TECHNICAL EXHIBIT 2 - MAFFS Operation Manual.pdf

Revised 15 APRIL 2016

OPERATION MANUAL

MAFFS

MODULAR AIRBORNE FIREFIGHTING SYSTEM

PART NUMBER 113000-301

Notice: Reproduction of the information or illustrations contained in this manual is not permitted without specific approval of the Assistant Director, Fire Operations, U.S. Forest Service

NOTICE: Reproduction for non-military or non US government use of the information or illustrations contained in this publication is not permitted without specific approval of the Assistant Director, Fire Operations U.S. Forest Service

D.5 - Technical Exhibit 2

15 APRIL 2016

15 APRIL 2016 A

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page.

Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands

Dates of issue for original and changed pages are:

Original 0 01 MARCH 2014 Revised 15 APRIL 2016

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 75 CONSISTING OF THE FOLLOWING

Page No. Change No. Page No. Change No. Page No. Change No.

Title 0 A 0 I - iv 0 1-1 – 1-6 0 2-1 -2-36 0 3-1 – 3-2 0 4-1 – 4-2 0 5-1 – 5-2 0 A-1 – A-17 0 B-1 – B-8 0 C-1- C-8 0 D-1 –D-8 0 E-1 – E-8 0 F-1 – F-25 0

*Zero in this column indicates an original page

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TABLE OF CONTENTS

Paragraph Title Page

CHAPTER 1 INTRODUCTION ..................................................................................................................................1-1

1.1. Forward Pallet Description......................................................................................................................... 1-2

1.2. Center Pallet Description ........................................................................................................................... 1-3

1.3. Aft Pallet Description.................................................................................................................................. 1-4

1.4. Discharge Nozzle Assembly Description ................................................................................................... 1-5

1.5. Paratroop Door Plug Description ............................................................................................................... 1-6

1.6. MAFFS Support Equipment....................................................................................................................... 1-7

CHAPTER 2 THEORY OF OPERATION ..................................................................................................................2-1

2.1. MAFFS AIR SYSTEM DESCRIPTION ...................................................................................................... 2-1

2.1.1. Initial System Charge ............................................................................................................................. 2-5

2.1.2. Normal Retardant Drop .......................................................................................................................... 2-5

2.1.3. Foam Tank Drop..................................................................................................................................... 2-5

2.1.4. Emergency Fluid Jettison / E-Dump....................................................................................................... 2-5

2.1.5. Forward Pallet Air Controls, Indicators and Connectors ........................................................................ 2-6

2.1.6. Center Pallet Air Controls, Indicators and Connectors........................................................................... 2-7

2.1.7. AFT Pallet Air Controls, Indicators and Connectors............................................................................... 2-8

2.2. HYDRAULIC SYSTEM DESCRIPTION..................................................................................................... 2-9

2.2.1. Normal Drop Opening Event .................................................................................................................. 2-9

2.2.2. Normal Drop Closing Event .................................................................................................................... 2-9

2.2.3. Emergency Jettision / E-Dump Event................................................................................................... 2-10

2.2.4. Aft Pallet Hydraulic Controls, Indicators, and Connectors ................................................................... 2-13

2.2.5. Nozzle Assembly Electrical and Hydraulic Controls, Indicators and Connectors ................................ 2-15

2.3. ELECTRICAL SYSTEM DESCRIPTION ................................................................................................. 2-16

2.3.1. Forward Pallet Controls, Indicators, and Connectors........................................................................... 2-17

2.3.1.1. Power Distribution........................................................................................................................... 2-18

2.3.1.2. Programmable Logic Control .......................................................................................................... 2-23

2.3.1.3. Drop, E-Dump and Nozzle Control Shelf ........................................................................................ 2-25

2.3.1.4. Resistive Soft Start Drawer............................................................................................................. 2-27

2.3.2. Center Pallet Electrical Controls, Indicators, and Connectors ............................................................. 2-28

2.3.3. Aft Pallet Electrical Controls, Indicators and Connectors..................................................................... 2-30

2.3.3.1. Drop Control Pendant ..................................................................................................................... 2-31

2.3.3.2. Cabin Control Box........................................................................................................................... 2-32

2.3.3.3. Foam Control Box ........................................................................................................................... 2-34

2.3.3.4. Vent Valve Control Box................................................................................................................... 2-35

2.3.3.5. Fill Control Box................................................................................................................................ 2-36

CHAPTER 3 SERVICING ..........................................................................................................................................3-1

3.1. GENERAL.................................................................................................................................................. 3-1

3.2. CLEANING................................................................................................................................................. 3-1

3.2.1. End of Day Cleaning............................................................................................................................... 3-1

3.2.2. End of Mission Cleaning......................................................................................................................... 3-2

3.2.3. End of Fire Season Cleaning.................................................................................................................. 3-2

3.3. PREPARATION FOR LONG TERM STORAGE ....................................................................................... 3-2

CHAPTER 4 INSPECTION........................................................................................................................................4-1

4.1. INTRODUCTION ....................................................................................................................................... 4-1

CHAPTER 5 H MODEL LOADING, INSTALLATION AND REMOVAL...................................................................5-1

5.1. MAFFS INSTALLATION AND REMOVAL OVERVIEW ............................................................................ 5-1

5.2. SPECIAL EQUIPMENT ............................................................................................................................. 5-1

5.3. MAFFS INSTALLATION ............................................................................................................................ 5-2

5.3.1. Aircraft Preparation................................................................................................................................. 5-2

