enabled.



Manual Mode Operation The operations of the various switches on the panel are summarized in the table below.

Table 4 ~ Switch functionality in manual mode.

Parameter Device Type Action Comments

Mode Switch

(MAN)

Auto, Timer, EM

Switch

Set Mode to MAN When the switch is set to MAN,

the electro-mechanical

relay/timer system has control.

NO REDUNDANCY IN MAN

MODE.

Hyd Power Switch Turns on hydraulic power Energize EDUMP valves, BLEED

valve, pressurize hydraulic

system

Fire switch Switch – 1NO,

1NC

Open the doors when

pressed, Close doors when

released

Located on flight stick

Armed Sw Switch Arms hydraulic system

directional valves (hardware),

turn armed lamp on if real

time diagnostics OK

AUTO armed is not active when

in MAN mode (NO

REDUNDANCY IN MAN

MODE)

Open Gate Sw Switch Open the doors at 1/8 speed, Open doors manually using the

secondary electro-mechanical

system

Close Gate

Sw

Switch Close the doors at 1/8 speed, Close doors manually using the


system

Run Pump Sw Switch Active switch to manually

turn on the pump

Run the pump using the


system

Note that the system hardware is not able to turn the pump off when in manual (MAN) mode in the

event of a detected pump error. The pilot should monitor the RUN PUMP LED and make sure the

system has sufficient oil before using manual mode since the automatic pump error detection used

to detect errors is not active when operated in MAN mode.

Salvo System Activation GENII FRDS systems incorporate an automatic salvo backup system. The function of this sub-

system is to open the doors in the event that the primary (AUTO) system is unable to open the

doors due to a hardware or software error.

GENII systems provide two independent automatic salvo systems (one system is controlled by an

independent supervisor microprocessor (AUTO SALVO) while relays and hardware timers only (MAN

SALVO) control the second system).

The two independent automatic salvo systems are only active in AUTO or TIMER modes of

operation. The function of these systems is to monitor whether or not the primary AUTO/TIMER

system opened the gatebox doors as expected when the system is armed and the “FIRE” button is

depressed.



Automatic Salvo Activation If the doors do not open as expected in AUTO or TIMER mode when the system is “ARMED”,

hydraulic power is present, and the “FIRE” button is depressed, the system will perform the

following actions:

� Open the gatebox doors using a directional valve

o The AUTO SALVO microprocessor system uses valve 2 on the hydraulic manifold

o The MAN SALVO electro-mechanical system uses valve 3 on the hydraulic manifold

� Run the pump for a specified time interval

� Illuminate the AUTO SALVO or MAN SALVO LED to indicate which of the two independent

auto salvo systems has been activated.

o Note that normally the AUTO SALVO system is activated first.

o The MAN SALVO system is activated only if the AUTO SALVO system was unable to

open the doors for some reason within the specified amount of time.

See the sections below for more information regarding the AUTO SALVO and MAN SALVO system

operation.

Pilot Activated Salvo

The manual salvo system can be activated using the red MAN SALVO button regardless of the pilot

interface switch settings. On GENII systems, this button is located adjacent to the power quadrant

on the L/H side of the cockpit.

o This RED button overrides the power, mode, and arm switches to open the gatebox doors.

If no hydraulic pressure is present in the system (system power is off), the doors will open

slowly as the pump delivers flow to open them.

o To open the doors using the MAN SALVO button, depress the red “SALVO” button. This will

run the pump, open the doors and then leave the doors in the open state after a timeout

period. The pump will run until the system pressure reaches 3000 PSI and then it will turn

off automatically.

o This latching button disables auto and manual operation when activated (depressed).

��Caution: Never press this button unless you intend for the gatebox doors to open and

you have verified that all personnel are clear of the gatebox doors.

��Always deactivate the MAN SALVO button to resume normal system operation. The

button should be in the extended position for normal operation.

��Always turn the Arm switch off prior to moving the Emergency dump lever back to its

normal position to prevent inadvertent Auto or Manual Salvo.

Auto Supervisor Activated Salvo No pilot action is required for this event to occur. The microprocessor controlled AUTO SALVO

system monitors the doors to make sure they open when expected. If the doors do not open



within 0.8 seconds after the fire switch has been pressed, this system will take over, isolate the

primary system and attempt to open the gatebox doors.

� Pre-conditions: MODE=AUTO or TIMER, HYD PWR=ON, ARMED=ON

� Activation Condition: If “FIRE” button is depressed and the gatebox doors do not open

within 0.8 seconds, an AUTO SALVO condition is triggered.

o If the AUTO SALVO system has been activated, this means that primary system

(AUTO or TIMER mode) failed to open the doors.

� The AUTO SALVO LED will be illuminated when this system is activated.

� Valve 2 (middle directional valve) on the hydraulic manifold is used to open the doors.

� The pump is operated for 20 seconds, then is turned off.

� The gatebox doors will remain open until the salvo condition is cleared.

MAN System Activated Salvo No pilot action is required for this event to occur. The electro-mechanical MAN SALVO system

monitors the doors to make sure they open when expected. If the doors do not open within 1.2

seconds after the “FIRE” switch has been pressed (this is 0.4 seconds after the AUTO SALVO

system would have tried to open the doors), this system will take over, isolate the primary and

secondary systems and attempt to open the gatebox doors.

� Pre-conditions: MODE=AUTO or TIMER, HYD PWR=ON, ARMED=ON

� Activation Condition: If “FIRE” button is depressed and the gatebox doors do not open

within 1.2 seconds, a MAN SALVO condition is triggered.

� This MAN SALVO system is activated 0.4 seconds after the AUTO supervisor is activated.

o If the MAN SALVO system has been activated, this means that the AUTO SALVO

system failed to open the doors.

� The MAN SALVO LED will be illuminated when this system is activated.

� Valve 2 (middle directional valve) on the hydraulic manifold is used to open the doors.

� The pump operates until a pressure of 3000 PSI is reached and runs as required to maintain

hydraulic pressure. It’s operation is controlled via a relay and a pressure switch.

� The doors will remain open until the salvo condition is cleared.

Recovery from an Automatic Salvo Condition To reset the system after a AUTO or MAN SALVO event, the error must be cleared. To clear the

error on GENII systems perform the following actions:

� Turn the ARM switch to the “OFF” position.

� Turn the HYD POWER switch to the “OFF” position.

� The condition should be cleared and the MAN SALVO button should not be illuminated.

� Turn the HYD POWER switch to the “ON” position and operate the system as required.

If MAN SALVO is still displayed after performing the steps above, check the following:

� Verify that all breakers are pushed in are not tripped.

� Verify that the MAN SALVO red button is not pressed in.

� Verify that the relay enclosure is connected properly and receiving power as expected. MAN

SALVO is displayed any time the relay enclosure is not receiving power as expected and the

pilot interface is active.



System Tests The FRDS system passively monitors many parameters any time the HYD POWER switch is set to

the ON position and the mode is set to AUTO or TIMER. However, some items are only tested

when the pilot initiates a SysTest menu item, since outputs and valves must be activated to fully

test the system. The self-test feature incorporated in the unit is able to detect the following

problems:

� Stuck valves

� Incorrectly wired valves (in most cases)

� Burned out wires

� Burned out coils

� Problems with the pump or accumulator

� Faulty or improperly adjusted sensors

� Improper manifold orifice installation

� Damaged or non-operational pilot interface switches

� Other errors

We recommend that the tests shown in Table 5 be performed by the pilot on a regular basis to

ensure that the system is operating as expected:

Table 5 ~ Recommended Pilot Initiated System Test Schedule.

System Test Type Recommended

Test Interval

Comments

Pilot (no doors) Daily Test can be performed with hoppers fully

loaded

Pilot (ALL) Weekly Hoppers must be empty for this test

Auto Salvo Weekly Hoppers must be empty for this test

Man Salvo Weekly Hoppers must be empty for this test

Maint SysTest As required Hoppers must be empty for this test

System Self Diagnostic Tests – SysTest Menu To enter the SysTest menu, perform the following steps:

� From the main AUTO or TIMER menu press the

NO/MENU switch.

