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Aircra&  Electrical  Systems  

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Instrument  Pricing  

•  Bendix/King  KCS55A  HSI  

!  Starts  at  $22,188  

•  Aspen  Avionics  EFD1000  

!  Starts  at  $6,180  

•  Includes  backup  baQery  

•  2011  Avia>on  Consumer  declares  the  HSI  dead  

!  It  costs  more  to  repair  an  HSI  than  to  replace  it  with  

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Electrical  Systems  

•  Engine  igni>on  and  controls  

!  BaQery  powered  propulsion  systems  

•  Communica>ons  

•  Naviga>on  &  Autopilots   •  Lights  

•  Flight  controls   •  Landing  gear  

•  Environmental  controls   •  Entertainment  system  

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Part  23  Requirements  

•  Must  be  able  to  furnish  the  required  power  at   the  proper  voltage  to  each  load  circuit  essen>al   for  safe  opera>on  

•  Must  be  free  from  hazards  in  itself,  in  its  method   of  opera>on,  and  in  its  effects  on  other  parts  of   the  aircra&  

•  No  failure  or  malfunc>on  of  any  electrical  power   source  may  impair  the  ability  of  the  remaining   source  to  supply  load  circuits  essen>al  to  safe   opera>on  

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Part  23  Requirements  

•  Each  system  must  be  designed  so  that  essen>al   load  circuits  can  be  supplied  in  the  event  of  

reasonably  probable  faults  or  open  circuits  

•  There  must  be  at  least  one  generator/alternator   if  the  electrical  system  supplies  power  to  load   circuits  essen>al  for  safe  opera>on  

•  There  must  be  a  means  of  giving  immediate   warning  to  the  flight  crew  of  a  failure  of  the   generator/alternator  

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Part  23  Requirements  

•  There  must  be  a  master  switch  installed  in  the   electrical  system  that  allows  the  electrical  power   source  to  be  disconnected  from  the  main  bus  

!  The  point  of  disconnec>on  must  be  adjacent  to  the  

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Wire  Selec>on  

•  Copper   !  BeQer  conductor   •  Aluminum   !  Less  expensive   !  Lighter  weight   !  Corrosion  issues  

!  Easy  to  nick  when  removing  insula>on   !  #6  gage  or  larger  

!  Should  not  be  used  in  areas  of  severe  vibra>on  

•  Specialty  wires  (e.g.  coax  or  twisted  pair)  

!  Follow  the  manufacturer’s  recommended  

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Wire  Selec>on  

•  Selec>ng  insula>on  type  

!  Copy  what  is  on  the  aircra&  

•  Check  for  updates  

!  Follow  the  manufacturer’s  recommended  

procedures  

•  The  general  rule  of  thumb  for  replacing  

aluminum  electrical  cable  with  copper  is  that   copper  of  two  wire  gages  smaller  (larger  

number)  may  be  used  to  replace  aluminum  

!  e.g.  8  gage  aluminum  can  be  replaced  with  10  gage  

copper  

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Wire  Selec>on  

•  Wire  size  selec>on  factors  

!  Allowable  power  loss  

!  Permissible  voltage  drop   !  Current  carrying  capability  

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Wire  Current  Carrying  Capacity  

The American Wire Gauge (AWG) system is used to indicate the size, cross-sectional area, of electrical wire

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Sample  Problems  

•  Round  up  to  the  larger  size  

•  28V,  20  A  con>nuous  for  30’,  in  a  bundle  

!  #10  

•  14V,  200  A  for  a  starter  (intermiQent)  for  15’,   single  wire  

!  #1  

•  28V,  50  A  con>nuous  for  60’,  in  a  bundle  

!  #4  

•  What  is  the  maximum  length  of  single  #16  wire   carrying  28V  and  25  A  intermiQent  

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Connectors  

•  Use  only  high  quality  connector  

!  Lasts  longer  

!  Reduces  troubleshoo>ng  >me  and  cost   !  Mil  spec  (AN  or  MS)  are  a  good  start  

•  Use  crimp  style  connectors  when  possible  

!  Soldered  connec>ons  can  “bird  cage”  

•  Female  side  should  be  the  power  side  

•  Male  side  should  be  the  ground  or  no  power   side  

•  Use  the  correct  crimper  and  follow  the   manufactures  recommended  procedures  

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Connectors  

•  Use  moisture-­‐proof  connectors  when  it  may  be   exposed  to  moisture  

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Terminal  Strips  

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Terminal  Strips  

•  Terminal  strip  –  used  to  manage  wire   connec>ons  

•  O&en  use  for  centralized  power  and/or  ground  

!  Bus  bars  

•  All  terminal  studs  are  anchored  against  rota>on   •   AC43.13-­‐1B  Par  11-­‐174(c)  

!  No  more  than  four  terminal  lugs  or  three  terminal  

lugs  and  a  bus  bar  should  be  connected  to  any  one   stud.  Total  number  of  terminal  lugs  per  stud  includes   a  common  bus  bar  joining  adjacent  studs.  Four  

terminal  lugs  plus  a  common  bus  bar  thus  are  not   permiQed  on  one  stud.  