5.3.2. Paratroop Door Preparation ................................................................................................................... 5-2

5.3.3. Door Plug Installation ............................................................................................................................. 5-2 ii 15 APRIL 2016

5.3.4. MAFFS Loading...................................................................................................................................... 5-2

5.3.5. MAFFS INSTALLATION......................................................................................................................... 5-2

5.4. MAFFS REMOVAL .................................................................................................................................... 5-2

5.4.1. MAFFS Removal .................................................................................................................................... 5-2

5.4.2. MAFFS Unloading .................................................................................................................................. 5-2

5.4.3. Aircraft Return To Normal....................................................................................................................... 5-2

5.5. MAFFS LOADING FOR AIRLIFT .............................................................................................................. 5-2

5.5.1. C-130-E/H Locking Points and Center of Gravity Data .......................................................................... 5-3

5.5.2. C-130-J Locking Points and Center of Gravity Data .............................................................................. 5-5

CHAPTER 6 MAFFS TRAILER OPERATION ..........................................................................................................6-1

APPENDIX A SYSTEM OPERATION AND FUNCTIONAL CHECKS ...................................................................A-1

APPENDIX B C-130-H MAFFS OPERATIONS COCKPIT CREW CHECKLIST ...................................................B-1

APPENDIX C C-130-H MAFFS OPERATIONS LOADMASTER CHECKLIST......................................................C-1

APPENDIX D C-130J MAFFS OPERATIONS PILOT CHECKLIST.......................................................................D-1

APPENDIX E C-130J MAFFS OPERATIONS LOADMASTER CHECKLIST........................................................ E-1

APPENDIX F FOREST SERVICE MAFFS INSTALLATION JOB GUIDE ............................................................. F-1

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LIST OF FIGURES

Figure Title Page Figure 1-1 C-130 MAFFS Installation ........................................................................................................................ 1-1 Figure 1-2 Forward Pallet Components ..................................................................................................................... 1-2 Figure 1-3 Center Pallet Components ....................................................................................................................... 1-3 Figure 1-4 Aft Pallet Components .............................................................................................................................. 1-4 Figure 1-5 Nozzle Assembly Components................................................................................................................. 1-5 Figure 1-6 Paratroop Door Plug Components ........................................................................................................... 1-6 Figure 2-1 MAFFS Air System Schematic ................................................................................................................. 2-3 Figure 2-2 Forward Pallet Air Controls and Indicators ............................................................................................... 2-6 Figure 2-3 Center Pallet Controls, Indicators and Connectors .................................................................................. 2-7 Figure 2-4 Aft Pallet Air Controls, Indicators and Connectors ................................................................................... 2-8 Figure 2-5 Hydraulic Schematic ............................................................................................................................... 2-11 Figure 2-6 Aft Pallet Hydraulic Controls, Indicators and Connectors....................................................................... 2-13 Figure 2-7 Nozzle Assembly Electrical and Hydraulic Controls, Indicators, and Connectors.................................. 2-15 Figure 2-8 C-130 MAFFS Electrical Layout ............................................................................................................. 2-16 Figure 2-9 Power and Control Rack Assembly Components .................................................................................. 2-17 Figure 2-10 Power Distribution Front Panel Electrical Controls, Indicators and Connectors (Sheet 1 of 2) ........... 2-19 Figure 2-11 Power Distribution Rear Panel Electrical Controls, Indicators and Connectors ................................... 2-22 Figure 2-12 PLC Drawer Controls, Indicators and Connectors ............................................................................... 2-24 Figure 2-13 Dump, Drop and Nozzle Control Shelf Electrical Controls, Indicators and Connectors....................... 2-25 Figure 2-14 Resistive Soft Start Drawer Controls, Indicators, and Connectors....................................................... 2-27 Figure 2-15 Center Pallet Electrical Controls, Indicators, and Connectors ............................................................. 2-28 Figure 2-16 Drop Pendant Controls, Indicators and Connectors............................................................................. 2-31 Figure 2-17 Cabin Control Box Controls, Indicators and Connectors...................................................................... 2-32 Figure 2-18 Foam Injection Control Box Operators Controls, Indicators and Connectors ..................................... 2-34 Figure 2-19 Vent Valve Control Box Controls, Indicators and Connectors............................................................. 2-35 Figure 2-20 Fill Control Box Controls, Indicators and Connectors.......................................................................... 2-36 Figure 5-1 MAFFS Tie Down Locations..................................................................................................................... 5-3 Figure 5-2 MAFFS Tie Down Locations..................................................................................................................... 5-5

LIST OF TABLES

Table Title Page Table 5-1 Required tools........................................................................................................................................... 5-1 Table 5-2 MAFFS C-130-E/H Station Locking Point Locations ................................................................................. 5-3 Table 5-3 MAFFS Center of Gravity Data.................................................................................................................. 5-4 Table 5-4 MAFFS C-130J-30 Station Locking Point Locations ................................................................................. 5-5 Table 5-5 MAFFS Center of Gravity Data.................................................................................................................. 5-6 iv 15 APRIL 2016

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CHAPTER 1 INTRODUCTION

The USFS C-130 MAFFS (Figure 1-1) is a constant flow, 3000 gallon, roll-on/roll-off aerial firefighting system for the C- 130 E, H, and J aircraft. The MAFFS is similar to the legacy system with the addition of onboard air compressors. This allows the MAFFS to charge the air system with aircraft generator power. The unit is self contained and can operate independently of an air tanker base. The MAFFS has been engineered to meet or exceed the Interagency Air tanker Board Criteria for Retardant Systems.