� The menu shown below should be displayed.

� Use the selector wheel to highlight SysTest

� Press the selector wheel to enter SysTest mode

� Use the selector wheel to select the test to be

performed

� Follow instructions on the screen

NOTE: The red MAN SALVO button is active in this mode. Depressing the MAN SALVO button will

cause the pump to operate and the doors to open slowly.



The SysTest submenu contains the following five menu items:

• Pilot (no doors) – Testing with no gatebox door movement allowed

• Pilot (ALL) – Comprehensive tests with gatebox door movement allowed

• Auto Salvo – Test the microprocessor-controlled AUTO SALVO system

• Man Salvo – Test the electro-mechanical MAN SALVO system

• Maint SysTest – Same as Pilot(ALL) with PASS/FAIL and diagnostic information displayed

Note that it is necessary to scroll the menu using the data

wheel to display all of the items shown above, since only

four items can be displayed at one time on the four line

display.

The individual submenu items are fully described in the

following sections.

Pilot (no doors) – System Test This submenu item allows the pilot to quickly test system components that DO NOT result in the

gate doors being operated. This set of tests is useful when there are contents in the hopper that

should not be released. The total time of this set of tests requires about 45 seconds. The tests are

performed without the need for operator intervention unless any of the tests fail, in which case an

error indicator remains on the screen until cleared by the pilot. The set of tests that are performed

are:

• Switch Test (optional) – Pilot must cycle all switches during this test, then press the data

wheel in once all “illuminated blocks” indicating the switch positions are not illuminated to

continue to the next test (See Trotter Controls Document# TS-0005 for more information on

the switch test)

• Valve Mon1 Mon2 Test – Confirm valves connected OK, and wiring is OK.

• Hyd Pump pressure limit test

• Bleed / Edump Pass Fail test

Pilot (ALL) – System Test

CAUTION: The gatebox doors are operated during this test. Verify that all ground

personnel are clear before selecting this test.

This submenu item allows the pilot to test ALL system components quickly, including those that

result in the gate doors being opened. This set of tests is useful when the hopper is empty. The

total time of this set of tests requires about 2 minutes.

The tests performed are almost identical to the comprehensive maintenance system tests described

below except that no status is displayed to the pilot unless a failure is detected. Trotter Controls

Document# TS-0005 has a detailed description of the items that are tested.

The tests are performed without the need for operator intervention unless any of the tests fail, in

which case an error indicator remains on the screen until cleared by the pilot. The set of tests that

are performed are:



• Switch Test (optional) – Pilot must cycle all switches during this test, then press the data

wheel in once all “illuminated blocks” indicating the switch positions are not illuminated to

continue to the next test (See Trotter Controls Document# TS-0005 for more information on

the switch test)

• Valve Mon1 Mon2 Test – Confirm valves connected OK, and wiring is OK.

• Valve Wiring Test – Confirm valves function as expected and are connected properly.

• Gate prox switch test – Verify that the door home sensors function properly.

• Hyd Pump pressure limit test – Verify that the hydraulic pump and sensor are OK.

• Bleed / Edump Pass Fail test – Verify that the bleed and EDUMP valves function properly.

• Gate Angle voltage Test – Verify that the gatebox angle sensor functions properly.

Auto Salvo – System Test

CAUTION: The gatebox doors are operated during this test. Verify that all

ground personnel are clear before selecting this test.

This submenu item allows the pilot to test the primary microprocessor controlled automatic salvo

system (Auto Salvo) for ensuring that a dump occurs when the pilot requests one. This test should

be performed only when the hopper is empty. After starting this test, the operator is instructed to

press the DUMP (fire) switch. The primary system will inhibit dumping and the redundant system

should then initiate an AUTO SALVO. The display should read AUTO SALVO (in large text). Turn

the ARMED switch off to terminate this test after a salvo has occurred.

Man Salvo – System Test



This submenu item allows the pilot to test the secondary electro-mechanical automatic salvo

system (Man Salvo) for ensuring that a dump occurs when the pilot requests one. This test should

be performed only when the hopper is empty. After starting this test, the operator is instructed to

press the DUMP (fire) switch. The primary system and first redundant system will inhibit dumping

and the second redundant system should then initiate a MAN SALVO. The display should read MAN

SALVO (in large text). Turn the ARMED switch off to terminate this test after a salvo has occurred.

Maint SysTest – Maintenance Personnel – System Test



This submenu item allows maintenance personnel to test any or all system components. Unlike the

Pilot(no doors) and Pilot(ALL) tests, these tests require the operator to acknowledge the result of

each test, whether the test passes or fails. The operator may choose which tests to perform and

which tests to skip. The set of tests that may be performed are:



• Switch Test – Pilot must cycle all switches during this test, then press the data wheel in

once all “illuminated blocks” indicating the switch positions are not illuminated to continue

to the next test (See Trotter Controls Document# TS-0005 for more information on the

switch test)

• Valve Mon1 Mon2 Test

• Valve Wiring Test

• Gate prox switch test

• Hyd Pump pressure limit test

• Bleed / Edump Pass Fail test

• Hyd Pump rate & Bleed/eDump Test

• Continuous Hyd System Flush

• Gate Angle voltage Test

All of the tests performed in any of the SysTest menu choices are described in detail in a separate

document, Trotter Controls Document# TS-0005.

Salvo Button Test



This switch acts independently from all switches on the pilot interface. On GENII systems, this red

button is located adjacent to the power quadrant on the L/H side of the cockpit.

Pressing the Salvo Button results in the following action regardless of the Pilot Interface switch

settings:

� The hydraulic pump runs until 3000 PSI is reached

� The doors are opened

� MAN SALVO is displayed on the pilot interface.

● To reset the MAN SALVO condition in MAN Mode:

o Depress and release the MAN SALVO switch

o Set the ARMED switch to the OFF position.

o Turn hydraulic power OFF

o Turn hydraulic power ON to resume normal operation.

NOTES: If the system is in MAN mode, not ARMED and HYD power OFF, depressing the SALVO

switch will reset the MAN salvo condition

● To reset the MAN SALVO condition in AUTO or TIMER Mode:

o Depress and release the MAN SALVO switch

o Set the ARMED switch to the OFF position.

o Resume normal operation.

NOTES: If the system is in AUTO or TIMER mode and not ARMED, depressing the SALVO SWITCH

will reset the MAN salvo condition.

The Salvo Button should be tested for all possible combinations of the ARM switch, Mode

Switch, and Hydraulic Power switch.



System Test Persistent Errors The FRDS computer saves the results of the system tests to EEPROM so that an error is indicated

any time the system has failed to pass SysTest as expected. This feature has been added to alert

the pilot that the system previously failed during the pilot initiated system test (SysTest) of the

controls and hydraulics hardware. These errors can only be reset by successfully performing the

system tests for the system hardware.

Two error conditions can be detected and will persist even if power is removed from the system

until the hardware is able to pass the system tests.

� "021_Panel Switch Err" - The switch test failed or was aborted by the pilot during the

current or previous SysTest.

� "105_Systest Err" - Some hardware item failed during the current or previous SysTest.

Error number 021 indicates that either a panel switch error had occurred during SysTest, or that

the operator had aborted the panel switch test without successfully completing the test by testing

all possible switch positions.

Error number 105 indicates that some error had occurred during a previous run of SysTest, and a

successful run of SysTest had not been completed since the error occurred.

Clearing Persistent SysTest Errors

While the RUN PUMP switch and the "Clear Errors" menu item of the “Maint” menu can be used to

“clear all errors”, these will NOT clear the persistent errors 021 and 105. These errors can only be

cleared by successfully running a SysTest procedure.

To clear error “021_Panel Switch Err”, perform either “PILOT (no doors)”, “PILOT (ALL)”, or “Maint

SysTest”.

o Make sure to cycle all switches during the switch test per Trotter Controls

Document# TS-0005.

o Do not press the data wheel to exit the switch test until all of the switches have been

properly cycled and the “illuminated block” indicators for each switch position have

gone out as each switch is actuated.

o The error is automatically cleared once the switch test has been properly performed

with no detected failures.