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Terminal  Strips  

•  All  stud  nuts  should  be  >ghtened  

!  Even  nuts  with  no  connec>ons  

•  Connec>ons  should  be  firmly  held  together  with   two  nuts  or  suitable  locking  provisions  

•  Spacers  or  washers  should  not  be  used  between   the  tongues  of  terminal  lugs  

•  Tightening  terminal  connec>ons  should  not   deform  the  terminal  lugs  or  the  studs  

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Terminal  Strips  

•  Terminal  lugs  should  be  so  posi>oned  that  

bending  of  the  terminal  lug  is  not  required  to   remove  the  fastening  screw  or  nut  

•  Terminal  lugs  should  be  so  posi>oned  that   movement  of  the  terminal  lugs  will  tend  to   >ghten  the  connec>on.  

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Wire  Terminal  Lugs  

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Wire  Terminal  Lugs  

•  The  tensile  strength  of  the  wire-­‐to-­‐terminal  joint   should  be  at  least  equivalent  to  the  tensile  

strength  of  the  wire  itself  

•  Wire  should  extend  past  the  barrel  and  be   visible  a&er  crimping  

•  The  terminal  must  crimp  both  the  bare  wire  and   the  insula>on  

•  Use  ring  type  terminals  to  prevent  wire   disconnect    

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Wire  Terminal  Lugs  

•  Aircra&  grade  color  coding:  

!  Red  -­‐  #22  through  #18  wire   !  Blue  -­‐  #16  through  #14  wire   !  Yellow  -­‐  #12  through  #10  wire  

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Wire  Terminal  Lugs  

X

X

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Wire  Splices  

•  Splicing  is  permiQed  on  wiring  as  long  as  it  does   not  affect  the  reliability  and  the  

electromechanical  characteris>cs  of  the  wiring   •  No  more  than  one  splice  in  any  wire  segment  

between  any  two  connec>ons  or  other   disconnect  points  

!  Except:  

•  AQaching  to  the  spare  pigtail  lead  of  a  poQed  connector  

•  Splicing  mul>ple  wires  to  a  single  wire  

•  Adjus>ng  wire  size  to  fit  connector  contact  crimp  barrel  

size  

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Wire  Splices  

•  When  several  wires  in  a  bundle  are  to  be  spliced,   the  wires  should  be  cut  so  that  the  splices  are  

staggered  along  the  bundle   •  Use  crimp  type  splice  

!  Don’t  use  solder  splice  

•  Splices  should  not  be  used  within  12  inches  of  a   termina>on  device  

!  Except:  

•  AQaching  to  the  spare  pigtail  lead  of  a  poQed  connector  

•  Splicing  mul>ple  wires  to  a  single  wire  

•  Adjus>ng  wire  size  to  fit  connector  contact  crimp  barrel  

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Wire/Cable  Labeling  

•  Wires  and  cables  should  be  labeled  or  marked   for  future  maintenance  

•  Many  aircra&  have  individual  wires  

manufactured  with  iden>fica>on  markings  to   match  their  wiring  diagrams  

•  Wires  markings  (AC43-­‐13-­‐1B  par  11-­‐208):  

!  At  each  end  and  every  15”  

•  Under  3”,  no  label  

•  3”  to  7”,  label  in  center  

!  Indirect  (aQached  labels)  

•  At  each  end  and  then  every  6’  (feet)  

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Cable  Lacing  

•  Used  secure  and  organize  bundles  of  wires  and   cable  

!  Can  secure  a  bundle  with  in  a  bundle  

•  Don’t  use  zip  >es  

!  Sharp  edges  

!  Chafes  insula>on  

!  Gets  briQle  when  old  

•  Use  flat  lacing:  MIL-­‐T-­‐43435B  

!  Waxed  coa>ng  makes  it  easier  to  lace  

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Wire  Harnesses  

•  Video  

•  An  aircra&  can  have  miles  of  wire  

•  The  wiring  is  organized  into  a  wiring  harness   •  A  wire  harness  is  made  up  of  individual  wires  

and  wire  bundles  

•  New  wire  harnesses  are  created  using  a  wiring   board  or  jig  

•  Electrical  upgrades  may  come  with  their  own   harness  

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Wire  Harnesses  

•  Wire  connec>ons  may  be  protected  in  a  junc>on   box  

!  Non-­‐vapor-­‐>ght  boxes  must  have  a  drain  hole   !  Unused  holes  must  be  plugged  up  

!  Fire  proof  junc>on  boxes  are  constructed  of  stainless  

steel  (CRES)  

