TRiW Aeronautical Systems, Lucas Aerospace COMPONENT MAINTENANCE MANUAL, WITH ILLUSTRATED PARTS LIST DC STATIC VOLTAGE REGULATOR AND PROTECTION PANEL 51509-002 SERIES 51509-002, 51509-002A, 51509-002B, 51509-002R Original Issue: December 15, 1972 Revision 7: October 2, 2002 ARB, OR TECHNOLOGY WERE EXPORTED FROM THR UNITED STATES PORT’ ADMINISTRATION REGULATION. DIVERSION CONTRARY TO U.S LAW IS PROHIBIT © Copyright 2000 TRW Aeronautical Systems, Lucas Aerospace - Copyright in this manual and associated documents and drawings belongs to TRW Aeronautical Systems, Lucas ‘Aerospace. Alll rights reserved, No reproduction of all or part of this manual shall be made without the prior written consent of TRW Aeronautical Systems, Lucas Aerospace. This document contains information that may be confidential. Disclosure to others of information contained herein requires the written consent of TRW Aeronautical Systems, Lucas Aerospace. This manual produced at the Aurora, OH plant. TITLE PAGE — 0210202 (©2000 TRW Aeronautical SystemsTi Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series EXCLUSIVE DISTRIBUTORS The Equipment Service organization at TRW Aeronautical Systems, Lucas Aerospace is complemented by the TRW Aeronautical Systems, Lucas Aerospace Equipment Service Centers (ESC), the exclusive stocking distributor of TRW Aeronautical Systems, Lucas ‘Aerospace paris and technical publications. REGION ADDRESS COMMUNICATIONS AMERICAS: —_TRW Aeronautical Systems PHONE (1) 201 567 6400 Lucas Aerospace ESC AOG 1) 201 567 6411 30 Van Nostrand Avenue FAX 1) 201 541 7610 Englewood, NJ 07631-4396 USA FAX 1) 201 894 1965 EUROPE/ ‘TRW Aeronautical Systems PHONE (44) 121 4515788 MIDEAST/ Lucas Aerospace ESC AOG (44) 121 457 5904 AFRICA: Stratford Road FAX (44) 121 451 5881 Solihull B90 4LA England ASIA ‘TRW Aeronautical Systems PHONE (65) 545 9975 PACIFIC: Lucas Aerospace ESC AOG (65) 545 6253 35 - 37 Loyang Way FAX (65) 545 0419 Republic of Singapore 1750 ‘TRW Aeronautical Systems PHONE (61) 2 9315 3700 Lucas Aerospace ESC AOG (61) 2.9937 2553 84-92 Epsom Road FAX (61) 2.9313 7676 Zetland, Sydney NSW 2017 Australia ‘RW Aeronautical Systems PHONE (86) 592 573 0089 Lucas Aerospace ESC AOG '86) 592 573 1098 Lucas TAECO Aerospace FAX (86) 592 573 0090 (Xiamen) Co. Ltd GAOAQI International Airport Xiamen 361006 Fujian Peoples Republic of China Parts and assemblies not authorized for repairin the field must be sent to the TRW Aeronautical ‘Systems, Lucas Aerospace Repair and Overhaul (R&O) at the location below. REGION ADDRESS COMMUNICATIONS ALL: TRW Aeronautical Systems PHONE (1) 330 995 1000 Lucas Aerospace FAX 1) 330 995 1117 777 Lena Drive Aurora, OH 44202 USA CAUTION: ANY USE OF PARTS, MATERIALS, OR PROCESSES NOT AUTHORIZED BY TRW AERONAUTICAL SYSTEMS, LUCAS AEROSPACE FOR THE MAINTENANCE OR SERVICE OF THESE UNITS MAY AFFECT THEIR CONTINUED AIRWORTHINESS OR INVALIDATE CERTIFICATION, EXCLUSIVE DISTRIBUTORS Page ii ©2000 TRW Aeronautical systems = 24-30-38 Oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Generator Control Unit, 51509-002 Series HIGHLIGHTS TO: Holders of Component Maintenance Manual with IPL for DC Generator Control Unit Model 51509-002 Series. Attached to this transmittal letter is Revision 7 of the Component Maintenance Manual with IPL (basic issue dated December 15, 1972). REVISION 7, DATED 2 OCTOBER 2002 Document Comparison Summary Documents Name Modification Date Newer Document: _Introduetion.fim June 20, 2002 11:08 am Older Document: __Introduetion.fm. September 4, 2001 4:51 pm ‘Text Content Changes Page Numbers Composite Newer Older Change Text xxiti xxii xxi