To clear error "105_Systest Err”, perform the PILOT (ALL) system test.

o Perform the “PILOT (ALL)” system tests per Trotter Controls Document# TS-0005.

o Do not exit the test or abort during the test sequence.

o The error is automatically cleared once the SysTest has been performed and the

hardware is verified to operate properly.

o Note that performing a “Maint SysTest” or a “Pilot (no doors)” SysTest WILL NOT

clear error 105. A successful PILOT (ALL) test is the only way to clear this error.

Maint SysTest can be utilized to diagnose the cause of the system failure but will not

clear the persistent error.



Menu System The menu system is a multi-level set of menus that you enter by pressing the “NO/MENU” switch

from the main AUTO or TIMER screen. Rotate the selector knob to the desired option and press the

selector knob to select that option. To exit any menu, press the NO switch, which results in

returning to the main AUTO or TIMER screen. Some menus have an “EXIT” option which will return

to the previous (higher level) menu.

Please note, screens may differ slightly on LCD type Pilot Interfaces.

Main Menu

The Main menu contains the following menu items:

• Maint – Maintenance Functions

• Config – Set the aircraft configuration

• SysTest – Perform hardware diagnostics

• Fuel Ferry – Special mode for ferry operations

• ErrorHistory – Display of logged errors

• Exit – Exits the current screen

Maint Menu

This menu item opens a “Maintenance” submenu that contains the following menu items:

• Tweak Parameters – Adjust system operation parameters - See Trotter Controls

Document ER-0074 for details.

• Digital Inputs – View the various inputs from switches and sensors in the system

• Digital Input Map – View a map of all inputs simultaneously

• Digital Outputs – View and/or force selected outputs

• Digital Output Map – View a map of all outputs simultaneously

• Analog Inputs – View the various voltages from sensors monitored by the system

• Analog Calibrate – Calibrate the system A/D converters (factory use only)

• Err Msg Index/Counts – Show a listing of all errors that can occur

• Clear Errors – Clear active errors but don’t clear the count of errors that have occurred

• Clear Err Counts – Clear the counts for the number of times a given error has occurred.

This clears the counts for all error counters.

• Clear ErrHistory – Clear the error history buffer

• System Reset – Restart/Re-boot the primary microprocessor

• Save Memory – Save memory to the internal and/or external data memory

• Read EEprom – Read the leakage data and other information from the external memory

• Compare RAM/EE – Display the differences in active parameters and the EEPROM memory

• Logo/Version – Display the Air Tractor Logo and software version installed

• Leakage Table – Display the tank leakage calibration factors

• Exit – Exit the menu



Config Menu

This menu item opens a “Configuration” submenu that contains the following menu items:

• Aircraft – Select the aircraft type and hardware configuration

• Learn – Set learning mode for dump pit calibration. Refer to PS-0032

• H/Ware – Future Use - Hardware configuration options.

• Exit – Exit the menu

SysTest Menu

This menu item opens a “SysTest” submenu. This menu selection is used to select the various

diagnostics self tests that can be performed by the system. The system test features are described

in System Test section of this document.

Error History

From the Main menu, select “Error History”. This display shows any errors that have occurred in

chronological order. Errors displayed include those encountered during the current run, as well as

those that have occurred during previous runs of the system. A “system reset” entry (code 001)

separates the current run errors from those of previous runs. The most recent error is at position

number 1 of the error history table, with the oldest error at position number 50. The position of

the entry at the beginning of the current run is indicated by “(1st boot entry)”. Errors at positions

lower than this entry (through position number 1) have occurred during the current run of the

system. Errors at positions higher than this entry (through position number 50) have occurred

during prior runs of the system.

Digital Inputs

This menu option allows maintenance personnel to view the values of various digital inputs to the

system. Each input is listed with its hardware pin designator and preceded with its current value,

either “ON” (in highlighted text) or “OFF” (in normal text). The sequence number of the input is

displayed in highlighted text. The sequence number ranges from 0 to 81 and is associated with the

“Digital Input Map” display (described next). Panel switches appear at the beginning of the digital

input display to facilitate easy testing.

Note: “Digital Inputs” mode is the ONLY mode (other than Pilot Assisted Test – SysTest) in which

an AUTO dump is INHIBITED. In all other modes, if the system is “ARMED” and “Hyd Power” is on

and the Fire switch is pressed, an auto dump will be performed. “Digital Inputs” mode will inhibit

an auto dump if the MODE switch is in either the “AUTO” or the “TIMER” position. Note that simply

inhibiting an auto dump will NOT prevent a dump from happening; because if an auto dump DOES

NOT occur, one of two backup systems (AUTO SALVO or MAN SALVO) will take control and open

the gate doors.



Digital Input Map

This menu option allows maintenance personnel to

view the values of all digital inputs to the system on a

single screen. Since there are 21 characters per line

and 4 lines per screen, up to 84 inputs may be viewed

at once. Digital inputs are numbered from 0 to 83, and

are listed sequentially on the display with 0 to 20 on

the top line, 21 to 41 on the second line, 42 to 62 on

the third line, and 63 to 83 on the bottom line. To facilitate ease of reading the display, a digit

(0,1,2,3,4,5,6,7,8) is displayed every 10 positions to indicate positions 0,10,20,30,40,50,60,70,

and 80. A slash mark “/” is displayed every 5 positions at position 5,15,25,35, etc. Positions that

correspond to an input value of “ON” will contain a block character. Positions that correspond to an

input value of “OFF” will NOT contain a block character. The sample display below shows all inputs

“OFF” except for inputs numbered 1, 10, 13, 15, 31, 33, 77, 79, 80, and 81.

To facilitate easier reading of the display when many “ON” states (block characters) exist, when a

block character is present at a position that is a multiple of five (0,5,10,15,20,etc.), a narrow block

character is used instead of the full-sized block character. Note that the first 11 digital input values

(positions 0 to 10) represent the current state of the Pilot Interface panel switches, as viewed from

left to right. A complete list of the digital input numbers can be viewed in the “Digital Inputs”

display.

Digital Outputs

This menu option allows maintenance personnel to view

and optionally change the values of various digital

outputs in the system. Each output is listed with its’

hardware pin designator and with its’ value, either “ON”

or “OFF”, along with whether the output is “forced” on

or off.

To force an output either “ON” or “OFF”, perform the following:

� Use the data wheel to scroll the output to be controlled to the top of the screen.

� Use the “YES” switch to turn the output on or use the “NO” switch to turn the output off.

o Note that HYD PWR and the ARMED switch must be on for some outputs to function

due to the hardware design

� Pressing the data wheel in exits this screen

If an output is forced, an asterisk “*” is displayed. The sequence number of the output is displayed

in highlighted text. The sequence number ranges from 0 to 23 and is associated with the “Digital

Output Map” display (described next). Panel LED indicators appear at the beginning of the digital

outputs to facilitate easy testing.

To exit this mode, press the selector knob, at which time all “forces” will be removed and all

outputs will be reset to the state they were in when this mode was entered.

Note: Setting tweak number 91 to the special value of 99 will cause “Digital Outputs” mode to

KEEP any forces set by the user and NOT restore them upon exit from this mode. This may be

useful for maintenance personnel to force a digital output and then view the resulting change of

a digital input (in “Digital Inputs” mode, described earlier).



Digital Output Map

This menu option allows maintenance personnel to

view the values of all digital outputs of the system on

a single screen. Digital outputs are numbered from 0

to 24. The format of the screen is the same as “Digital

Input Map” (described above), except there are fewer

outputs to display, so fewer lines are used on the

display. Unlike “Digital Outputs” mode, this mode can

only be used to DISPLAY the state of digital outputs, not force them on or off.

The sample display above shows all outputs “OFF” except for outputs numbered 1, 2, 6, 7, 8, and

9.