The installation and operation of the MAFFS requires no permanent modification to the aircraft. The MAFFS is designed to interface with the A/A32H-4A Cargo Handling System/ECHS. As a palletized unit, the MAFFS can be rolled onto the C- 130 from its own support trailer.

The MAFFS consists of five major assemblies: Forward Pallet, Center Pallet, Aft Pallet, Paratroop Door Plug, and Nozzle Assembly. The following paragraphs describe the primary function of each of the assemblies.

It should be noted that there are several differences in the configuration of the MAFFS between the C-130-E/H and the C- 130-J. These differences are listed below. Detailed explanations of the differences can be found in the USFS Maintenance manual.

NOTE: All items listed below are found in the conversion kit.

• J-Rails

• S-Duct Bellows

• Bulkhead Electrical Cables

• Flight Deck Drop Pendant Extension Cable

• Vent Tube

• FOD Guard

• Soft Start Relays

Figure 1-1 C-130 MAFFS Installation

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1.1. Forward Pallet Description

The forward pallet (Figure 1-2) contains the air compressor and motors and the electrical power and control rack. The FWD pallet can be mechanically and electrically disconnected from the MAFFS during loading, unloading, or maintenance.

Figure 1-2 Forward Pallet Components

Legend for Figure 1-2 Item Component or Assembly Item Component or Assembly

1 Power and Control Rack 5 Filtration Assembly 2 Motor #1 6 Motor #2 3 Compressor #1 7 Compressor #2 4 Condensate Tank Assembly 8 Compressor Heat Shield

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1.2. Center Pallet Description

The center pallet (Figure 1-3) contains the main water/retardant tank and cradle structure. It also contains the high pressure reservoirs, arming valves, regulators, vent valve, and other air system components. The CTR pallet is structurally connected to the aft pallet.

Figure 1-3 Center Pallet Components

Legend For Figure 1-3 Item Component or Assembly Item Component or Assembly

1 Main Retardant Tank 6 High-pressure Reservoirs 2 Float Sensors 7 High-pressure Regulators 3 Air Inlet 8 Arming Valves 4 Vent Pipe 9 Tank Support Cradle 5 Retardant Outlet Pipe

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1.3. Aft Pallet Description

The aft pallet (Figure 1-4) contains the loadmaster stations, foam injection system, main and jettison hydraulic system, inboard duct weldment, and right hand fill station. The Loadmaster is responsible for operation of the system during MAFFS missions. Incorporated into the station are three (3) control boxes used to control and monitor the operation of the MAFFS. Also at the loadmaster station is one of the drop control pendants which contain the Drop Button, trigger, arming light and a guarded E-Dump/Jettison switch. A second drop control pendant is available at the co-pilot station with identical functionality. The Overboard Vent Pipe Assembly (not shown) is structurally attached to the AFT pallet. An outboard portion of the OBVP is removed during system loading and unloading. Retardant or water is added to the C-130 MAFFS using the fill station on the right side of the AFT pallet. The fill port deploys out of the right hand paratroop door.

The fill station includes a panel meter indicating the fluid level in the main tank in 50 US gallon increments and an electrical connector for interfacing to the aircraft intercom (ICS) system. During fill operations the vent valve is open, venting the main tank out the paratroop door plug via the overboard vent pipe. In the event of an overfill condition, retardant or water will spill out of the paratroop door via the overboard vent pipe.

Figure 1-4 Aft Pallet Components

Legend For Figure 1-4 Item Component or Assembly Item Component or Assembly

1 Foam Tank Assembly 6 Observer Crew Station 2 Vent Control Box 7 Fill Control Box 3 Cabin Control Box 8 Ground Fill Pipe 4 Foam Control Box 9 External Air Compressor

Input 5 Loadmaster Crew Station 10 Hydraulic System

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1.4. Discharge Nozzle Assembly Description

The discharge nozzle assembly (Figure 1-5) is attached to the AFT pallet inboard duct and to the CTR pallet via structural supports during MAFFS missions. The nozzle assembly is removed for loading, unloading, or storage. The nozzle assembly includes the hydraulic actuator, pintle and throttle body which provide a controlled flow of water or retardant during drop commands. An armed indicator strobe light on the nozzle assembly is activated when the system is armed to warn the ground crew.

Figure 1-5 Nozzle Assembly Components

Legend For Figure 1-5 Item Component or Assembly Item Component or Assembly

1 Pintle 4 Hydraulic Actuator Assembly

2 Throttle Body 5 FOD Guard 3 Flow Straightener 6 Armed Strobe Light

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1.5. Paratroop Door Plug Description

The aircraft left paratroop door is raised and secured for MAFFS missions and replaced with the MAFFS door plug (Figure 1-6). This allows the MAFFS discharge nozzle and OBVP to be routed through the door location and maintain a pressurized aircraft. Four door pressure latches secure the door plug. When the door is properly installed and latched in place, conformation of pressure integrity is sent to the cockpit through the C-130 aircraft pressure sensing system.

Figure 1-6 Paratroop Door Plug Components

Legend For Figure 1-6 Item Component or Assembly Item Component or Assembly

1 Door Latches 3 Nozzle Assembly Opening 2 Overboard Vent Opening 4 Window

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1.6. MAFFS Support Equipment

The following items are additional equipment for the MAFFS mission.