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Wire  Harnesses  

•  Conduit  may  be  used  to  route  wire  

!  Protec>ve  piping  -­‐  rigid  or  flexible  

!  Protects  wire  from  physical  or  mechanical  damage  

•  Moving  parts  

!  Supports  wire  

!  Ends  of  conduit  should  be  flared  or  have  end  

coverings  to  protect  wire  

!  Use  bonded  clamps,  electrically  conduc>ve,  to  

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Wire  Harnesses  

•  Conduit  

!  Should  be  placed  so  it  is  not  used  as  a  handhold  or  

step  

!  Use  installa>on  powder  (soapstone)  to  help  with  

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Wire  Bundles  

•  Used  to  organize  wiring  

•  Wires  should  be  parallel  in  a  bundle  

•  Should  be  placed  so  crew  or  cargo  will  not   damage  

•  Should  be  routed  away  from  where  water  will   collect  

•  Should  be  routed  over  baQery  

•  Redundant  systems  should  take  separate  routes   •  Should  be  routed  above  fluid  lines  

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Wire  Bundles  

•  Conduit  should  be  routed  as  direct  as  possible   •  FAA  recommends  minimizing  the  number  of  

wires  per  bundle  to  reduce  failure  risk   •  Use  shielding  for:  

!  Cri>cal  connec>ons  

•  Cartridge  actuated  fire  ex>nguishers,  rescue  hoist  shear,  

and  emergency  jepson  devices    

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Wire  Bundles  

•  Bend  radius  should  be  at  least  10  >mes  the   outside  bundle  diameter  

!  Individual  coax  bend  radius  is  6  >mes  the  outside  

diameter  

•  Wiring  at  terminal  lugs  or  connectors  should   have  sufficient  slack  to  allow  two  re-­‐

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Wire  Mechanical  Issues  

•  Support  wire  so  there  is  less  than  1/2”  deflec>on   between  support  points  

•  Connectors  should  have  strain  relief  

!  Hold  wire  secure  

•  Use  MS-­‐21919  clamps  

!  Cushioned  clamps  

!  Insulated  for  wire  bundles  

!  Bonded  (connected  to  ground)  used  for  conduit  and  

fluid  lines  

!  Close  opening  with  safety  wire  to  help  with  

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Wire  Mechanical  Issues  

•  MS-­‐21919  clamps  

!  Interval  not  to  exceed  24”  

!  Snug  fit  without  pinching  wires  

•  Use  grommets  

•  Use  edge  grommet  

•  Seal  wire  coming  through  firewall  or  landing  well   •  Wire  sleeving  helps  protect  and  organize  wires  

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Clamps  

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Circuit  Protec>on  –  Part  23  

•  Protec>ve  devices,  such  as  fuses  or  circuit   breakers,  must  be  installed  in  all  electrical   circuits  other  than:  

!  Main  circuits  of  starter  motors  used  during  star>ng  

only  

!  Circuits  in  which  no  hazard  is  presented  by  their  

omission  

•  A  protec>ve  device  for  a  circuit  essen>al  to  flight   safety  may  not  be  used  to  protect  any  other  

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Circuit  Protec>on  –  Part  23  

•  Each  reseQable  circuit  protec>ve  device  (“trip   free”  device  in  which  the  tripping  mechanism   cannot  be  overridden  by  the  opera>ng  control)   must  be  designed  so  that:  

!  A  manual  opera>on  is  required  to  restore  service  

a&er  tripping  

!  If  an  overload  or  circuit  fault  exists,  the  device  will  

open  the  circuit  regardless  of  the  posi>on  of  the   opera>ng  control  

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Circuit  Protec>on  –  Part  23  

•  If  the  ability  to  reset  a  circuit  breaker  or  replace   a  fuse  is  essen>al  to  safety  in  flight,  that  circuit   breaker  or  fuse  must  be  so  located  and  

iden>fied  that  it  can  be  readily  reset  or  replaced   in  flight  

•  For  fuses  iden>fied  as  replaceable  in  flight:  

!  There  must  be  one  spare  of  each  ra>ng  or  50  

percent  spare  fuses  of  each  ra>ng,  whichever  is   greater  

!  The  spare  fuse(s)  must  be  readily  accessible  to  any  

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Circuit  Protec>on  –  AC  43  

•  A  circuit  breaker  must  be  rated  so  that  it  will   open  before:  

!  The  current  ra>ng  of  the  wire  aQached  to  it  is  

exceeded  

!  The  cumula>ve  ra>ng  of  all  loads  connected  to  it  are  

exceeded  

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Circuit  Protec>on  –  AC  43  

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Circuit  Protec>on  –  AC  43  

•  A  circuit  breaker  must  always  open  before  any   component  downstream  can  overheat  and  

generate  smoke  or  fire  

•  Wires  must  be  sized  to  carry  con>nuous  current   in  excess  of  the  circuit  protec>ve  device  ra>ng  

!  Circuit  breakers  are  designed  as  circuit  protec>on  for  

the  wire,  not  for  protec>on  of  black  boxes  or   components  

•  Circuit  protec>on  should  be  as  close  to  the   power  bus/source  as  possible  