The first 5 digital output values (positions 0 to 4) represent the current state of the LED lamps on

the Pilot Interface panel. A complete list of the digital output numbers can be viewed in the

“Digital Outputs” display.

Analog Inputs

This menu option allows maintenance personnel to view the values of various analog (voltage)

inputs to the system.

Each input is listed with its hardware pin designator

and listed with its analog “count” value, both an

unfiltered count (marked as “ct”) and a filtered

(averaged) count (marked as “av”).

An analog voltage is displayed along with a

conversion to units-of-measure for some analog

values.

Pressing the “YES” switch will freeze (data hold) the numeric portion of the display (“HOLD” is

indicated in the upper right of the display) and the bar graph, if displayed, will then be more

responsive (for viewing accelerometer response). Pressing the “YES” switch again will un-freeze

the display.

Analog Calibrate

The voltage inputs on each pilot interface are calibrated at the factory to ensure that the units are

interchangeable in the field. This procedure applies a known voltage to the optically isolated inputs

on the pilot interface and automatically adjusts various calibration parameters in the system to

ensure that the voltage sensed by the unit is the same as the “real world” voltage applied to the

system.

This menu option allows maintenance personnel to view and optionally recalibrate the low and high

calibration values for each analog input. More details on the analog calibration procedure can be

found in Trotter Controls Document# PS-0025.

Normally, factory personnel only perform this calibration. Do not attempt this procedure unless

you know what you are doing and have determined that it is necessary. The system will not

operate properly if this calibration is not correct.



Err Msg Index/Counts

This feature provides maintenance personnel with a comprehensive list of all possible error

messages generated by the system in numerical order.

� Each error message is preceded with a three-digit error number.

� If an error has occurred, (the error message has a non-zero count), the error count is

displayed in inverse text instead of the error number.

� The error count includes the number of “past” (inactive) errors and is followed by ‘*’ if the

error is also currently active.

When this menu item is first entered, the first entry displayed (entry number zero) will contain the

total number of active errors, or if there are no active errors, will display “000_No errors”. If a

value other than zero is displayed, this count represents the total number of currently active errors

which are present elsewhere in the error table.

Using the twist knob to scroll through the error message index will show active errors with a count

followed by ‘*’ to indicate that the error is currently active.

Trotter Controls Engineering Report 0075 provides details on the error codes that can be generated

by the system.

Clear Errors

Clears any active errors in the current active error table, but retains the error count (the number of

times each error has occurred). This has the same effect as momentarily pressing the “RUN PUMP”

switch to clear active errors. This will also clear hydraulic system errors that may have caused the

pump to shut down.

Clear Err Counts

Clears all errors (and error counts) in the current active error table (but NOT the error history

table). This will also clear hydraulic system errors that may have caused the pump to shut down.

Clear ErrHistory

Clears the error history table. Does NOT affect the current active error table in any way.

System Reset

Performs a software system reset, which restarts the microprocessor/microcontroller. The same

function can be obtained by cycling power to the unit using the circuit breaker panel.

Save Memory

See Trotter Controls document PS-0035 for details on the types of memory used by the FRDS

system as well as memory management procedures.

If any changes are made to any parameters (such as the leakage table) which are to be retained

beyond the current system run, this option writes these values to EEprom (non-volatile memory) to

be recalled at the next system restart. After selecting this option by pushing the selector knob, a

secondary menu will be displayed, offering the options “Ext” (External), “Int” (Internal), and

“Both”. The default selection is “Both”. After selecting one of these and pushing the selector knob,

memory will be saved to primary (bank A) EEPROM.



Secondary (bank B) EEPROM, which is used for emergency backup, is not writable by the user, and

is written only at the factory when the unit is first calibrated.

Note: If the system was started with FACTORY DEFAULTS (by holding down the “NO” switch at

startup), an additional prompt of “SAVE FACTORY VALUES?” will occur, warning the user that

currently saved memory values are about to be over-written with factory default values. The user

can respond with either the YES or NO switch. DON’T select YES unless you know what you

are doing, this sets all calibration values back to the factory default values.

FACTORY USE ONLY: Secondary (bank B) EEPROM can be saved by factory personnel by holding

both the “YES” and “LAMP TEST” switches in the up position (wait for LED’s to turn on) and then

pushing the selector knob.

Read EEprom

This option reloads memory from its last saved state, restoring any changes to parameters that

have been made since the last “Save Memory” operation. After selecting this option by pushing the

selector knob, a secondary menu will be displayed, offering the five options “Ext”, “Int”, “Int

(analog cal)”, “Ext (leakage)”, and “Int (leakage) BACKUP”. The default selection is “Ext”, which is

the external memory loaded at system restart. After selecting one of these and pushing the

selector knob, memory will be read from primary (bank A) EEPROM, either in its entirety, or only

the selected region from the selected bank of memory. Secondary (bank B) EEPROM, which is used

for emergency backup, can be read by holding the YES switch while pressing the selector knob.



Compare RAM/EE

This option compares current memory with the contents of EEprom, byte-by-byte, displaying any

differences. Note that for this option to be completely useful, the system should have been started

with “FACTORY VALUES” by holding the “NO/MENU” switch down at system startup, which inhibits

automatic reading of EEprom.

Below the heading of “Tw Area RAM Int Ext”, several items are displayed on the screen for each

byte that differs between RAM and EEprom.

The value displayed under the heading “Tw” is the byte number (“tweak” number) in memory. The

value displayed under the heading “RAM” is the value contained in RAM memory. If the system was

started with “FACTORY VALUES” (see above), this value is the factory value.

The values displayed under the heading “Int” is the corresponding value contained in Internal

EEprom. The upper value corresponds to bank A memory, while the lower value corresponds to

bank B memory. The values displayed under the heading “Ext” is the corresponding value

contained in External EEprom. The upper value corresponds to bank A memory, while the lower

value corresponds to bank B memory. The indicator under the heading “Area” may contain one of

the following, depending upon which area of memory the value resides:

� “Leak” if the value is within the Leakage Table.

� “Cal” if the value is within the Analog Calibration Table.

� “Errs” if the value is within the Current Error Table.

� “Hist” if the value is within the Error History Table.

� “SWs” if the value is within the area of memory for saving user-changeable panel switch

settings.



� “*Cal” if the value is within the Analog Calibration Table, but NOT IN THE AREA THAT

SHOULD VARY. (This last indicator SHOULD NOT OCCUR and should be considered an error

in the factory section of the calibration table.)

If the indicator under the heading “Area” is blank, the memory byte which is different (between

RAM and EEPROM) should be checked to see if there is a specific reason that this value is NOT the

same as the factory default value. Note that the values for Tw=6 and Tw=7 will differ if ANY

values in that bank are different, as these two values represent the EEPROM checksum. If the

values of Tw=6 and Tw=7 are the same for any set of memory banks, those banks are identical.

Push the selector knob to display the next value that is different. Press the “NO” switch to exit the

Compare RAM/EE function. Hold the “YES” switch while pushing the selector knob to skip to the

next value in a different “Area”. For example, use this to bypass listing all differences in the “Errs”

or “Hist” areas.

At the end of the display of all memory values that are

different, a Signature Summary screen will appear with

five sets of digital signatures (displayed in hexadecimal).

Each set contains two signatures – the first one is for

analog calibration, the second one is for leakage table.

The five sets of signatures represent RAM, Internal A,

External A, Internal B, and External B.

A sample screen is shown at the bottom of the previous page.

To skip directly to the Signature Summary screen, depress the “RUN PUMP” switch momentarily

while pushing the selector knob.



Logo/Version

This option displays the logo screen (also displayed at

system startup). The logo is displayed until the

operator either rotates the selector knob or presses the

“NO/MENU” switch. The Version number and Version

Date are also displayed. Pressing “YES” will display the

Version Time. Pressing “YES” again will display the

“FRDS” intro screen, which contains two digital “signatures”, one for the Analog Calibration table,

and the other for the Leakage Table. These digital signatures are useful to determine if any

changes have been made to the Analog Calibration table or the Leakage Table. Pressing “YES”

once more exits this function.