• Ground Air Compressor

• S-Duct Cart

• Door Cradle

• MAFFS Trailer

1-8 15 APRIL 2016

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CHAPTER 2 THEORY OF OPERATION

2.1. MAFFS AIR SYSTEM DESCRIPTION

The air system contains two (2) high pressure reservoirs each connected in series to a Fisher regulator and electronically actuated arming valve. When the system is armed, the main tank is pressurized with regulated air from both of the high pressure reservoirs in preparation for calibrated retardant drop. Redundant sensors and relief valves maintain system integrity and prevent damage to the air system.

The C-130 MAFFS high pressure reservoirs can be charged using one of three methods. First, a ground support compressor can be connected to the external air supply port to charge the reservoirs. This is the primary means of charging other systems which do not offer on-board compressors. Second, a ground cart power source can be utilized to power the MAFFS and operate compressor C1. With only one compressor operating, the MAFFS charge time will be double the normal aircraft power, two (2) compressor charge time. Third, aircraft AC and DC power can be utilized to power the MAFFS and operate both compressors C1 and C2 simultaneously.

The high pressure air system includes the following components. Check valves (V18 and V22) provide backflow protection and isolation of the compressor charging and external air supply ports. Pressure switches (PS1 and PS2) signal the Entertron COMP1PLC and COMP2PLC for control of compressor C1 and C2. Pressure transducer PT1 provides an analog signal to the MAFFSCM PLC for drop control. Manual drain valves (V16 and V17) are used to remove condensate accumulation from each high pressure reservoir.

The high pressure reservoirs are connected in series to a Fisher regulator (R1 and R2) and an arming valve (V1 and V2) to allow pressurization and regulate airflow into the main retardant tank. The Fisher regulators are set to 100 PSI. The regulator pilot lines are isolated using two (2) high pressure solenoids (V30 and V31), to prevent high pressure air leakage with the system disarmed and to power the regulator with the system armed. The sense lines are connected from the regulator to one of the air inlets on top of the main retardant tank. Separate inlet locations are used to account for variations in tank pressure within the tank. A baffle structure also protects the sense line from water and high velocity airflow which affect the accuracy of the pressure reading.

The main tank air system includes the following components. Pressure switches (PS3 and PS4) signal the PLC based on the air pressure level in the main tank. Power is connected to low pressure switch PS3 when the system is not armed. In this mode the TANK PRESS indicator lamp on the CCB signifies that the pressure level in the main tank exceeds 5 PSI, and that proper caution should be exercised before operating the system. When the system is armed, power is connected to the high pressure switch PS4. In this mode the TANK PRESS indicator lamp on the CCB signifies that the pressure level in the main tank is below 95 PSI and that drop performance may be degraded. Pressure relief valve V6 vents the air in the main tank to the overboard vent pipe when the main tank pressure exceeds 150 PSI. The rupture disk RD1 provides rapid venting of air outside the aircraft through the overboard vent pipe, preventing dangerous pressure build up in the tank. The diameter of the rupture disk and overboard vent pipe have been sized to prevent dangerous pressure build up in the main tank in the event of a complete regulator failure. With a 10” diameter rupture disk, the main tank pressure will not exceed 195 psi. This is derived from the maximum mass flow rate of air entering the main tank of 136 lbm/s at 1250 +/-50 PSI (the maximum reservoir air pressure).

Normal venting and sealing of the main tank is provided by a vent valve V3. The valve is automatically controlled by relay logic during system arming and disarming. The valve can also be manually controlled by the operator to vent the system during servicing and seal the system during aircraft takeoff. The operation of arming valves (V1 and V2) is tied to the vent valve state. The arming valves are not opened until cams on the vent valve actuator signals that the vent valve is in the closed state.

The following components near the loadmaster station provide a visual indication and manual override of the air pressure system. Pressure gauge G1 provides a visual indication of the air pressure level in the main tank. Pressure gauge G2 provides a visual indication of the air pressure level in the high pressure reservoirs. Valve V9 allows air to be manually purged from the main tank to the overboard vent pipe. Valve V10 allows air to be manually purged from the high pressure reservoirs to the overboard vent pipe.

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Legend for Figure 2-1 Ref

Desg.

Description Ref

Desg.

Description

C1 Compressor V4 Foam Metering Valve C2 Compressor V5 Foam Isolation Valve G1 Main Tank Pressure Gauge V6 Pressure Relief Valve (150

PSIG)

G2 Reservoir Pressure gauge V7 Pressure Relief Valve (1250

PSIG)

G3 Foam Regulator Pressure

Gauge V9 Main Tank Purge Valve

G4 Foam Tank Pressure Gauge V10 Reservoir Purge Valve PS1 Pressure Switch (1200

PSIG)

V14 3-Way Solenoid (Foam

Inject Pilot) PS2 Pressure Switch (600 PSIG) V15 3-Way Solenoid (Foam

Arming ) PS3 Pressure Switch (5 PSIG) V16 Reservoir condensate drain valve PS4 Pressure Switch (95 PSIG ) V17 Reservoir condensate drain valve R1 Pressure Regulator (100

PSIG)

V18 Check Valve

R2 Pressure Regulator (100

PSIG)

V19 Check Valve

R3 Pressure Regulator (125

PSIG)

V20 Check Valve

RD1 Main Tank Rupture Disk

(195 PSIG)

V22 Check Valve (External Air Input)

RD2 Foam Tank Rupture Disk

(150 PSIG)

V23 Condensate Drain Valve

T1 High-pressure Reservoir V25 Water Separator Drain Valve

T2 High-pressure Reservoir V26 Water Separator Drain Valve

T3 Foam Tank V27 Oil Separator Drain Valve T4 Main Retardant Tank FL1 Water Separator

V1 Arming Valve FL2 Water Separator V2 Arming Valve FL3 Oil Separator V3 Vent Valve

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Figure 2-1 MAFFS Air System Schematic

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2.1.1. Initial System Charge

The air system is charged using the two on-board compressors C1 and C2 (Figure 2-1) located on the forward pallet.