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Circuit  Protec>on  –  AC  43  

•  Use  of  a  circuit  breaker  as  a  switch  is  not   recommended  

!  Use  of  a  circuit  breaker  as  a  switch  will  decrease  the  

life  of  the  circuit  breaker  

•  Automa>c  reset  circuit  breakers,  that  

automa>cally  reset  themselves  periodically,  are   not  recommended    

•  Circuit  breakers  should  be  periodically  cycled  

with  no  load  to  enhance  contact  performance  by   cleaning  contaminants  from  the  contact  surfaces  

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Circuit  Protec>on  

•  Protec>on  based  on  current  not  voltage   •  Circuit  breaker:  

!  Automa>cally  opens  a  circuit  any  >me  excessive  

current  flows  through  it  

!  Pilot  can  reset  

!  Mechanic  can  disable  with  zip  >e  

•  Fuse:  

!  One  use  device  

•  Internal  wire  or  metal  strip  melts  away  

!  Slow  and  fast  blow  types  

•  Slow  blow  are  used  for  devices  that  have  a  large  startup  

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Circuit  Protec>on  

•  Current  Limiter:  

!  Very  large  slow  blow  fuse  

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Switches  

•  Switches  should  be  derated  from  their  nominal   current  ra>ng  for  the  following  types  of  circuits:  

!  Circuits  containing  incandescent  lamps  

!  Induc>ve  circuits  have  magne>c  energy  stored  in  

solenoid  or  relay  coils  

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Switches  

•  Dera>ng  a  switch  will  obtain  reasonable  switch   efficiency  and  service  life  

•  Any  abnormal  side  to  side  movement  of  the   switch  should  be  an  alert  to  imminent  failure   •  “On-­‐off”  two-­‐posi>on  switches  should  be  

mounted  so  that  the  “on”  posi>on  is  reached  by   an  upward  or  forward  movement  of  the  toggle   •  Inadvertent  opera>on  of  switches  can  be  

prevented  by  moun>ng  suitable  guards  over  the   switches  

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Grounding  

•  Inadequate  bonding  or  grounding  can  lead  to   unreliable  opera>on  of  systems,  e.g.,  EMI,  

electrosta>c  discharge  damage  to  sensi>ve  

electronics,  personnel  shock  hazard,  or  damage   from  lightning  strike  

•  Ground  types:  

!  AC  returns   !  DC  returns   !  All  others  

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Grounding  

•  For  distributed  power  systems,  the  power  return   point  for  an  alterna>ve  power  source  should  be   separated  

•  Power  return  or  fault  current  ground  

connec>ons  within  flammable  vapor  areas  must   be  avoided  

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Bonding  

•  The  process  of  electrically  connec>ng  all  isolated   components  to  the  aircra&  structure  

•  Provides  a  path  for  return  current  from  the   components  

•  Provides  a  low-­‐impedance  path  to  ground  to  

minimize  radio  interference  from  sta>c  electrical   charges  

•  Provides  a  path  to  ground  to  dissipate  sta>c   charge  from  fire  hazards  like  fuel  systems  

(85)

Bonding  

•  All  conduc>ng  objects  on  the  exterior  of  the   airframe  must  be  electrically  connected  to  the   airframe  through  mechanical  joints,  conduc>ve   hinges,  or  bond  straps  capable  of  conduc>ng   sta>c  charges  and  lightning  strikes  

•  All  isolated  conduc>ng  parts  inside  and  outside   the  aircra&,  having  an  area  greater  than  3  in2  

and  a  linear  dimension  over  3  inches  must  be   bonded  to  the  aircra&  structure  

(86)

Bonding  

•  The  metallic  conduit  should  be  bonded  to  the   aircra&  structure  at  each  termina>ng  and  break   point  

•  Bonding  connec>ons  should  be  secure  and  free   from  corrosion  

!  Stainless  steel  components  use  copper  jumpers  

•  Bonding  jumpers  should  be  made  as  short  as   prac>cable  

•  Resistance  of  each  connec>on  does  not  exceed   0.003  ohm  

(87)

Bonding  

•  Bond  aQachment  hardware  selec>on   considera>ons:  

!  Mechanical  strength   !  Ease  of  installa>on  

(88)

Electrical  System  

•  BaQery  

!  Stores  electrical  energy  

!  Provides  DC  electrical  energy   !  Starts  engine(s)  

!  Filters  power  

!  Provides  needed  power  during  short  high  load  

situa>ons  

!  Must  be  recharged  

•  A  baQery  stores  only  about  10  to  30  minutes  worth  of  

energy  

•  Recharging  comes  from  engine  driven  alternator/

(89)

BaQery  and  Master  Switch  

A  reverse-­‐biased  diode  installed  across  the  coil  of  the  baQery  contactor     allows  the  induced  current  that  is  produced  when  the  master  switch  contacts  open    

to  be  dissipated  in  the  coil  rather  than  arcing  across  the  switch  contacts.  