Leakage Table

Each aircraft is dump tested at the factory and calibrated to compensate for minor differences in

the gatebox door and venting system seen on production systems. This leakage table is specific to

a given aircraft and must be transferred to any replacement pilot interface.



Trotter Controls Document# PS-0035 provides details on the GEN II FRDS memory management

features as well as a step-by-step procedure for moving the leakage factors for your aircraft into a

replacement pilot interface unit.

This feature allows maintenance personnel to view the

currently stored leakage table and compare it with the

factory-value leakage table. Use the selector knob to

scroll the display up or down through the active and

factory tables.

Press the “YES” switch to alternate between the “active” and “factory” tables to view differences.

The coverage levels in the factory table are followed by the indicator “F” to indicate they are

factory values.

“Active” leakage values that differ from the

corresponding “factory” value are highlighted in

inverse text. This also includes the column headings

for “GtD” (Gallons to Dump), which can be changed by

the user from the default 200, 400, 600 gallons to a

different calibration delivery value.

Note that it is necessary to use the data wheel to scroll through all of the leakage values since the

system uses a four-line display.

The left hand column contains the coverage level for each row of leakage values. Leakage factors

for a coverage level of 0.5 and 1.0 are shown in the figures above.

Each column of data is for the gallons to dump (GtD) settings used to determine each leakage

factor. The gallons to dump (or GtD) settings are 200, 400, 600, and 800 in the figures shown

above. The leakage factors for each of these settings are shown versus coverage level in the table.

For example, the leakage factor for a coverage level of 1.0 and a gallons-to-dump setting of 400 is

32 gallons in the figures shown.

Note that the leakage table is not normally changed except by performing calibration test dumps of

known quantities of water, which allow the system to “learn” by repeated dumps. The leakage

table can also be changed manually using the “Tweak Parameters” feature, described below.



System Operation Parameters (Tweak)

(This information also appears in document ER-0074 - FRDS Gen2 System Operation Parameters.)

This feature provides maintenance personnel with a means of viewing and making changes to

system parameters that cannot otherwise be viewed or manually altered. This option can be used

to manually change leakage tables, calibration tables, and other internal parameters used to

control operation of the system. Maintenance personnel may view all parameters. While some

parameters can be freely changed by maintenance personnel, other internal system parameters

are “protected” by pass-code and can be modified only while in telephone contact with a factory

engineer.



A detailed list of the system parameters or “tweak” values are shown in Trotter Controls

Engineering Report 0074.

A partial list of system operation parameters that can be displayed and changed are:

� Enable / Disable pilot interface display mirroring

� Leakage Table

� Analog Calibration Table

� System Clock

� System Scan Loop cycle time in various modes (display only)

� Manual testing of trajectory following parameters using valves in auto-dump mode

� Detailed System Error Table (including intermittent error counts)

� Facility for inhibiting the detection and display of certain specific error codes

� Facility for inhibiting the detection and display of ALL error codes

� Secondary Error codes for more extensive troubleshooting

� Internal System Parameters that control:

o testing of system watchdog

o valve control algorithm testing

o defines which of the directional valves are controlled by Gate Open and Close

switches when operated in AUTO or TIMER mode

o Timer Mode valves for opening and closing gate

o valve-control timing and internal tuning parameters

o memory read/write (both external and internal memory)

o facility for inhibiting checksum errors while reading memory

o internal settings for time delays, hydraulic pressure, and other hardware parameters

o Many other parameters.

Parameters are of two types:

o single-byte values (which range in value from 0 to 255)

o two-byte (word) values (which range from 0 to 65535).

o The value in position zero of the tweak table indicates whether values are expressed in 1

or 2 byte format.

If the value of tweak position 0 is ‘1’, the tweak numbers will be listed sequentially, 0, 1, 2, 3, 4, 5,

and so on. If the value of tweak position 0 is ‘2’, the tweak numbers will be listed in increments of

two – 0, 2, 4, 6, 8, and so on. This value can also be toggled between 1 and 2 while in tweak

mode by depressing the “LAMP TEST” switch.

To use this feature, select “Tweak Parameters” from the MAINT menu.

Use the twist selector knob to scroll the tweak numbers up or down. Push the selector to scroll

rapidly 100 positions in the same direction as the last “twist”.

To change (edit) the value of a tweak number, position the desired number at the top of the

screen, and press the “YES” switch. If the user is authorized to change this value, Edit mode will

be entered.

When in Edit mode, the value will be highlighted, and twisting the selector will change the value up

or down. Pushing the selector button will change the value (by 100) in the direction of the last

twist. Pressing “LAMP TEST” will change the value (by 1000) in the direction of the last twist.

Pushing the selector while holding “LAMP TEST” will change the value (by 10,000) in the direction

of the last twist.



Note that changing a value by 100, 1000, or 10000 is only useful when changing two-byte (word)

values. To zero a two-byte (word) value, see “change-immediate” mode, described below.

When the desired value is displayed, press “YES” to accept the change and store the value in that

tweak position. Pressing the “NO” switch will abort the change and leave the value unchanged.

Pressing “YES” or “NO” exits tweak edit mode and returns to tweak display mode.

Note: While the user is ALWAYS allowed to display the current value of any tweak parameter, the

user is limited to changing (using Edit mode) only “unprotected” tweak values. These unprotected

tweak values include areas of the Analog Calibration Table (tweak numbers 96-191), the Leakage

Table (tweak numbers 10-89), and some user-changeable tweak values in the range of tweak

numbers 90-95. All other tweak values (currently above tweak number 192) are considered

“protected” and are only changeable with special authorization from a factory engineer.

A “change-immediate” mode is also provided. In this mode, twisting the selector knob will change

the value of the parameter IMMEDIATELY, without pressing the “YES” switch to store the

highlighted value.

To enter “change-immediate” mode, press and hold the “YES” switch while momentarily pushing

the selector button. Note that because the value is changed immediately while twisting the

selector knob, pressing “NO” (abort change) has the same affect as pressing “YES” (accept

change). This feature is useful for changing some system parameters (such as PWM duty cycle or

GATE switch valve) while simultaneously observing their effect. Pressing the “LAMP TEST” switch

while in “change-immediate” mode will ZERO the value being edited.

To exit tweak display mode, press the “NO” switch.

Programmer note: Tweak position zero, in addition to the values of 1 and 2, may also contain

either a value of 9 (byte mode) or 10 (word mode). This will cause the tweak values to be

displayed in hexadecimal format instead of decimal. If this value is set to 4, tweak values will be

displayed in floating point format. Pressing “LAMP TEST” will toggle between byte and word mode.

Pressing “RUN PUMP” will toggle between decimal and hex format. Switching from “AUTO” to

“TIMER” will change to floating point display. Switching back to “AUTO” will display in hex (either

word or byte) mode.

See Trotter Controls document ER-0074 for details on various system operation parameters

(“tweaks”) and adjustment procedures.



FRDS Menu Tree

Below is a diagram of the FRDS menu system.

