Breeze Eastern Winch Assembly Rescue Hoist

Breeze Eastern Winch Assembly Rescue Hoist (Helicopter Search & Rescue / Cargo)

The Breeze-Eastern Helicopter Rescue Hoist & Cargo Winch Assembly (System Series: HS-20200 / BL-10300 Series) is an electro-mechanical and electro-hydraulic precision aerial lifting system engineered for mission-critical search and rescue (SAR), tactical deployment, human external cargo (HEC), and internal/external cargo retrieval. Designed specifically for high-stress offshore and maritime rescue environments—such as United States Coast Guard (USCG), naval fleet support, and civil defense utility operations—this assembly mounts directly to standard boom arm provisions and cabin suspension swing beams.

The assembly integrates a continuous-duty traction or level-wind drive spool, a high-torque DC motor drive, an electromagnetic dynamic failsafe braking system, and a squib-actuated pyrotechnic emergency cable cut assembly. Its primary structural chassis is machined from high-tensile, anodized aeronautical-grade aluminum alloys and passivated stainless steel components to prevent galvanic corrosion in saltwater/high-humidity offshore envelopes.

Model Details:

• Manufacturer: Breeze-Eastern LLC (USA)
• CAGE Code: 08484
• Primary MPN: BL-10300-66-4 / HS-20200-501 (Airframe Provision Sub-Series: HS-20200-106, HS-20200-511, HS-20200-516)
• Bell Helicopter Interface P/N: 412-186-100 / Kit 412-150-400, 412-150-750
• National Stock Numbers (NSN):
  • 1680-01-560-9052 (Winch, Aircraft Mounted)
  • 1680-01-440-9794 (BL-10300-50B Variant)
  • 1680-01-237-4726 (BL-10300-167 Variant)

Terminal Allocations & Wiring Schematic Guide

• Pin A (Motor Power +28V DC): Primary positive DC bus supply from the aircraft electrical mission bus; feeds directly into the primary motor armature contactor.
• Pin B (Motor Ground/Return 0V): Heavy gauge return tie point to primary airframe structural ground.
• Pin C (Hoist Up / Reel-In Command): 28V DC discrete control input signal triggered by pilot collective cyclic switch or hoist pendant thumb wheel.
• Pin D (Hoist Down / Reel-Out Command): 28V DC discrete control signal activating the reverse motor polarity relay circuit.
• Pin E (Proximity / Limit Switch Common): Feeds system safety interlocking loops (interrupted if the cable reaches the safe minimum 4-wrap drum threshold).
• Pin F (Limit Deceleration Interlock): Auto-slowdown signal engaged when hook bumper contacts the upper fairlead switch.
• Pin G & H (Emergency Cable Cutter Squib Bridgewires): Isolated pyrotechnic ignition circuit; requires isolated safety-switch interlock on the pilot and crew chief panels to prevent uncommanded severing.
• Pin J (Tachometer / Speed Sensor Signal): Pulse train output feeding the cockpit digital line-out display and speed governor module.

Compatibility

• Bell Helicopter: Bell 205A-1, Bell 212 (Twin Two-Twelve), Bell 412 / 412EP / 412EPI / 412EPX, and UH-1H / UH-1N Iroquois (Huey) equipped with Hoist Provision Kits 412-150-400 / 412-150-750.
• Eurocopter / Airbus Helicopters: AS365 Dauphin / HH-65 Dolphin series (USCG variants), AS332 Super Puma (interface configuration dependent).
• Sikorsky: S-61 / S-76 / H-3 series airframes with compatible mission electrical drops.
• Agusta-Bell: AB-212 and AB-412 civil and defense maritime configurations.
• Marine / Rig Installation: Certified for offshore static cranes, davit-arm marine rescue stations, and specialized offshore supply vessel (OSV) cargo retrieval systems operating a dedicated 28V DC hydraulic/electric power pack.