(90)

Electrical  Load  

•  Examples:  

!  Radios  and  Instruments  

•  Radios  take  much  more  power  when  transmipng  

!  Lights  

!  Pitot  tube  heat  

!  Deicing  hea>ng  elements   !  Flap  and  trim  motors  

!  Entertainment  systems   !  Charging  baQery  

(91)

Electrical  Load  

•  Electrical  power  load  is  constantly  changing  and   greater  than  the  baQery  can  provide  

!  Requires  an  engine  driven  power  source  that  can  

regulate/vary  the  amount  of  power  provided  

•  Power  sources  

!  Engine  driven  generators  or  alternators   !  Auxiliary  Power  Unit  (APU)  

(92)
(93)
(94)

Ground  Power  Unit  (GPU)  

•  Source  of  electric  energy  external  to  the  aircra&  

!  BaQery  cart  

!  Engine  driven  generator  

•  Uses:  

!  Start  aircra&  

(95)

GPU  Circuit  

(96)

Single  Engine  Power  System  

(97)

Twin  Engine  Power  System  

Light  twin-­‐engine  aircra&  electrical  power  system  using  individual  electronic  voltage  regulators  and  overvoltage  protectors.   The  alternator  paralleling  circuit  is  built  into  the  voltage  regulators.  

Used to balance parallel power by keeping voltage the same

(98)
(99)
(100)

DC  Generators  

•  DC  generators  have  slip  rings  that  are  split  to   create  DC  voltage  

!  The  split  slip  ring  is  called  the  commutator  

•  Generators  are  rated  (sized)  by  the  amount  of   current  they  provide  at  a  given  voltage  

!  e.g.  60  A  at  12  volts  

!  Ra>ng  is  stamped  on  the  generator  case  

•  More  coils  reduce  the  voltage  ripple  and  provide   a  “cleaner”  power  source  

(101)
(102)
(103)
(104)
(105)

Field  Frame  

(106)

DC  Generators  

•  Field  frame  

!  Holds  field  windings/coil  

!  The  magne>c  material  holding  the  coil  is  called  the  

field  pole  shoes  

•  Made  of  laminated  iron  

!  Reduces  the  eddy  current  effects  

•  Has  a  residual  magne>c  field  

!  If  the  field  coils  are  not  energized,  the  residual  magne>c  field  

creates  a  “residual  voltage”  when  the  generator  is  turned  

!  Enables  a  generator  to  work  without  a  baQery  

•  Residual  magne>c  field  can  be  restored  by  flashing  the  

(107)

DC  Generators  

•  Field  coils  

!  Used  to  generate  the  magne>c  field  that  generates  

the  electricity  

!  The  higher  the  current  through  the  field  coils  the  

stronger  the  magne>c  field  

•   The  higher  the  output  of  the  generator  

•  Varying  the  field  coil  current  varies  the  output  of  the  

generator  

!  Should  be  a  low  resistance  

(108)

DC  Generator  Armature  

(109)

DC  Generators  Types  

•  Defined  by  how  the  field  coils  are  arranged   •  Series  Wound  with  armature  coils  

!  Never  used  in  aircra&  

•  Parallel  (Shunt)  Wound  with  armature  coils  

•  Compound  Wound  

!  Has  both  series  and  parallel  wound  field  coils   !  Best  type  

!  Interpoles  are  used  to  counteract  field  distor>on  

•  Overcomes  the  effect  of  armature  reac>on  

(110)

DC  Generators  Mechanical  Regulators  

(111)

DC  Generators  Mechanical  Regulators  

•  Also  called  vibrator-­‐type  voltage  regulator  

•  Controls  the  output  voltage  by  controlling  how   much  current  goes  to  the  field  coil  

!  Changes  the  resistance  in  series  with  the  field  coil  to  

control  the  current  

!  Higher  resistance  -­‐>  lower  field  current  -­‐>  lower  

power/voltage  output  

!  Lower  resistance  -­‐>  higher  field  current  -­‐>  higher  

power/voltage  output  

•  Uses  three  relays  to  control  voltage,  current   limits  and  reverse  current  

(112)

DC  Generators  Mechanical  Regulators  

(113)
(114)
(115)

DC  Generators  Mechanical  Regulators  

•  Relays:  

!  Voltage  Regulator  

•  Opens  (high  resistance)  and  closes  (lower  resistances)  

•  Constantly  pulsing  

!  Generates  a  lot  of  EMI  noise  

•  The  longer  closed  the  more  current  flows  through  the  field  

coils  

!  Higher  power  output  

!  Higher  current  and/or  voltage  

!  Current  Limiter  

(116)

DC  Generators  Mechanical  Regulators  

•  Relays:  

!  Reverse  Current  

•  Disconnects  baQery  from  the  generator  if  the  baQery  

voltage  is  higher  than  the  generator  

!  Prevents  draining  of  baQery  

•  If  it  fails,  current  flows  through  the  generator  armature  

opposite  the  normal  direc>on  and  through  the  shunt  field   in  the  normal  direc>on  