FRDS MENU TREE (Revised 04/08/2010)

Notes: [X]

1. HIGHLIGHT AN ITEM THEN PUSH SELECTOR KNOB TO ENTER SUBMENU

2. YES SW CAN BE USED FOR ACTIVATING OUTPUTS

NO SWITCH CAN BE USED FOR DEACTIVATING OUTPUTS

3. SELECTOR KNOB WILL EXIT THIS SUBMENU4. NO SWITCH WILL EXIT THIS SUBMENU

PRESS SELECTOR KNOB

*UNABLE TO BE

CALIBRATED

MAIN MENU

YES/FOAM

SW

NO/MENU

SW

MAINT

CONFIG

SYSTEST

FUEL FERRY

ERROR HISTORY

FOAM INJECT

AIRCRAFT

LEARN

HARDWARE

MAIN AUTO/TIMER

DISPLAY

PILOT (NO DOORS)

PILOT (ALL)

AUTO SALVO

MAN SALVO

MAINT SYSTEST

TWEAK PARAMETERS [4]

DIGITAL INPUTS [3]

DIGITAL INPUT MAP [3]

ERR MSG INDEX/COUNTS[3]

ANALOG CALIBRATE [3]

CLEAR ERRORS

CLEAR ERR COUNTS

DIGITAL OUTPUTS [2][3]

DIGITAL OUTPUT MAP [3]

READ EEPROM [4]

ANALOG INPUTS [3]

SYSTEM RESET [4]

LEAKAGE TABLE [4]

COMPARE RAM/EE [4]

CLEAR ERR HISTORY

SAVE MEMORY [4]

LOGO/VERSION [4]VERSION

YES

DATE/TIME

YES

AIRCRAFT

CAL/LEAK

SIGNATURES

BOTH

EXT

INT

ACTIVE

FACTORYYES

PHOTO

ACCEL ONE

ACCEL TWO

GATE ANGLE

HOPPER

HYD PRES

FOAM GAL

DERIVED G *

BATT + 24 V

PANEL TEMP *

EXT (EXTERNAL)

INT (INTERNAL)

INT (ANALOG CAL)

EXT (LEAKAGE)

INT (LEAKAGE) BACK UP

EXT (ANALOG CAL) BACKUP

YES

MAIN DISPLAY

PRESS SEL. KNOB TO

CLEAR ERRORS

Figure 4 ~ FRDS menu tree



Error Overview A detailed description of the error codes, their meaning, and possible error resolution actions are

presented in Trotter Controls Engineering Report 0075.

An abbreviated description of the types of errors that can be detected is presented below.

The GENII FRDS system has comprehensive built in diagnostics to detect the following problems:

� Broken wires

� Burned out valve coil

� Blown fuse

� Stuck hydraulic valve

� Faulty Pressure Switch

� Faulty Pressure Sensor

� Faulty Microprocessor Output

� Faulty Relay

� Faulty pump

� Other hardware faults

� System errors

Some errors are checked anytime power is applied to the system and the operation mode is AUTO

or TIMER. These error conditions are checked passively (meaning that no valve or control action is

required for the test). Passive errors are detected during Auto and Timer mode operation of the

FRDS when the HYD PWR switch is on. Some passive errors can only be detected when the HYD

PWR switch AND the ARMED switches are on.

Testing for other error conditions requiring that a valve or other output be turned on is performed

during the Pilot Assisted Test or Maintenance Tests (SysTest). These SysTest errors are detected

during the Pilot Assisted test or the Maintenance Test. If a failure is detected during the SysTest

diagnostics, a persistent error code 021 or 105 is saved (See System Test Persistent Errors on

Page 30).

System errors have to do with the operating software and hardware internal to the CPU chip. These

errors should not normally occur.

A brief description of the types of faults and the resulting system status is shown in the following

sections.

Detected errors will affect the operation of the system. A message will be displayed showing the

effect of detected errors on system operation.

Please note, errors 112, 113 and 114 will be accompanied by the primary error causing

one of the following,

Reduced Accuracy

Error Code Displayed: 112_Accuracy Loss

This state indicates that the system has full redundancy but the amount of fluid delivered may not

be accurate.



The pilot should be aware that the system may yield inaccurate delivery results (i.e. flow rate or

delivered gallons not accurate) when this state is displayed and fly accordingly. The AUTO armed

light flashes and is not steady on when this state is detected.

Typically, this is caused by the hydraulic pressure being too low to operate the doors quickly.

• This indicates that the control system is operational but the accuracy of the delivery has

been compromised.

• For example, the hydraulic pressure is low which may cause the gates to operate slowly

causing more or less water to be dumped.

Reduced Redundancy (AUTO/TIMER mode only)

Error Code Displayed: 114_Redundancy Loss

This state indicates that the system may have a problem with one or more the redundant SALVO

systems or hydraulic valve. This can be caused by any fault detected in the primary system,

backup electro-mechanical system, or backup supervisor system.

The pilot should be aware that the system might yield inaccurate delivery results or not open as

expected when this state is displayed and fly accordingly. The AUTO armed light flashes and is not

steady on when this state is detected.

• This error indicates that one or more of the backup dump control systems has been

compromised and may be inoperable.

• For example the Auto Salvo system (uP) and/or the electro-mechanical Salvo system, may

be inoperable

Note that when the system is operated in manual mode, there is no system redundancy.

Reduced Accuracy & Redundancy (AUTO/TIMER mode only)

Error Code Displayed: 113_Accur+Redun Loss

This indicates that errors that would cause a combination of both accuracy and redundancy loss

have been detected.

The pilot should be aware that the doors may not open when this state is displayed and fly

accordingly. The AUTO armed light flashes and is not steady on when this state is detected.

Note that when the system is operated in manual mode, there is no system redundancy.

Clearing Pump Errors

When the system is operated in AUTO or TIMER mode, the system can detect a number of errors

with the pump. When an error is detected, the hydraulic pump is disabled to prevent possible

damage to the pump.

Pump errors can be cleared by pressing the RUN PUMP switch. Note that the pump can be forced

to operate in all modes by holding the RUN PUMP switch down.



Caution: Holding the RUN PUMP switch down continuously will cause the pump to build pressure

until the pump’s mechanical pressure relief valve is activated. This pressure is in excess of the

system’s normal operating pressure.

Caution: The system cannot disable pump operation when operated in the MAN mode. Please

verify that adequate oil is present in the system before operating the system in MAN mode. The

pilot should monitor the PUMP ON LED on the pilot interface to make sure that the pump is not

operated continuously due to some fault condition.

Setting System Preferences The pilot is able to adjust the default parameter settings for AUTO and TIMER modes of operation. To set the power up defaults for AUTO and TIMER modes, do the following:

1. Power up the unit. 2. Set the mode switch to AUTO 3. Adjust the coverage and gallons to dump settings as desired 4. Set the mode switch to TIMER 5. Adjust the timer settings as desired 6. Press the NO/MENU switch to access the main menu 7. Select MAINT => SAVE MEMORY => BOTH

The settings for AUTO and TIMER set in steps 3 and 5 above are now the new default settings that are active when power is applied to the system.

Maintenance Trotter Controls Engineering Report 0077 is a detailed preventative maintenance document for the

system. Please refer to this document for details on the recommended preventative maintenance

for the GENII FRDS unit.

There are various fuses and relays in the system that are user-replaceable items if required. These

fuses are located in the relay enclosure located on the RH side of the aircraft behind the baggage

compartment.

Fuse, Relay, & Status LED Location and Function The GEN II FRDS unit incorporates protection for all the wiring on the aircraft per applicable FAA

regulations and Air Tractor standard design criteria.



Figure 5 ~ Relay enclosure located on the RH side of the fuselage behind the baggage

compartment.

Fuses used to limit the maximum current possible are located inside the relay enclosure and are

mounted to the various printed circuit boards mounted in the enclosure. These fuses can be

replaced by the user if required.

The various relays used to control the electro-mechanical system are also included in the relay

enclosure and are mounted on the circuit board. These relays are socket mounted and can be

replaced by the user if necessary.

The circuit boards located inside the relay enclosure also have various LED’s on them to indicate

the status of fuses, relays, outputs, and other items.

The function and locations of relay, fuses, and LED’s are shown in the following tables and pages

for reference.



Table 6 ~ Fuse, Led, and Relay placement for relay enclosure main circuit board

assembly 5950-0008 REV D and Prior.



Table 7 ~ User replaceable fuses located inside the relay enclosure.

FUSE

No.