Compressor operation is initiated with connection of a ground support cart to the electrical box or with the aircraft engine generators. During the ground charging sequence air compressor C1 charges the system. When airborne both air compressors, which are connected in parallel, operate simultaneously to charge the high pressure reservoirs. Check valve V18 prevents pressure blow back. Two pressure switches (PS1 and PS2) regulate pressure to between 600 PSIG and 1200 PSIG at the input of the two high-pressure tanks (T1 and T2). It should be noted, if an initial charge is required and the high-pressure tanks contain more than 600 PSIG of pressure, the compressor start switch on the power distribution drawer in the forward pallet electrical rack must be activated. Pressure regulators (R1 and R2) regulate the 1200 PSIG tank pressure down to 100 PSIG and are isolated by ball valves (V1 and V2). At this point the high-pressure and main retardant tank pressures are ready for the arming and retardant drop sequence. Additionally, pressure regulator valve (R3) regulates the 1200 PSIG high-pressure down to 125 PSIG for pressurization of the foam tank, when a foam drop is required.

2.1.2. Normal Retardant Drop

A normal retardant drop consists of two distinct actions, arming the system and dropping the retardant. To initiate a drop, the arming switch, on the Cabin Control Box, located on the aft pallet loadmaster seat is toggled to the ARMED position and released. By toggling this switch to the ARMED position, the electrical controller closes vent valve (V3) followed by ball valves (V1 and V2) opening, allowing the regulated air (100 PSIG) from the high-pressure tanks (T1 and T2) to enter the main retardant tank, pressurizing it to the 100 PSIG nominal pressure. Pressure switch (PS4) sends a signal to the PLC, which illuminates the tank pressure lamp on the Cabin Control Box when the main retardant tank is below its initial minimum operating pressure. When the main retardant tank has reached 95 PSIG the pressure indicator on the Cabin Control Box will extinguish, signaling the MAFFS is ready to drop. During the retardant drop sequence, ball valves (V1 and V2) remain open allowing a constant 100 PSIG pressure to remain in the tank throughout most of the drop. At the end of a partial drop, and when system depressurization is warranted, the arming switch must be toggled to the disarmed position. By toggling the switch to the disarmed position the electrical control box opens butterfly valve V3, venting any residual air pressure out of the aircraft through the overboard vent pipe and closes ball valves (V1 and V2). Tank Pressure will illuminate and remain illuminated until the main retardant tank pressure falls below 5 PSIG. At 5 PSIG the tank pressure lamp on the Cabin Control Box will extinguish.

2.1.3. Foam Tank Drop

The foam tank is mounted on the aft pallet of the MAFFS. The foam tank stores a maximum of 177.5 gallons of Class A foam. This tank remains un-pressurized until the foam system is armed. The foam system is armed by setting the foam switch on the Foam Control Box to the ON position. This action commands the 3-way solenoid valve (V15) to open. The foam mix ratio switch on the Foam Control Box controls the position of ball valve (V4). During the drop sequence, when the drop switch on the Drop Control Pendant is depressed, the PLC activates the 2-way solenoid valve (V14) causing the 125 PSIG to open the pneumatic isolation valve (V5) injecting the pressurized foam through the foam injection ring into the main tank flow.

2.1.4. Emergency Fluid Jettison / E-Dump

The E-Dump control allows the operator to jettison the water or retardant in case of an emergency. The E-Dump command is executed with the guarded E-Dump switch on either of the drop control pendants. The E-Dump provides a non-pressurized discharge of fluids from the main tank. When the E-Dump command is executed, the vent valve is opened to discharge air pressure from the main tank and the discharge nozzle is moved to the full open position. The arming valves remain closed during E-Dump to prevent adverse thrust from the MAFFS. The E-Dump electrical control circuit utilizes an aircraft qualified stand-by battery to provide emergency power to the MAFFS during E-Dump operation.

The jettison hydraulic system provides adequate pressure to open the nozzle regardless of the state of the main hydraulic system. The E-Dump control system is designed for high reliability, low maintenance and overall safety.

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2.1.5. Forward Pallet Air Controls, Indicators and Connectors

Figure 2-2 Forward Pallet Air Controls and Indicators

Legend For Figure 2-2 Item Name Control/Indicator/

Connector Function

1 Drain Valve (V23) Control Drains condensate from condensate drain tank

2 Drain Valve (V27) Control Drains condensate from water separator

(FL1)

3 Drain Valve (V26) Control Drains condensate from water separator

(FL2)

4 Drain Valve (V25) Control Drains condensate from oil separator (FL3) 5 Connection High-pressure air output to MAFFS center pallet

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2.1.6. Center Pallet Air Controls, Indicators and Connectors

Figure 2-3 Center Pallet Controls, Indicators and Connectors

Legend For Figure 2-3 Item Name Control/Indicator/

Connector Function

1 Main Tank Purge Valve (V9) Control When open, purges air from main retardant tank to overboard vent pipe

2 Air Reservoir Purge Valve (V10) Control When open, purges air from high-pressure reservoirs to overboard vent pipe

3 Main Tank Pressure Gauge (G1) Indicator Monitors pressure of main retardant tank 4 Reservoir Pressure Gauge (G2) Indicator Monitors pressure of high-pressure reservoirs.