(117)
(118)
(119)

DC  Generators  Maintenance  

•  Check  belt  and  moun>ng   •  Check  connec>ons  

•  Clean  all  oil  and  dust  

!  Track  down  source  of  oil  

•  Check  brushes  

!  At  least  1/2  their  original  length  

•  Usually  has  a  wear  mark  

!  Pig  tail  is  secure  

(120)

DC  Generators  Maintenance  

•  Check  brushes  

!  Check  spring  strength  

•  Weak  spring  will  cause  brushes  to  bounce  and  create  

arcing  

!  Shape  end  of  new  brushes  

•  Check  gap  between  commutator  bars  

!  Gap  should  be  at  least  as  deep  as  the  width  of  the  

mica  (insulator)  

(121)

DC  Generators  Maintenance  

•  Growler  Test  

!  Checks  for  shorted  coils  in  generators  or  motors   !  Tester  creates  a  magne>c  field  in  each  coil  

•  If  the  coil  is  shorted,  the  output  voltage  will  be  low  

!  Can  be  measure  with  a  volt  meter  or  light  

!  Video  

•  Test  insula>on  with  a  Megohmmeter  (Megger)  

!  Measures  very  high  resistance  ranges  with  high  

voltage  

(122)

DC  Generators  Dual  

•  Dual  generator  systems  have  an  equalizing   circuit  that  insures  the  two  generators  are   pupng  out  the  same  voltage  

!  Raises  the  low  generator  and  lowers  the  high  

(123)

DC  Generators  Dual  

(124)

DC  Generators  -­‐  FAA  Ques>on  

•  If  any  one  generator  in  a  24-­‐volt  dc  system   shows  low  voltage,  the  most  likely  cause  is  

A.  an  out-­‐of-­‐adjustment  voltage  regulator.   B.  shorted  or  grounded  wiring.  

C.  a  defec>ve  reverse  current  cutout  relay.  

(125)

DC  Alternator  

Stator or Armature Winding

(126)

DC  Alternator  

Stator or Armature Winding Field Winding

(127)

DC  Alternator  

(128)

DC  Alternator  

•  Components:  

!  Stator  (Armature)  windings  (coil)  

•  The  power  comes  from  the  stator  winding  

•  Loca>on  on  the  case  and  doesn’t  rotate  

!  Field  windings  (coil)  

•  Rotates  

•  Smooth,  gapless  slip  rings  

•  No  permanent  magnet  

!  Diodes  

•  Converts  AC  to  DC  

!  Regulator  

(129)

DC  Alternator  

•  Advantages:  

!  Lighter  –  no  permanent  magnets   !  Slip  ring  used  for  field  coils  

•  Lower  current  requirements  

•  Smooth  

•  Brushes  last  longer  

•  No  EMI    

!  AC  to  DC  conversion  done  by  diodes  

•  Less  EMI  

(130)

DC  Alternator  

•  Advantages:  

!  Solid  state  regulator  

•  Less  EMI  

•  Wider  adjustment  range  

!  Power  at  lower  RPMs  

•  Last  longer  than  mechanical  regulators  

•  Disadvantages:  

!  Needs  baQery  power  to  provide  startup  current  for  

(131)

DC  Alternator  

•  Stator  

!  Usually  three  phase  

•  Six  poles  

!  Two  per  phase  

!  The  frequency  of  the  wave  form  is  determined  by  

(132)

Typical  Charging  System  

ALT

Power  Bus  Bar   Alt Out

Alt Out Breaker B Main   Solenoid   Shunt   Resister   Amp   Meter   BaQery   + - Over   Voltage   Sensor   Red Orange Black Alt Fld Alt Fld Breaker Voltage   Regulator/   ACU   S Alt Switch A F F LO/OV Light I Main Switch

(133)

DC  Alternator  

•  Solid  state  regulator  

!  Components:  

•  Regulator  

•  Overvoltage  protec>on  

•  Packaged  separately,  combined  or  built  into  alternator  

!  Regulator    

•  Regulates  field  winding  current  

•  Circuit  is  very  similar  to  solid  state  voltage  regulator  

!  Zener  diode  used  to  reference  alternator  output  voltage   !  Transistors  control  field  winding  current  

!  Overvoltage  protec>on  

(134)

Alternator  Troubleshoo>ng  Steps  

•  Setup  

•  Connec>ons  

•  Electrical  Components   •  Finish  Up  

(135)

Setup  

•  Avionic  must  be  turned  off  

!  Protects  them  from  damage  

•  Master  switch  –  On  –  when  checking  voltage  

•  Master  switch  –  Off  –  when  checking  resistance   •  Select  mul>-­‐meter  range  before  measuring  

•  Secure  item  before  running  engine   •  Check  circuit  breakers  

(136)