FUSE

RATING

(AMPS)

[1]

CIRCUIT PROTECTED

FUSE SCHEDULE – I2C PCB 5950-0012

F1 2 I2C BUS POWER (I2C Board)

FUSE SCHEDULE – RELAY PCB 5950-0008

F1 3 SPARE2-REG

F2 10 GND – (Valve Common)

F3 3 EDUMP2

F4 3 EDUMP1

F5 3 BLEED-SOL

F6 3 RUN_PUMP

F7 3 VALVE3-CLOSE

F8 3 VALVE3-OPEN

F9 3 VALVE2-CLOSE

F10 3 VALVE2-OPEN

F11 3 VALVE1-CLOSE

F12 3 VALVE1-OPEN

F13 5 VBUS2, V1 & V2 VALVES (open & close)

F14 5 VBUS1 (µP AUTO SALVO VOLTAGE SELECT)

F15 10 +V BATT SUPPLY IN (VBAT-IN)

F16 10 +V BATT SUPPLY IN 2 (V+)

F17 5 VBUS4, RUN_PUMP, SPR1, SPR2, BLEED AND

EDUMP VALVES

F18 2 VBUS3, V3 VALVES (open & close)

F19 2 SPARE +28V TO CN2

F20 2 HOME-PRX1

F20 2 HOME-PRX2

F20 2 HYD_SW

F20 2 FOAM_LVL

F20 2 HYD_PRESS

F20 2 SPARE-IN1

F20 2 +V – (SW / SENSOR SUPPLY COMMON)

F21 2 EM_VALVE_POWER & HYD POWER – ARMED

F22 5 SPARE1- OUTPUT (not regulated)

F23 5 EM_V+_SW_SUPPLY, VREG 5, 6 & 7

F24 2 +V_EM_AUTO_SALVO

F25 N/A Jumper installed

F26 N/A Jumper Installed

F27 N/A Jumper Installed

F28 .75 [7] VBUS4 (FACTORY REPLACE ONLY)

F29 .75 [7]VREG5 (FACTORY REPLACE ONLY)

NOTES: [x]

1. Pin / Fuse numbers correspond to termination points on PCB ASSY P/N 5950-0008 and

P/N 5950-0012 located inside the enclosure.

2. Connects Relay Box to MultiBox 16 point Multibox.



3. Port numbers are for a 16 point Multibox used to connect valves and sensors to the

system and are shown for reference only.

4. The +V supply for the 16 point Multibox is supplied via pin 19 of connector CN7. Fuse

20 protects this circuit in addition to the sensors and switches connected to pins 13 ~ 18

on CN7 (since the +V supply for all circuits is via Pin 19).

5. The sourcing outputs for valve control are individually fused at 3 amps.

6. The common ground for valve outputs is fused at 10 amps.

7. This fuse is only present on Rev E and after.



Table 8 ~ LED indicator legend for the relay enclosure main circuit board.

RELAY PCB 5950-0008 REV D and prior

LED

No.

“ON” WHEN THE FOLLOWING

CIRCUIT IS ENERGIZED. HYD

POWER MUST BE ON AND SET TO

AUTO.

RELAY / FUSE

SIGNAL NAME

(UP = MICROPROCESSOR)

(UP = AUTO/TIMER)

LED1 SPARE – IN1 SPARE1

LED2 PRESSURE BELOW 2500 PSI (MAN) HYD_SW

LED3 DOORS CLOSED HOME-PRX2


LED5A Auto Salvo K28, K30, K31,

K32, K34, K35 UP_AUTO_SALVO

LED5B VALVE1 – OPEN UP-V1-OPEN

LED5C VALVE2 – OPEN UP-V2-OPEN

LED5D VALVE1 – CLOSE UP-V1-CLOSE

LED6A VALVE3 – OPEN UP-V3-OPEN

LED6B VALVE2 – CLOSE UP-V2-CLOSE

LED6C RUN PUMP UP-RUN_PUMP

LED6D VALVE3 – CLOSE UP-V3-CLOSE

LED7A SPARE2 UP-SPARE2

LED7B SPARE1 UP-SPARE1

LED7C EDUMP1 UP-EDUMP1

LED7D BLEED SOL UP-BLEED_SOL

LED8A EDUMP2 UP-EDUMP2

LED8B SP1 NOT USED

LED8C SP2 NOT USED

LED8D SP3 NOT USED

LED9A VREG 5 ON VREG5

LED9B VREG 6 ON VREG6

LED9C VREG 7 ON VREG7

LED9D TP7 / OPTO 2D TP7

LED27 MODE SW – MAN

K13, K14, K15,

K16, K17, K18,

K22, K23 I_EM_PWR1

LED28 HOME PROX 2 K19 HOME-PRX2

LED29 V3 CLOSE K20 I_EM-V3-CLOSE_COIL

LED30 RUN PUMP K21 EM-RUN-PUMP

LED43 EM VALVE POWER FUSE 21 EM_VALVE_PWR

LED44 EM POWER FUSE 23 EM_V+_SW_SUPPLY

LED45 EM AUTO SALVO POWER FUSE 24 V_EM_AUTO_SALVO

LED46 BATTERY SUPPLY POWER FUSE15 / K37 VBAT-IN

LED47 MAN SALVO COMPLETED CYCLE K29, K33, 36 EM_AUTO_SALVO_DN

LED48 ARM SWITCH K24 HYD_PWR_SW_&ARMED-

SW



Table 9 ~ Fuse, Led, and Relay placement for relay enclosure main circuit board

assembly 5950-0008 REV E.



Table 10 ~ LED indicator legend for the relay enclosure main circuit board.

RELAY PCB 5950-0008 REV E on

LED

No.

“ON” WHEN THE FOLLOWING CIRCUIT

IS ENERGIZED. HYD POWER MUST BE

ON AND SET TO AUTO.

RELAY / FUSE

SIGNAL NAME

(UP = MICROPROCESSOR)

(UP = AUTO/TIMER)

LED1 SPARE – IN1 SPARE1

LED2 PRESSURE BELOW 2500 PSI (MAN) HYD_SW



LD1 Auto Salvo K28, K30, K31,

K32, K34, K35 UP_AUTO_SALVO

LD2 VALVE1 – OPEN UP-V1-OPEN

LD3 VALVE1 – CLOSE UP-V1-CLOSE


LD5 VALVE2 – CLOSE UP-V2-CLOSE


LD7 VALVE 3 CLOSE UP-V3-CLOSE

LD8 RUN PUMP UP-RUN_PUMP

LD9 SPARE1 UP-SPARE1

LD10 SPARE2 UP-SPARE2

LD11 BLEED SOL UP-BLEED_SOL

LD12 EDUMP1 UP-EDUMP1

LD13 EDUMP 2 UP-EDUMP2

LD14 NOT DUMP SW NOT_DUMP_SW

LD15 DUMP SW DUMP_SW

LD16 EM V+ SW SUPPLY EM_V+_SW_SUPPLY

LD17 SSCL-HIGH (SCL-HIGH) SCL (I2C SCL HIGH)

LD18 SCL-LOW SCL (I2C SCL LOW)

LD19 SDA-LOW SDA (I2C SDA LOW)

LD20 VREG 5 ON VREG5





LD25 MON2 MON2-POWER (POWER OK)

LD26 EM-05 EM-05 (EM CIRCUIT OK)

LD27 EM-06 EM-06 (EM CIRCUIT OK)

LD28 SDA-HI SDA (I2C SDA HIGH)

LED27 MODE SW – MAN

K13, K14, K15,

K16, K17, K18,

K22, K23 I_EM_PWR1

LED28 HOME PROX 2 K19 HOME-PRX2

LED29 V3 CLOSE K20 I_EM-V3-CLOSE_COIL

LED30 RUN PUMP K21 EM-RUN-PUMP

LED43 EM VALVE POWER FUSE 21 EM_VALVE_PWR

LED44 EM POWER FUSE 23 EM_V+_SW_SUPPLY

LED45 EM AUTO SALVO POWER FUSE 24 V_EM_AUTO_SALVO

LED46 BATTERY SUPPLY POWER FUSE15 / K37 VBAT-IN



LED47 MAN SALVO COMPLETED CYCLE K29, K33, 36 EM_AUTO_SALVO_DN

LED48 ARM SWITCH K24 HYD_PWR_SW_&ARMED-SW

Table 11 ~ LED indicators on the power solenoid driver circuit board installed on the

5950-0008 relay circuit board assembly inside the relay enclosure.

POWER – SOLENOID DRIVER PCB – 5950-0027

LED

No.