Deleted: “overhaul, service, ” xxiii xxiii xxi Replaced: “restoration ” With: “maintenance ” elites eet al Inserted: “TRW Aeronautical Systems, Lucas ...” xxiii xxiii xxi Replaced: “Panel Series $1509” With: “Panel” xxiii xiii xxi Replaced: “” With: “Maintenance includes, but is...” xxiii weil xxi Inserted: “Replacement of non-reusable ...” xxiii xiii xxi Deleted: “An illustrated parts list is.” xxiii nil xxi Inserted: “All weights and measures used ...” xxiv xxiv xxi Replaced: “ Quality assurance shall also ...” With: “Components of a GCU undergoing ...” xxiv xxiv xxi Replaced: “specifications (applicable to special ...” With: “are recovered” xxiv xxiv xxi Replaced: “soldering” With: “products of disassembly” xxiv xxiv xxi Replaced: “non-destructive testing, ...” With: “will be examined 100% ...” xxiv xxiv xxi Replaced: “) have been complied with ” With: “Quality Assurance activity will maintain ...” xxiv xxiv coi Inserted: “parts, TRW Aeronautical Systems...” xxiv xxiv xxii Inserted: “. All spares must be ..” xxiv xxiv ii Replaced: “have traceability to having been ...” With: “be traceable to, ” xxiv xiv xxi Inserted: “All repair and overhaul facilities ...” RY KY lil Replaced: “All repair and overhaul facilities ..” With: “Standard, Non-Standard ...” HIGHLIGHTS Page 1 ©2000 TRW Aeronautical SystemsTR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with lilustrated Parts List DC Generator Control Unit, 51509-002 Series Documents Name Modification Date Newer Document: _ 00001-Description.fm June 20, 2002 11:08 am Older Document: 00001-Description.fim October 4, 2000 5:25 pm Text Content Changes Page Numbers Composite Newer Older Change Text 1 1 Replaced: “1006 ” With: “2001 ” 1 1 1 1 Replaced: “1007” With: “2002” 3 3 2 Inserted: “Leading Particulars” 3 3 3 Replaced: “002A, 51509-002B...” With: “002 Series” 4 4 4 Inserted: | “DC Static Voltage Regulator and ..” Documents Name Modification Date Newer Documet 01001-Testing.fm June 20, 2002 11:08 am Older Document 01001-Testing.fm October 4, 2000 5:25 pm. Text Content Changes Page Numbers Composite Newer Older Change Text 1006 1006 1006 Inserted: “(Figures 10001 and 10004...” 1006 1006 1006 Replaced: “Fig 10003” With: “Figure 10004” 1008 10081008 Replaced: “Fig, 1006” With: “Figure 2001” 1023 10231023 Replaced: “through Mod “A” ...” With: “Block Diagram” 1024 10241024 Deleted: 1025 1025 1029 Replaced: “Mod “A” Schematic” With: “Block Diagram” 1026 1026 1030 Deleted: “” Documents Name Modification Date ‘Newer Document: _02001-Schematies.fim June 20, 2002 11:08 am Older Document: 02001-Schematics.fm October 4, 2000 5:25 pm ‘Text Content Changes Page Numbers Composite Newer Older Change Text 2003 2003 2002 Inserted: | “Oct 02/02” HIGHLIGHTS, Page2 ©2000 TRW Aeronautica SystemsTi Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with llustrated Parts List DC Generator Control Unit, 5509-002 Series Documents Name Modification Date Newer Document: 03001-Disassembly.fim June 20, 2002 11:08 am Older Document: _03001-Disassembly.fm October 4, 2000 5:25 pm ‘Text Content Changes Page Numbers Composite Newer Older Change Text 3001 3001-3001 Deleted: Desolder electrical connections per...” 3001 30013001 Inserted: “Perform all soldering per ANSI...” Documents ‘Name Modification Date Newer Document: _05001-Check.fm June 20, 2002 11:08 am Older Document: 05001-Check.fm October 4, 2000 5:25 pm ‘Text Content Changes Page Numbers Composite Newer Older Change Text 3004 5004 S004 Replaced: “1010” With: “2005” 5004 5004 S004 Replaced: “1011” With: “2006” 5004 5004 5004 Replaced: “1012” With: “2007” 5004 5004 5004 Replaced: “1013” With: “2008” 