5 Aux Air Connector Center pallet connection to external air compressor input 6 Foam Air Connector Center pallet connection to foam system 7 Pressure Regulator (R3) Control Foam system pressure regulator 8 Pressure Relief Valve (V28) Control Foam system pressure relief valve 9 Foam Shutoff Valve (V29) Control When closed, isolates the foam system from the high pressure air system.

10 Foam Pressure Gauge (G3) Indicator Monitors pressure output from foam regulator

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2.1.7. AFT Pallet Air Controls, Indicators and Connectors

Figure 2-4 Aft Pallet Air Controls, Indicators and Connectors

Legend For Figure 2-4 Item Name Control/Indicator/

Connector Function

1 Foam Tank Pressure Gauge (G4)

Indicator Monitors air pressure in the foam tank

2 Vent Control Box Control / Indicator When disarmed, manual control of Vent Valve Indicates Vent Valve state

3 Cabin Control Box Control / Indicator Primary control and monitor of MAFFS 4 Foam Control Box Control / Indicator Control and monitor of MAFFS foam system 5 Loadmaster Station Loadmaster / Operator Station 6 Observer Station Crew Station 7 Fill Control Box Indicator / Connector Provides fluid level indication and ICS connection 8 ICS JACK (P154) Connector Aircraft ICS connection 9 Panel Meter Indicator Main tank fluid level 10 Shutoff Valve Control Fill port shutoff valve 11 Fill Port Connector Main tank fill port 12 External Air Supply Connector Interface for external air compressor charging of high-pressure reservoirs

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2.2. HYDRAULIC SYSTEM DESCRIPTION

The C-130 MAFFS hydraulic system is an open-loop control system and is capable of re-pressurization via an onboard hydraulic pump. The system utilizes stored, pressurized hydraulic fluid in the accumulators to position the pintle inside the discharge nozzle by controlling the position of a piston in the hydraulic actuator assembly. Normal operation of the discharge nozzle is controlled by the MAFFSCM PLC. The PLC commands four isolation valves (HV1, HV2, HV3, and HV4) open or closed using two output signals. The pintle position sensor in the hydraulic actuator assembly provides a feedback signal to the PLC indicting the position of the pintle in the discharge nozzle.

Hydraulic pump operation is controlled by the Entertron COMP1PLC. Compressor C1 and the hydraulic pump are interlocked to prevent compressor operation until the hydraulic system reaches normal operating pressure of 2500 to 2950 psi. LPS1 and HPS1 signal the PLC based on the hydraulic pressure level in the main hydraulic system. LPS2 and HPS2 signal the PLC based on the hydraulic pressure level in the jettison hydraulic system. When hydraulic pressure falls below 1900 PSIG, the PLC turns on the hydraulic pump to recharge accumulators. The MAFFS is capable of initiating an emergency dump (jettison) independent of main accumulator re-pressurization.

The hydraulic system utilizes MIL-PRF-83282 type hydraulic fluid. Each accumulator (AC1, AC2, AC3, and AC4) has a 1,500 PSIG nitrogen gas pre-charge before the hydraulic systems are pressurized. The normal hydraulic pump supply pressure range is 2,758 PSIG to 2,900 PSIG with normal discharge pressure above 1,900 PSIG. Check valves CV1 and CV2 are installed between the hydraulic pump output and the main and jettison accumulators and provide isolation of the main and jettison hydraulic systems. Accumulators AC1, AC2, and AC3 are utilized by the main hydraulic system.

Accumulator AC4 is utilized by the jettison hydraulic system.

The hydraulic system installation on the AFT pallet includes the aforementioned hydraulic pump, accumulators and the following components. The hydraulic reservoir supplies hydraulic fluid to the pump and collects fluid that is displaced during nozzle open and close operation. Flex lines, formed tubing and fittings provide connections between the reservoir, pump, hydraulic manifold, accumulators, and hydraulic actuator assembly. Orifices OR1 and OR2 in the hydraulic manifold assembly control the hydraulic flow rates during nozzle closing to prevent adverse shocking of the discharge nozzle fluid seal when the discharge nozzle shuts. Hydraulic pressure gauges G1, G2, G3, and G4 are located on the gas side of each accumulator and provide a visual indication of the gas pre-charge level and the pressure in the hydraulic system during operation. Manual bypass valves BV1 and BV2 are used by the crew to relieve hydraulic pressure from the main and jettison system during MAFFS shutdown or maintenance

2.2.1. Normal Drop Opening Event

During a normal opening event (Figure 2-5) isolation valves HV1 and HV4 are opened electrically and valves HV2, HV3, and HV5 are closed. Hydraulic pressure from the main accumulators forces the actuator to retract, opening the pintle in the throttle body. The MAFFSCM PLC in the Power and Control Rack monitors the pintle position using a linear potentiometer in the nozzle assembly. When the pre-selected pintle position is reached, isolation valves #1 and #4 close to hold constant hydraulic pressure across the actuator and prevent the pintle from changing position. This position is maintained for a pre-determined amount of time or when the drop trigger is released.

WARNING

Don't open emergency accumulator handle IN FLIGHT or EMERGENCY DUMP capability may be lost

2.2.2. Normal Drop Closing Event

During a normal closing event (Figure 2-5) isolation valves HV2 and HV3 are opened and valves HV1, HV4, and HV5 are closed. Hydraulic pressure from the main accumulators forces the actuator’s piston extend outward closing the pintle in the discharge nozzle. The closing event is initiated when either the pre-determined time set for the drop conditions has expired or whenever the drop trigger is released.