Part Number Cross-References

• Breeze-Eastern Systems: BL-10300-66-4, BL-10300-50, BL-10300-50A, BL-10300-50B, HS-20200-106, HS-20200-501
• Bell P/N Equivalents: 412-186-100, 412-150-400, 412-150-750
• Military / USCG Cross Reference: NSN 1680-01-560-9052, Cage Code 08484
• Competing Alternative Drop-ins: Collins Aerospace / Goodrich 44301 / 44311 Series 600 lb Rescue Hoists (mount and electrical kit dependent).

Features

1. High-Torque 28V DC Continuous-Drive Spooling: Provides continuous lifting capacity of 600 lbs with smooth variable-speed transition (up to 250 ft/min), preventing jerk-loads on human external cargo.
2. Redundant Dual Braking & Clamping Matrix: Integrates an automatic mechanical sprag brake with an electromechanical load holding brake that locks immediately during emergency cutoff or uncommanded electrical loss.
3. Precision Level-Wind Cable Guidance: Features an oscillating diamond-screw level-wind tracking mechanism that eliminates cable piling, bird-nesting, and pinching under irregular offshore swing angles.
4. Integrated Pyrotechnic Cable Guillotine: Built-in emergency CAD squib cartridge allows instantaneous cable separation by the crew chief or pilot in the event of load entanglement or catastrophic ditching scenarios.
5. Harsh-Environment Marine Passivation: Electrostatic powder-coat finish, fluorosilicone internal drive shaft seals, and 316-grade stainless hardware prevent saltwater ingress, pitting, and galvanic degradation.

Industrial & Tactical Applications

• Open-Water Search and Rescue (SAR): Standard hoist system for recovery of downed aviators, distressed mariners, and vessel evacuation operations in open-ocean swell conditions.
• Human External Cargo (HEC) Operations: Offshore rig crew transfers, power line maintenance sling operations, and tactical tactical insertions compliant with FAA AC 133-1B.
• Emergency Medical Evacuation (MEDEVAC): Rapid hoisting of standard rescue litters, stokes baskets, rescue nets, and survival harnesses.
• Maritime Law Enforcement & Boarding: Rapid insertion and extraction of tactical boarding teams onto non-compliant marine vessels.
• Aircraft Internal Cargo Handling: Internal cabin winch line deployment for heavy freight loading and recovery on cargo-configured utility helicopters.

Frequently Asked Questions

Can this Breeze-Eastern hoist assembly be interchanged with a Goodrich/Collins Aerospace hoist without structural airframe modifications?

No. While both hoists may attach to standard Bell 212/412 hardpoints, they use platform-specific mounting boom geometries, interface brackets, electrical harness pin-outs, and control pendants. Converting between Breeze-Eastern and Collins/Goodrich requires the specific STC conversion kit and rewiring of the cockpit interface panel.

What is the minimum operating cable wrap requirement on the winch drum?

A minimum of 4 full wraps must remain on the drum at all times during descent to prevent shearing the mechanical swaged terminal ball anchor inside the drum core. The internal electromechanical limit switch is factory-calibrated to trip automatically and prevent payout beyond this margin.

What is the standard overhaul interval (TBO) for this rescue hoist system?

Standard Time Between Overhaul (TBO) is typically 10 years or 1,500 to 2,000 operational operating hours / cable load cycles (whichever occurs first), with intermediate 12-month or 100-hour operational inspections mandated per the OEM Component Maintenance Manual (CMM).

Is the unit capable of variable speed control using a crew chief pendant?

Yes. When paired with standard proportional thumb-wheel pendants, the control circuit regulates current delivery to provide smooth acceleration from 0 ft/min up to maximum payout speed, mitigating dynamic G-loading on suspended personnel or sensitive cargo.

Can this hoist operate continuously without cooling downtime?

The DC motor assembly is continuous-duty rated up to its thermal junction threshold. However, under full continuous load (600 lbs) at maximum ambient temperatures (+50°C), thermal management protocols recommend observing standard duty cycles (typically 10 minutes hoisting / 20 minutes cooling) to prevent insulation degradation on the motor armature, unless equipped with high-airflow cooling shrouds.