5004 5004 5004 Replaced: “1014” With: “2009” 5004 5004 5004 Replaced: “1015 ” With: “2010” 5004 5004 5004 Replaced: “1016” With: “2011” 5004 5004 5004 Inserted: “Perform all soldering checking per ..” Documents ‘Name Modification Date Newer Document: 06001-Repair.fm June 20, 2002 11:08 am Older Document: 06001-Repair.fm October 4, 2000 5:25 pm ‘Text Content Changes Page Numbers Composite Newer Older Change Text 6003 6003 6003 Inserted: “Surface Repair” 6007 60076005 Inserted: “Replacing” 6007 60076005 Replaced: “Boards ” With: “Board” 6007 60076005 Deleted: “'s” 6007 60076005 Replaced: “Component Removal” With: “Assembly Components” 6007 6007 600s Inserted: “THIS EQUIPMENT CONTAINS PARTS AND...” 6008 6008 6005 Replaced: “PWB's (95...” With: “PWB and chassis assembly components ” HIGHLIGHTS Page 3 ©2000 TRW Aeronautical SystemsTR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Generator Control Unit, 51509-002 Series 6008 60086005 Replaced: “a conformal ” With: “an approved silicone resin ” 6008 60086005 Replaced: “dissolve conformal ” With: “soften ” 6008 60086005 Deleted: “from soldered joint ” 6008 6008 6005 Replaced: “xylene or equivalent” With: “isopropyl! alcohol” 6008 6008-6005 Replaced: “dissolved coating ” With: “resin ” 6008 6008 6005 Replaced: “joint ” With: “component and solder joints ” 6008 6008-6005 Replaced: “pad or lint-free ...” With: “pad” 6008 6008 6005 Replaced: “Identify component by the reference ...” With: “Perform all soldering per ANSI...” Documents Name Modification Date Newer Document: 07001-Assembly.fin June 20, 2002 11:08 am Older Document: 07001-Assembly.fin October 4, 2000 5:25 pm. ‘Text Content Changes Page Numbers Composite Newer Older Change Text 7001 7001-7001 Replaced: “Solder electrical connections pet MIL...” With: “Perform all soldering per ANSI...” 7006 7006-7006 Replaced: “Use only rosin cored solder ...” With: “Perform all soldering per ANSI...” 7007 70077007 Replaced: “Use only rosin cored solder ..” With: “Perform all soldering per ANS Documents Name Modification Date Newer Document: 15001-Storage.fim June 20, 2002 1:01 pm Older Document: 15001-Storage.fm, October 4, 2000 5:25 pm ‘Text Content Changes Page Numbers Composite Newer Older Change Text 15001 15001 15001 Replaced: “Introduction” With: “Storage” 15001 15001 15002 Replaced: “Before preparing DC Static Voltage ...” With: “Before preparing GCU for shipment .. 15001 15001 15002 Replaced: “Packing Date” With: “GCU Mod Status” 15002 15002 15002 Inserted: “, Heat seal bags opening” 15002 15002 15002 Replaced: “Pack with Ran Pack cushioning...” With: “Wrap all six sides of...” 15002 15002 15002 Replaced: “Apply waterproof tape to all...” With: “Place domestically packaged GCU into ..” 15002 15002 15002 Inserted: “Securely and completely, seal ...” 15002 15002 15002 Replaced: “Information and ESDS tags ” With: “tag ” 15002 15002 15002 Replaced: “container making ” With: “shipping container. Make” HIGHLIGHTS Page 4 ©2000 TRW Aeronautical SystemsTR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series RECORD OF REVISIONS Revision Number Date Issued Date Inserted into Initials cMM Original Issue Dec 15/72 Revision 1 | Feb 15/75 Revision 2 Jan 30/76 Revision 3 Apr 30/77 Revision 4 "Sept 22/80 Revision 5 Mar 31/86 Revision6 | _—_ Oct 06/00 Revision 7 | Oct 02/02 Retain this record in front of CMM. On receipt of revisions, insert affected pages into manual. Record revision number, date issued, date inserted into CMM, and initials on this page. RECORD OF REVISIONS Page iil ©2000 TRW Aeronautical Systems. 