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2.2.3. Emergency Jettision / E-Dump Event

During an E-dump event (Figure 2-5) isolation valves HV4 and HV5 are commanded open. Hydraulic fluid pressure from the E-dump accumulator forces the nozzle full open. During the E-dump process the linear potentiometer is bypassed.

Once an E-dump event is initiated all air pressure will be vented and fluid evacuated from the retardant tank. However pressure may still exist in the high pressure air reservoir.

Legend for Figure 2-5 Ref Desg. Description Ref Desg. Description

A1 Hydraulic Actuator G1 Pressure gauge (0 -3000 PSIG)

AC1 Primary System Accumulator (416 Cu. IN.

Max)

G2 Pressure gauge (0 -3000 PSIG)

AC2 Primary System Accumulator (416 Cu. IN.

Max)

G3 Pressure gauge (0 -3000 PSIG)

AC3 Primary System Accumulator (416 Cu. IN.

Max)

G4 Pressure gauge (0 -3000 PSIG)

AC4 Jettison Accumulator (416 Cu. IN. Max) HPS2 Jettison High-pressure Switch (2900 PSIG) ACV1 Air Charging Valve HSP1 Pump Off Pressure Switch (2900 PSIG) ACV2 Air Charging Valve HV1 Isolation Valve #1 ACV3 Air Charging Valve HV2 Isolation Valve #2

ACV4 Air Charging Valve HV3 Isolation Valve #3 BV1 Primary Bypass Valve HV4 Isolation Valve #4 BV2 Jettison Bypass Valve HV5 Jettison Isolation Valve BV3 Drain Shutoff Valve LPS2 Jettison Low-pressure Switch (1900 PSIG)

C1 Hydraulic Pressure Quick Disconnect LSP1 Primary Low-pressure Switch (1900 PSIG) C3 Hydraulic Return Quick Disconnect OR1 0.185 Orifice

CV1 Check Valve OR2 0.106 Orifice CV2 Check Valve P/M Hydraulic Pump/Electric Motor FL1 System Filter (2 Micron) R Reservoir (1294.34 Cu. IN.)

FL2 Case Drain Filter (10 Micron)

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Figure 2-5 Hydraulic Schematic

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2.2.4. Aft Pallet Hydraulic Controls, Indicators, and Connectors

Figure 2-6 Aft Pallet Hydraulic Controls, Indicators and Connectors

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Legend Figure 2-6 Item Name Control/Indicator/

Connector Function

1 Pressure Gauge (G1) Indicator Pressure monitor for accumulator #1.

2 Pressure Gauge (G2) Indicator Pressure monitor for accumulator #2.

3 Pressure Gauge (G3) Indicator Pressure monitor for accumulator #3.

4 Pressure Gauge (G4) Indicator Pressure monitor E-Dump accumulator 5 Reservoir Site Glass Indicator Indicates reservoir hydraulic fluid level during pressurized and non-pressurized states.

6 Hydraulic Pump/Motor (P/M) Control Electrically operated pump/motor that provides hydraulic pressure to the system.

7 Drain valve (BV3) Control Reservoir hydraulic fluid drain 8 System Hydraulic Filter (FL1) Control 2 Micron filter used to remove impurities from hydraulic fluid.

9 Case Drain Filter (FL2)

(Not shown) Control 10 Micron filter used to remove impurities from hydraulic fluid.

10 Isolation valve (HV1) Control When valve is opened it provides the hydraulic pressure to open the nozzle.

11 Isolation valve (HV2) Control When valve is opened it provides the hydraulic pressure to close the nozzle.

12 Isolation Valve (HV3) Control When valve is opened it provides the hydraulic return path to close the nozzle.

13 Isolation valve (HV4) Control When valve is opened it provides the hydraulic return path to open the nozzle.

14 E-Dump Isolation Valve

(HV5)

Control During E-Dump, valve is opened and provides the hydraulic pressure to open the nozzle.

15 Low-pressure Switch (LSP1) Control Signals PLC to turn on hydraulic pump when pressure is below 1900 PSIG.

16 High-pressure Switch (HSP1) Control Signals PLC to turn off hydraulic pump when pressure exceeds 2900 PSIG.

17 E-Dump Low-pressure Switch

(LSP2)

Control Signals PLC to turn on hydraulic pump when pressure is below 1900 PSIG.

18 E-Dump High-pressure

Switch (HPS2) Control Signals PLC to turn off hydraulic pump when pressure exceeds 2900 PSIG.

19 Check Valve (CV1) Control Maintains hydraulic pressure in primary circuit when hydraulic pump/motor is not operating.

20 Check Valve (CV2) Control Maintains hydraulic pressure in E-Dump circuit when hydraulic pump/motor is not operating.

21 Hydraulic Retract (C1) Connector Hydraulic connection. Retracts piston / opens nozzle when hydraulic pressure is applied.

22 Hydraulic Extend (C3) Connector Hydraulic connection. Extends piston / closes nozzle when hydraulic pressure is applied.