Connec>ons  

•  Check  all  mechanical  connec>ons  are  >ght   •  Check  grounding  straps  

•  Cleanup  all  corrosion  

•  Check  for  damaged  insula>on  

•  Recommend  customer  replace  old  aluminum   baQery  cable  

!  BeQer  cold  starts  

!  Save  money  through  longer  component  life  

•  Check  alternator  belt  

(137)

Typical  Charging  System  

ALT

Power  Bus  Bar   Alt Out

Alt Out Breaker B Main   Solenoid   Shunt   Resister   Amp   Meter   BaQery   + - Over   Voltage   Sensor   Red Orange Black Alt Fld Alt Fld Breaker Voltage   Regulator/   ACU   S Alt Switch A F F LO/OV Light I Main Switch

(138)

Electrical  Components  

•  Voltage  Tes>ng  Setup  (Voltage  On)  

!  Master  switch  (Bat  &  Alt)  -­‐  On   !  Alternator  field  switch  –  On  

!  Alternator  field  and  Main  alternator  breaker  –  On   !  To  generate  a  load,  turn  landing  lights  on  

•  Check  Amp  Meter  with  load  on  

!  If  needle  deflects,  it  is  OK  

!  If  no  deflec>on  plus  voltage  on  connec>ons  and  

(139)

Voltage  Regulator  

•  With  Voltage  On,  check  voltage  regulator  pins  

!  All  pins  should  be  close  to  Power  Bus  Bar  voltage  

•  If  Pin  S  is  low,  check  Over  Voltage  Sensor  (OVS)   connec>ons  

!  If  OVS  connec>ons  are  good,  OVS  is  bad  

•  If  Pin  F  is  low  

!  Disconnect  Pin  F  to  alternator  lead  

!  If  Pin  F  is  s>ll  low,  replace  Voltage  Regulator    

•  Regulator  is  shorted,  also  check  if  alternator  field  shorted  

(140)

Voltage  Regulator  

•  If  Pin  A  is  low  

!  Usually  a  connec>on  problem  

•  If  Pin  I  is  high  and  LV/OV  light  is  out  

(141)

Alternator  

•  Disconnect  alternator  leads  and  check  alternator   –  voltage  off  

•  Check  resistance  between  F  (field  lead)  and   ground  connec>on  

!  Range  –  3  to  6  ohms  

!  If  low,  field  coil  is  shorted  -­‐  replace  alternator   !  If  high  

•  Service  brushes  and  clean  commutator  

(142)

Alternator  

•  Check  for  open  Stator  by  measuring  resistance   between  B  (baQery  lead)  and  ground  

!  If  high,  stator  is  open  and  alternator  needs  to  be  

replaced  

!  May  have  to  use  “diode”  mul>-­‐meter  sepng  

•  Check  for  shorted  diode  bridge  

!  Place  a  mul>-­‐meter  in  series  with  alternator  B  lead  

to  measure  leakage  current  

!  Power  on  

!  If  leakage  current  is  over  0.5  mA,  bridge  is  bad  –  

(143)

Alternator  

•  Check  for  open  diode  bridge  

!  Power  on,  engine  at  1500  RPM  and  lights  on   !  Check  AC  voltage  on  B  lead  

(144)

Alternator  

•  Check  alternator  output  

!  Install  mul>-­‐meter  to  measure  current  in  to  F  lead   !  Power  on,  engine  at  1500  RPM  and  lights  on  

!  If  current  is  3.5  A  or  higher  and  alternator  output  is  

s>ll  low,  replace  alternator  

•  If  s>ll  unable  to  determine  problem,  run  external   regulator  test  outlined  in  Alternator  Test  

(145)

Finish  Up  

•  Do  a  final  complete  system  test  with  engine   running  and  lights  on  

•  Charge/test  baQery  

!  Remember  Diamond  DA42  crash  

•  Reinstall  and  >ghten  all  components   •  Clean  aircra&  

!  Return  aircra&  in  as-­‐good  or  beQer  shape  than  you  

received  it    

(146)

Large  Aircra&  Electrical  Power  

•  Some  turbine  engine  combine  a  starter  motor   and  generator  in  a  single  unit  

!  The  windings  serve  double  duty  

!  Power  is  applied  in  the  starter  mode  

!  Power  is  produced  in  the  generator  mode  

•  AC  (Alterna>ng  Current)  power  is  used  on  large   aircra&  

!  Usually  run  at  high  voltage  

•  Low  current  means  less  power  loss  in  wiring  

!  Easy  to  convert  to  different  voltages  with  a  

(147)

Large  Aircra&  Electrical  Power  

•  AC  (Alterna>ng  Current)  power  is  used  on  large   aircra&  

!  Commonly  run  at  400  Hz   !  Voltage  must  be  regulated  

!  Frequency  must  be  >ghtly  controlled   !  Mul>ple  generator  systems:  

•  Matched  voltage  

•  Matched  frequency  

•  Synchronized  AC  wave  forms  

!  In  phase  

(148)