24*30-38 — oct 02/02Ti Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series THIS PAGE INTENTIONALLY LEFT BLANK. RECORD OF REVISIONS Page iv ©2000 TRW Aeronautical systems 24*30-38 — oct 02/02Triw Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 5509-002 Series RECORD OF TEMPORARY REVISIONS Temporary Revision | Page Date Date | Initials} Date _| initials Number Number | Issued | Inserted Removed Retain this record in the front of the CMM. On receipt of temporary revisions, insert affected pages into the manual. Record the temporary revision number, page number, dale Issued, date inserted info the GMM, and intals on this page. When temporary revisions are removed from the CMM, record the date removed and initials. RECORD OF TEMPORARY REVISIONS age v ©2000 TRW Aeronautical Systems. = 24*30-38 Oct 02/02TrtiW Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 1509-002 Series THIS PAGE INTENTIONALLY LEFT BLANK RECORD OF TEMPORARY REVISIONS age vi ©2000 TRW Asronautcal systems 24-30-38 oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with tilustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series SERVICE BULLETIN LIST "Service Bulletin Date | Service Bulletin ‘Number Status | Rev | issued ‘Number. eau 706 Vale 7 [Panera '51508-004 Vale 2 | asies Retain this record in the front of the CMM. On receipt of service bulletins, record the service bulletin number, status (valid or invalid), revision number (if applicable) and the date issued. Unless invalidated, all service bulletins affecting the 1509-002 Series GCU should be kept with the CMM. SERVICE BULLETIN LIST Page vil ©2000 TRW Aeronautical Systems = 24-30-38 — oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with lilustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series THIS PAGE INTENTIONALLY LEFT BLANK SERVICE BULLETIN LIST Page vii ©2000 TRW Aeronautical systems 24-30-38 Oct 02/02Ti Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 1509-002 Series ERVI R Service ‘Service Date Information Lotter | Status | Rev Information Letter | Status | Rev | Date, ‘Number Number Retain this record in the front of the CMM. On receipt of Service Information Letters, record the Service Information Letter number, status, revision number (if applicable) and the date issued. Unless invalidated, all Service Information Letters affecting the 51509-002 Series GCU should be kept with the CMM. SERVICE INFORMATION LETTER LIST Page ix ©2000 TRW Aeronautical Systems =: 24-30-38 Oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series THIS PAGE INTENTIONALLY LEFT BLANK SERVICE INFORMATION LETTER LIST age x 22000 TRW Aeronautical systems 24-30-38 oct 02/02Titi Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series LIST OF EFFECTIVE PAGES Title Page Date EXCLUSIVE DISTRIBUTOR ..... ii Oct 02/02 RECORD OF REVISIONS Oct 02/02 Blank Oct 02/02 Blank Oct 02/02 Blank Oct 02/02 Blank Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Blank TABLE OF CONTENTS.............02005 see Oct 02/02 i Blank Oct 02/02 Blank Oct 02/02 Blank INTRODUCTION .........02. 0000 eee eee see bene Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 DESCRIPTION AND OPERATION ........... oo : Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 Oct 02/02 RECORD OF TEMPORARY REVISIONS SERVICE BULLETIN LIST... SERVICE INFORMATION LETTER LIST LIST OF EFFECTIVE PAGES LIST OF ILLUSTRATIONS. ...... LIST OF TABLES . TESTING AND FAULT ISOLATION LIST OF EFFECTIVE PAGES Page xi ©2000 TRW Aeronautical systems =: 2430-38 oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series LIST OF EFFECTIVE PAGES (Continued) Iitle Page Date TESTING AND FAULT ISOLATION (Continued) ee 1011 Oct 02/02 1012 Oct 02/02 1013 Oct 02/02 1014 = Oct 02/02 1015 Octo2/02 1016 © Oct 02/02 1017 Oct 02/02 1018 Oct 02/02 1019 Oct 02/02 1020 Oct 02/02 1021 Oct 02/02 1022 Oct 02/02 1023 Oct 02/02 1024 Blank 1025 Oct 02/02 1026 Blank SCHEMATICS AND WIRING DIAGRAMS eee 2001 = Oct 02/02 2002 Blank 2003 Oct 02/02 2004 Blank 2005 = Oct 02/02 2008 Blank 2007 = Oct. 02/02 2008 Blank 2009 = Oct 02/02 2010 Blank 2011 = Oct 02/02 2012 © Oct 02/02 2013 = Oct 02/02 2014 = Oct 02/02 2015 = Oct 02/02 2016 = — Oct 02/02 2017 =~ Oct 02/02 2018 Blank DISASSEMBLY «2.0.00... 