23 Main bypass valve (BV1) Control When opened, removes pressure from primary hydraulic system.

24 E-Dump bypass valve (BV2) Control When opened, removes pressure from E- Dump hydraulic system.

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2.2.5. Nozzle Assembly Electrical and Hydraulic Controls, Indicators and Connectors

Figure 2-7 Nozzle Assembly Electrical and Hydraulic Controls, Indicators, and Connectors

Legend For Figure 2-7 Item Name Control/Indicator/ Connector Function

1 Hydraulic Retract Connector Hydraulic connection, retract piston/open nozzle

2 Hydraulic Extend Connector Hydraulic connection, extend piston/close nozzle

3 J195 Connector Nozzle electrical interface 4 P124, J125, P125 Connector Nozzle electrical interface 5 Nozzle Strobe Light Indicator Flashes when MAFFS is Armed 6 P147 Connector Pintle position sensor interface 7 Ground cable Bonding cable installation

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2.3. ELECTRICAL SYSTEM DESCRIPTION

There are five (5) electrical sub-systems that comprise the MAFFS electrical control system. The sub-systems are power distribution, programmable logic control, drop control, nozzle control, and E-dump (jettison) control. These sub-systems are interconnected, wired and programmed to operate and control the C-130 MAFFS electrical, hydraulic, and air systems.

Figure 2-8 demonstrates the MAFFS Electrical System Layout. Most of the components are housed in the Power and Control Rack Assembly, which is located on the MAFFS forward pallet. Electrical power and control signal are distributed from the Power and Control Rack Assembly to the Cabin Control Box, Foam Control Box, Vent Control Box, Drop Pendants, Fill Station, valves, switches, and other electrical components.

Figure 2-8 C-130 MAFFS Electrical Layout

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2.3.1. Forward Pallet Controls, Indicators, and Connectors

Figure 2-9 Power and Control Rack Assembly Components

Legend For Figure 2-9 Item Component or Assembly Item Component or Assembly

1 Power Distribution Drawer 3 Program Logic Controller Shelf

2 Drop, Dump and Nozzle Control Shelf

4 Resistive Soft Start Drawer

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2.3.1.1. Power Distribution

The C-130 E, H, or J aircraft is retrofitted with a electrical panel to provide AC power and generator monitor connections for the MAFFS. MAFFS wire harnesses connect from the electrical panel to the front of the Power Distribution Drawer 40 KVA, 208VAC, 3 phase, 400 Hz power is available from each aircraft generator. MAFFS compressor #1 and hydraulic pump are connected to the aircraft LH generator. MAFFS compressor #2 is connected to the aircraft RH generator bus and operates independently of compressor #1 and the hydraulic pump.

The MAFFS Power Distribution system includes a provision to isolate the MAFFS AC power from the aircraft power system in case of an aircraft generator bus fault condition. High speed reacting relays are utilized to load shed the MAFFS AC power faster than the aircraft generator relay drop out time of 30 ms. This provision ensures that MAFFS AC power is isolated from the aircraft generator buses before the bus switching occurs. The only exception to this function is during compressor motor starting. During the first 5 seconds of compressor #1 starting, a relay will inhibit the MAFFS from responding to LH generator bus fault. After 5 seconds has expired, the MAFFS AC power will be load shed immediately in response to a LH generator bus fault. Similarly, during the first 5 seconds of compressor #2 starting, a relay will inhibit the MAFFS from responding to a RH generator bus fault. After 5 seconds has expired, the MAFFS AC power will be load shed immediately in response to a RH generator bus fault. These functions were implemented to insure consistent starting on C-130 J aircraft and do not affect the MAFFS ability to respond immediately to an Essential or Main AC bus fault.

The C-130 MAFFS control systems utilize 28 VDC power from the aircraft winch connector in the cargo compartment.

This power source is utilized for all control system components including PLCs, relays, sensors, valves, and switches.

Connections on the Power Distribution Drawer also provide a provision for a ground cart AC and DC power source. In this configuration, ground cart AC power is available to the hydraulic pump and compressor #1. Compressor #2 is not available for operation due to limitations on the ground cart power source. This configuration is selected when the Power Switch is set to Ground Mode on the CCB. The generator bus fault monitor connections are not utilized in ground cart power mode.

NOTE

Refer to USFS MAFFS Maintenance Manual for C130-J conversion

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Figure 2-10 Power Distribution Front Panel Electrical Controls, Indicators and Connectors (Sheet 1 of 2)

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Figure 2-10 Power Distribution Front Panel Electrical Controls, Indicators and Connectors (Sheet 2 of 2)

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Legend For Figure 2-10 Item Name Control/Indicator

/Connector Function

1 EMER STOP

(Emergency Stop)

Switch Disables AC power contactors.

Removes power from compressor motors and hydraulic pump.

2 COMP#1 START Switch Manually start compressor #1* (* Used when air pressure is above low set point but below high set point)

3 COMP#2 START Switch Manually start compressor #2* 4 AIR PWR (Air Power) Green Indicator When illuminated power is being supplied from aircraft

5 GND CART PWR

(Ground Cart Power) Green Indicator When illuminated power is being supplied from ground power cart 6 COMP #1 ENABLE Green Indicator When illuminated compressor #1 has been commanded ON 7 COMP #2 ENABLE Green Indicator When illuminated compressor #2 has been commanded ON 8 LH BUS FAULT (Left

Hand Buss Fault) Red Indicator (Air mode) When illuminated left hand buss is offline. (Ground Mode) Illuminated constantly

9 ESSENTIAL BUSS

FAULT

Red Indicator (Air mode) When illuminated Essential buss is offline. (Ground Mode) Illuminated constantly

10 MAIN AC BUSS FAULT Red Indicator (Air mode) When illuminated Main AC…