“ON” WHEN THE FOLLOWING

CIRCUIT IS ENERGIZED. HYD

POWER MUST BE ON AND SET TO

AUTO.

IC No.

(+24V OUT EXCEPT

AS NOTED)

SIGNAL NAME

LD1 VREG9 {3} IC1 (+15V) VREG9

LD2 VREG8 {3} IC2(+5V) VREG8

LD3 VREG5 {4} IC3 VREG5



LD6 EDUMP2 {2} IC6 EDUMP2

LD7 EDUMP1 {2} IC7 EDUMP1

LD8 BLEED {2} IC8 BLEED

LD9 SPARE2 {2} IC9 SPARE2

LD10 SPARE1 {2} IC10 SPARE1

LD11 RUN PUMP {2} IC11 RUN_PUMP

LD12 V1 OPEN {2} IC12 V1-OPEN

LD13 V1 CLOSE {2} IC13 V1-CLOSE


LD15 V2 CLOSE {2} IC15 V2-CLOSE


LD17 V3 CLOSE {2} IC 17 V3-CLOSE

Notes: {x}

1. All drivers on this circuit board are short circuit protected.

2. Maximum current output for each driver channel IC is 3 amps, voltage is internally

regulated to +24V maximum when driver is on.

3. Maximum current output for each linear voltage regulator IC is 1 amp

4. Maximum current output for switching voltage regulators is 3 amps

Preventative Maintenance Schedule The GEN II FRDS unit has been designed and tested to provide years of trouble free operation.

However, as with any aircraft system, some preventative maintenance is required to ensure

continued airworthiness and reliable operation.

Please refer to Trotter Controls Engineering Report 0077 for a comprehensive list of the

recommended preventative maintenance items.



Calibration & Setup The GEN II FRDS unit has been designed for ease of setup and maintenance. The items required

for a qualified installer to calibrate and commission a new system are detailed below.

� Install the electrical and hydraulic system and fill the reservoir with Dexron III oil per

applicable drawings and installation instructions – Refer to Air Tractor Service Letter 273

� Flush the hydraulic system – Refer to Trotter Controls Document# PS-0033

� Calibrate the system sensors – Refer to Trotter Controls Document#PS-0031

� Calibrate the leakage factors for the hopper – Refer to Trotter Controls Document# PS-0032

� Perform system diagnostics – Refer to Trotter Controls Document#TS-0005

Memory Management The GEN II FRDS Pilot Interface utilizes internal and external memory to maintain two copies of the

system operation parameters and calibration factors for redundancy.

If a new pilot interface is installed on the system, it is necessary to copy the calibration factors for

your aircraft from the existing interface to the replacement unit.

Please refer to Trotter Controls Document# PS-0035 for details on the following items:

� Memory Configuration

o Memory types and organization

o Memory failure modes and built-in recovery

� Moving Leakage Calibration from an old pilot interface to a replacement unit

o Method 1: Manually enter the leakage data

o Method 2:Replace the EEPROM Memory

� Manually entering pilot analog calibration data from ICEBERG data

� Resetting factory leakage calibration data

� Resetting factory analog calibration data

Updating System Firmware At the time of this manual revision, the latest version of the system software is Version 1.16.

Authorized personnel only should update the system firmware.

The firmware version is displayed on the first screen displayed when the pilot interface is first

powered on. It can also be viewed by selecting “Logo/Version” from the “Maint” menu.

Contact Trotter Controls if there is a need to upgrade the system software in the pilot interface.



Reference Documents

Manuals

9001-0012 ~ GEN II FRDS Operators Manual, Trotter Controls, Inc.

Technical Publications & Test Specifications

TP-1000 ~ Constant Flow Rate vs. Constant Gate Angle, Trotter Controls, Inc.

TP-1002 ~ GEN II FRDS System Description, Trotter Controls, Inc.

TS-0005 ~ GEN II FRDS Maintenance System Tests, Trotter Controls, Inc.

Engineering Reports

ER-0074 ~ GEN II FRDS System Operation Parameters, Trotter Controls, Inc.

ER-0075 ~ GEN II FRDS System Error Codes and Resolution, Trotter Controls, Inc.

ER-0077 ~ Preventative Maintenance Schedule, Trotter Controls, Inc.

Process Specifications

PS-0030 ~ GEN II FRDS– Pressure Relief Valve Adjustment, Trotter Controls, Inc.

PS-0031 ~ Hopper Contents and Gatebox Sensor Adjustment, Trotter Controls, Inc.

PS-0032 ~ Calibration Dumping Matrix, Trotter Controls, Inc.

PS-0033 ~ Hydraulic Flushing Procedure, Trotter Controls, Inc.

PS-0035 ~ GEN II FRDS– Memory Management, Trotter Controls, Inc.

Product Datasheets

DS-0001 Datasheet ~ Pilot Interface (VFD) FRDS GENII, Trotter Controls, Inc.

DS-0002 Datasheet ~ Relay Enclosure FRDS GENII, Trotter Controls, Inc.

DS-0003 Datasheet ~ Side Loader Gage (VFD) FRDS GENII, Trotter Controls, Inc.

DS-0015 Datasheet ~ Side Loader Gage (LCD) FRDS GENII, Trotter Controls, Inc.

DS-0023 Datasheet ~ Pilot Interface (LCD) FRDS GENII, Trotter Controls, Inc.



Drawings

51625 SH.12 & 13 ~ Instrument Installation – Upper Panel (802F), Snow Engineering Co.

52650 SH.1 ~ Instrument Installation – Upper Panel (1002F), Snow Engineering Co.

60513 ~ Assy – Gatebox Electrical, Snow Engineering Co.

60441 SH.10 ~ Control System Wiring Schematic (802F), Snow Engineering Co.

60441 SH.21 ~ Control System Wiring Schematic (1002F), Snow Engineering Co.

61566 SH.1 ~ Installation - Relay Box – FRDS (1002F), Snow Engineering Co.

61566 SH.2 ~ Installation - Relay Box – FRDS (802F), Snow Engineering Co.

61567 SH.1 ~ Installation - Multibox – FRDS (1002F), Snow Engineering Co.

61567 SH.2 ~ Installation - Multibox – FRDS (802F), Snow Engineering Co.

61572 SH.1 ~ Assy - Relay Box – FRDS (802F & 1002F), Snow Engineering Co.

61574 ~ Cable Assy. – Valve to Multibox, Snow Engineering Co.

61587 ~ Pilot Interface – GEN II FRDS, Snow Engineering Co.

80442 SH.4 ~ Float Installation – Hopper (802F), Snow Engineering Co.

80493 SH.4 ~ Assy - Gatebox Actuator, Snow Engineering Co.

80504 SH.10 ~ Hydraulic Schematic (802F), Snow Engineering Co.

80504 SH.21 ~ Hydraulic Schematic (1002F), Snow Engineering Co.

80577 SH.13 & 14 ~ Hydraulic System Installation (802F), Snow Engineering Co.

80577 SH.21 & 22 ~ Hydraulic System Installation (1002F), Snow Engineering Co.

80628 SH.2 ~ Installation – Hopper Fill Gauge (1002F), Snow Engineering Co.

80628 SH.3 ~ Installation – Hopper Fill Gauge (802F), Snow Engineering Co.

81424, SH.2 ~ Installation-Hydraulic Manifold-802, Snow Engineering Co.

81759 ~ Fitting Assy, Hydraulic Tank, Snow Engineering Co.

83056 SH.2 ~ Installation – Gatebox Actuator (Sensor Assy) (1002F) , Snow Engineering Co.

83118 ~ Float Installation – Hopper (1002F), Snow Engineering Co.

83222 SH.1 ~ Hydraulic Manifold Assy Fire Gate (802F), Snow Engineering Co.

83222 SH.21 ~ Hydraulic Manifold Assy Fire Gate (1002F), Snow Engineering Co.



83224 ~ Assy, Hydraulic Pump, Snow Engineering Co.

83230 ~ Filter Assy, Hydraulic System, Snow Engineering Co.

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