0.00000 ceeeeeee eee eee 3001 Oct 02/02 3002 = Oct 02/02 3003 Oct 02/02 3004 == Oct 02/02 3005 Oct 02/02 3006 Blank LIST OF EFFECTIVE PAGES Page xii ©2000 TRW Asronautical Systems 24-30-38 — oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with tlustrated Parts List DC Static Voltage Regulator and Protection Panel, 5509-002 Series Title Page Date (CLEANING et se eee eee hodon -4001 Oct 02/02 4002 Oct 02/02 +. 5001 Oct 02/02 5002 Oct 02/02 5003 Oct 02/02 5004 Oct 02/02 REPAIR Sbboaresos0no0n Gogoucon ++, 6001 Oct 02/02 6002 Oct 02/02 6003 Oct 02/02 6004 == Oct 02/02 6005 Oct 02/02 6006 Oct 02/02 6007 Oct 02/02 6008 Oct 02/02 6009 Oct 02/02 6010 Blank ASSEMBLY ........ 7 popbanonon +++. 7001 Oct 02/02 7002 © Oct 02/02 7003 = Oct 02/02 7004 = Oct 02/02 7005 — Oct 02/02 7006 Oct 02/02 7007 = ct. 02/02 7008 = Oct 02/02 7009 = Oct 02/02 7010 Oct 02/02 7011 =~ Oct 02/02 CHECK 7012 Blank 7013 © Oct 02/02 7014 Blank 7015 = Oct 02/02 7016 Blank 7017 ~~ Oct 02/02 7018 Blank FITS AND CLEARANCES 0.00.00... 000s eceeeeeeeeenen es 8001 Oct 02/02 8002 Blank SPECIAL TOOLS, FIXTURES, AND EQUIPMENT ...... 0... 0.0005 9001 Oct 02/02 9002 Blank LIST OF EFFECTIVE PAGES Page xiii ©2000 TRW Aeronautical systems 2430-38 — oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with lilustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series EFFI Title Page Date ILLUSTRATED PARTS LIST 5 : +... 10001 Oct 02/02 10002 Oct 02/02 10003 Oct 02/02 10004 Oct 02/02 10005 — Oct 02/02 10006 Oct 02/02 10007 Oct 02/02 10008 — Oct 02/02 10009 Oct 02/02 10010 Oct 02/02 10011 Oct 02/02 10012 Oct 02/02 10013 Blank 10014 — Oct 02/02 10015 Oct 02/02 10016 — Oct 02/02 10017 Oct 02/02 10018 — Oct 02/02 10019 — Oct 02/02 10020 Oct 02/02 10021 Oct 02/02 10022 Oct 02/02 10023 Blank 10024 Oct 02/02 10025 Oct 02/02 10026 Oct 02/02 10027 Blank 10028 Oct 02/02 10029 Oct 02/02 10030 Oct 02/02 10031 Blank 10032 Oct 02/02 10033 Oct 02/02 10034 — Oct 02/02 10035 Blank 10036 Oct 02/02 10037 Oct 02/02 10038 Oct 02/02 LIST OF EFFECTIVE PAGES Page xiv ©2000 TRW Aeronautical systems 24-30-38 — Cot 02/02TRI Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series LIST OF EFFECTIVE PAGES (Continued) Iitle Page Date ‘SPECIAL PROCEDURES . ee 11001, Oct 02/02 11002 Blank REMOVAL 2... 0.0.0. cc cee eee eee seen ees +. 12001 Oct 02/02 12002 Blank INSTALLATION «22.0... e ee cee cesses nent eee en ee +++. 13001 Oct 02/02 13002 Blank SERVICING «26... cece cee eee eee e eee ences 14001 Oct 02/02 14002 Blank 5S) (0) \ cl abpaen 15001 Oct 02/02 15002 Oct 02/02 REWORK... . ce eeeeesessesess 16001 Oct 02/02 16002 Oct 02/02 LIST OF EFFECTIVE PAGES Page xv ©2000 TRW Asronautical Systems —- 24*30-38 — oct 02/02TRiW Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series THIS PAGE INTENTIONALLY LEFT BLANK LIST OF EFFECTIVE PAGES Page xvi ©2000 TRW Aeronautical Systems 24"30-38 Oct 02/02Tw Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series [ABI INTENT: Title EXCLUSIVE DISTRIBUTOR RECORD OF REVISIONS .......... RECORD OF TEMPORARY REVISIONS . SERVICE BULLETIN LIST...... SERVICE INFORMATION LETTER LIST LIST OF EFFECTIVE PAGES . TABLE OF CONTENTS... LIST OF ILLUSTRATIONS. xix LIST OF TABLES . xxi INTRODUCTION . ail DESCRIPTION AND OPERATION 1 TESTING AND FAULT ISOLATION. .........0. 