Large  Aircra&  Electrical  Power  

•  AC  (Alterna>ng  Current)  power  is  used  on  large   aircra&  

!  Constant  Speed  Drives  (CSD)  are  used  to  control  

(149)
(150)
(151)
(152)

Large  Aircra&  Electrical  Power  

•  AC  (Alterna>ng  Current)  power  is  used  on  large   aircra&  

!  Constant  Speed  Drives  (CSD)  are  used  to  control  

generator  speed  and  phase  

•  Uses  a  mechanical  transmission  to  control  the  frequency  

(speed)  and  phase  

•  Transmission  consists  of  a  hydraulic  pump  driving  a  

hydraulic  motor  

!  The  amount  of  fluid  going  to  the  motor  is  varied  to  control  the  

speed  and  phase  

•  Usually  oil  cooled  

•  Can  be  electrically  taken  off  line  with  a  cockpit  switch  

•  In-­‐flight  failures  can  only  be  fixed  on  the  ground  

(153)

Large  Aircra&  Electrical  Power  

•  AC  (Alterna>ng  Current)  power  is  used  on  large   aircra&  

!  Integrated  Drive  Generator  (IDG)  is  a  brushless  

generator  

•  Used  in  high  power  applica>ons  

•  Has  a  built-­‐in  generator  that  provides  the  field  current  

when  the  generator  turns  

!  A  generator  inside  a  generator  

•  If  metal  found  in  oil,  replace  unit  

!  AC  voltage  can  be  converted  to  low  voltage  DC  with  a  

(154)
(155)

DC  to  AC  Converter  

•  Called  invertors  

•  Generates  AC  by  switching  the  DC  

!  Method  1:  Switch  DC  on  and  off   !  Method  2:  Switch  direc>on  of  DC  

•  Switching  is  accomplished  by:  

!  Electric  motor  

(156)
(157)

DC  Electric  Motors  

•  Very  similar  to  generator  except  electric  power  is   used  to  create  rota>on  

•  Major  components  

!  Armature  assembly   !  Field  assembly  

!  Brush  assembly   !  End  frame  

(158)
(159)
(160)
(161)

DC  Electric  Motors  

•  Types  (based  on  the  field  windings):  

!  Series  

•  Field  windings  are  a  few  turns  of  heavy  wire  connected  in  

series  with  the  armature  winding  

•  Good  star>ng  torque  

!  High  startup  current  

!  More  current  at  low  RPMs  

•  Bad  speed  control  

!  Shunt  (Parallel)  

•  Good  speed  control  

(162)

DC  Electric  Motors  

•  Direc>on  Change:  

!  Change  the  current  direc>on  in  the  field  windings   !  Change  the  current  direc>on  in  the  armature  

windings  

!  Changing  both  field  and  armature  windings  will  not  

change  direc>on  

!  Some  motors  have  two  field  windings  in  opposite  

direc>ons  to  enable  direc>on  switching  

•  Speed  can  be  varied  by  changing  field  winding   current  

•  Brushless  motors  replace  the  commutator  with   switching  transistor  

(163)

DC  Electric  Motors  

•  Armature  Brake:  

!  Fric>on  type  brake  applied  to  the  armature  

!  A  spring  is  used  to  apply  the  brake  force  and  an  

electric  magnet  is  used  to  withdraw  the  brake  

•  Stops  the  motor  quickly  when  the  electric  power  is  

removed  

(164)

External  Lights  

•  Types:  

!  Posi>on  (Naviga>on)  

•  Green  –  right  wing  >p  

•  Red  –  le&  wing  >p  

•  White  -­‐  ver>cal  stabilizer  

!  An>-­‐collision  

•  Types:  

!  Rota>ng  beam  lights   !  White  strobe  

!  Landing   !  Taxi  lights  

!  TSO  light  required  in  IFR  experimental  aircra&  

(165)

Miscellaneous  

•  AC  43.13-­‐1B  11-­‐35(d)  -­‐  In  installa>ons  where  the   ammeter  is  in  the  generator  or  alternator  lead   and  the  regulator  system  does  not  limit  the  

maximum  current  that  the  generator  or  

alternator  can  deliver,  the  ammeter  can  be   redlined  at  100  percent  of  the  generator  or   alternator  ra>ng  

•  Most  accurate  type  of  frequency-­‐measuring  

instrument  is  an  integrated  circuit  chip  having  a   clock  circuit  

(166)

Miscellaneous  

•  When  using  voltage  to  check  a  circuits  

resistance,  the  input  voltage  must  be  held   constant  

(167)

FAA  Ques>on  

•  How  can  it  be  determined  if  a  transformer  

winding  has  some  of  its  turns  shorted  together?  

a.  Measure  the  input  voltage  with  an  ohmmeter.   b.  The  output  voltage  will  be  high.  

c.  The  transformer  will  get  hot  in  normal  opera>on.  

References

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