1004 SCHEMATICS AND WIRING DIAGRAMS. 2001 DISASSEMBLY .. : 3001 CLEANING ~.. 4001 CHECK - 5001 REPAIR ... 6001 ASSEMBLY ... 7001 FITS AND CLEARANCES ....... 8001 SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 9001 ILLUSTRATED PARTS LIST bene 10001 SPECIAL PROCEDURES .... 11001 REMOVAL .... 12001 INSTALLATION ... 0.2.06. 0 ce eee e cece eee ee tee eee eee 13001 SERVICING ... 14001 STORAGE 15001 REWORK..... 16001 TABLE OF CONTENTS Page xvil ©2000 TRW Aeronautical Systeme == 24-30-38 oct 02/02TiiW Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series THIS PAGE INTENTIONALLY LEFT BLANK TABLE OF CONTENTS Page xvili ©2000 TRW Aeronautical Systems 24"30-38 — Oct 02/02TRF Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series LIST OF ILLUSTRATIONS Figure Title Page 4 DC Static Voltage Regulator and Protection Panel, 51509-002 Series ........ 3 DC Static Voltage Regulator and Protection Panel, 51509-002 Series, Installation 4 1001 Test Connection Diagram Bench and Pre-Closed Loop Test (5509-002, -002A, -002R) . . 1003 1002 Test Connection Diagram Bench and Pre-Closed Loop Test (51509-0028) pouousodsRodogobonanaodaddadd q 1004 1003 Test Connection Diagram, Ground Fault Pulse Generator 1005 1004 Closed Loop Test Connection (51509-002, -002A, -002R) ..... - 1016 1005 Closed Loop Test Connection Diagram (51509-0028) ........ 1017 1006 51509-002, -002A, -002R Block Diagram .... 1023 1007 51509-0028 Block Diagram... .. =. 1025 2001 5109-002, -002A, -002R through Mod “A” Schematic - 2003 2002 §1509-002, -002A, -002R through Mod “B" Schematic 2005 2003 §1509-002B Schematic = 2007 2004 51509-0028 Mod “A” Schematic. - 2009 2005 = PWB 51509-343, -343R, Rev H, Voltage Regulation and Paralleling Circuit Schematic ....... 2011 2006 © PWB 5109-343R, Rev P, Schematic... .. = 2012 2007 PWB 51509-3438, Rev B, 51509-343R, Rev E, Votege Regulation and Paralleling Circuit Schematic ve ees 2013 2008 © PWB 51509-343B, Rev H, Schematic ....... - 2014 2009 PWB 51509-353, -353B Line Contactor Circuit Schematic . = 2015 2010 PWB 51509-360 Protection Circuit Schematic. .... . pte 2016) 2011 PWB 51509-363, -3638, -364 Protection Circuit Schematic .......- 2017 6001 FAA-PMA Marking .. : ee ee C00r 7001 Chassis Assembly Detail (Sheet 1 of 2). 7003 7001 Chassis Assembly Detail (Sheet 2 of 2). . 7004 7002 Lead Connection Diagram 51509-002, 002A, -002R through Mod “A”... 7014 7003 Lead Connection Diagram 51509-002, 002A, -002R through Mod “B" ..... 7013 7004 Lead Connection Diagram 51509-0028... 7015 7005 —_ Lead Connection Diagram 51509-002B, Mod * oo 7017 10001 DC Static Voltage Regulator and Protection Panel eee re 10000 10002 PWB 51509-343 Voltage Regulation and Paralleling. sete ee tenes 10014 10003 PWB 51509-3438 Voltage Regulation and Paralleling .. .. - 10016 10004 PWB 51509-343R Voltage Regulation and Paralleling (Sheet 1 of 2) 10019 10004 PWB 51509-343R Voltage Regulation and Paralleting (Sheet 2of of2) 10020 10005 — 51509-353 Line Contactor Circuits. . 10024 10008 51509-3538 Line Contactor Circuit (Rev. E) . 10028 10007 PWB 51509-360 Assembly, Protection Circuit i =. 10032 10008 5109-363 and 51509-364 Protection Circuits...... 0.0... ee eevee. 10086 LIST OF ILLUSTRATIONS. Page xix ©2000 TRW Aeronautical Systems —-- 2430-38 Oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series THIS PAGE INTENTIONALLY LEFT BLANK LIST OF ILLUSTRATIONS Page xx ©2000 TRW Acronautcal Systems == 24-30-38 oct 02/02Ti Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with tlustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series LIST OF TABLES Table Title Page 1 Physical Characteristics . . 3 1001 Performance Test Conditions. = 1001 1002 Test Equipment 1002 1003 Fault Isolation Chart... . 1019 3001 Disassembly Tools and Fixtures - 3001 4001 Cleaning Materials ~ 4001 5001 Inspection Tools and Materials. . . +. 6001 6001 —_Repair Tools : - 6002 6002 Repair Materials . 6002 7001 Assembly Tools and Fixtures 7001 7002 Assembly Materials 7002 9001 Special Tools, Fixtures, and Equipment 9001 15001 Packaging Material. : 15001 16001 Rework Parts List...... 16001 LIST OF TABLES Page xxi ©2000 TRW Aeronautical systems 24-30-38 — Oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 5509-002 Series THIS PAGE INTENTIONALLY LEFT BLANK LIST OF TABLES Page xxii ©2000 TRW Aeronautical systems == 24-30-38 Oot 02/02TAR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Iilustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series 1. 2 INTRODUCTION Purpose This Component Maintenance Manual (CMM) provides detailed instructions for repair and maintenance of the TRW Aeronautical Systems, Lucas Aerospace Model 51509-002 Series DC Static Voltage Regulator and Protection Panel. Maintenance includes, but is ot limited to the following: + Replacement of non-reusable parts, such as miscellaneous hardware + Cleaning of subassemblies + Detailed inspection of parts, NDT inspections, and complete acceptance testing + Reconditioning of finishes as required + Replacement of parts as required Illustrated parts list for component identification and ordering of approved replacement parts. The structure and content of this manual is in general accordance with the requirements established by the Air Transport Association of America (ATA) for aircraft CMMs. This manual is formatted to conform to ATA Specification No. 100, All weights and measures used in this CMM are in English units, followed by Systeme Internationale (S!) equivalent in parentheses. Give careful attention to applicable warnings and cautions. Before starting any repair procedure, become thoroughly familiar with capabilities and limitations of equipment. Make sure all necessary safety equipment, test equipment, repair materials, special tools, and fixtures are available before starting any task. If errors, omissions, or other technical discrepancies exist in CMM, fill out a Technical Publication Comment Form. Send a copy of form to: Technical Publications Supervisor TRW Aeronautical Systems, Lucas Aerospace. User Qualification and Certification Requirements Information contained in this CMM is intended for use of persons trained and certified in repair and service of aircraft electrical accessories. Eligibility and certification of service technicians shall be in accordance with guidelines established by uy Federal Aviation . Cod Administration or an equivalent regulatory authority. (Refer to U.S. Code of Regulations 14 CFR Chapter 1, parts 65.101 through 65.103 and part 145.33.) Where special processes are included by reference to military or commercial standards, qualifications and certifications of personnel performing process shall be as indicated in cited standard. Make sure all detailed requirements of cited military or commercial standards used in repair of this equipment are followed. INTRODUCTION Page xxiii ©2000 TAW Aeronautical Systems 24*30-38 — oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with tllustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series 3. Quality Assurance Requirements Repair station Quality Assurance activity is responsible for correct performance of alll tests and inspections specified in this CMM. Quality Assurance activity shall also be responsible for maintaining all required tests, inspections and maintenance records for each unit received for service. All instrumentation and inspection equipment used shall be calibrated and controlled in accordance with ISO 10012-1; and all standards must be traceable to National Bureau of Standards or an equivalent standards regulatory authority. Quality Assurance activity shall be responsible for verifying that personnel, skills, and materials meet requirements of work being performed. Components of a CCU undergoing maintenance, that are recovered as products of disassembly, will be examined 100% to determine serviceability. Quality Assurance activity will maintain documentation during repair of any unit as evidence. 4. Safety Advisory This CMM describes physical and chemical processes that require use of chemicals or other commercially available materials that require precautionary attention WARNINGS, CAUTIONS and NOTES are used throughout text to highlight and emphasize important points. WARNINGS give information that must be followed precisely to avoid personal injury and/or possible death. CAUTIONS contain information that must be followed to avoid damage to equipment. NOTES provide information that assists technician in performance of tasks. 5. Authorized Components and Processes Policy RW Aeronautical Systems, Lucas Aerospace authorizes only use of genuine TRW Aeronautical Systems, Lucas Aerospace spare parts. TRW Aeronautical Systems, Lucas Aerospace also authorizes use of vendor parts as listed in IPL. These parts have been shown to meet stringent engineering design specifications and quality standards. All spares must be certified, and be traceable to, TRW Aeronautical Systems, Lucas ‘Aerospace Quality Assurance incoming and in-process inspection systems, All repair and overhaul facilities are obligated to provide FAA, or any other in-county ai authority, with proper traceability documientation indicating approval of all spare parts, materials and processes to ensure configuration compliance and continued air worthiness. Use of any unauthorized parts, or any parts not having been submitted to TRW Aeronautical Systems, Lucas Aerospace Quality Assurance inspection system will invalidate any and all factory warranties. All TRW Aeronautical Systems, Lucas Aerospace Warranties are automatically voided on any TRW Aeronautical Systems, Lucas Aerospace designed unit that has been modified by installation of any unauthorized parts, materials of unapproved processes supplied by other outside services. Repair station's Qualit Assurance activity shall assume product lability forall units that have been modified in this fashion. INTRODUCTION Page xxiv ©2000 TRW Asronautical Systems © 24-30-38 Oct 02/02TRF Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series Damage resulting from use of unauthorized replacement parts, materials or processes is not covered by TRW Aeronaut for any product or for any application, ‘Standard, Non-Standard Abbreviations and Symbols. Following is a list of abbreviations and acronyms used in this document. A AC AD APU AR ASC ATA BIT BITE om CMM CPU cr DIA pe ESD ESDS FAA GCR ccs CU Hz LD. IPL Iso kg kPa Lbs. LRU Ampere Alternating Current Analog to Digital Auxiliary Power Unit As Required Auxiliary Start Contactor Air Transport Association of America Built in Test Built In Test Equipment Centimeter Component Maintenance Manual Central Processing Unit Current Transformer Digital to Analog Direct Current Electrostatic Discharge Electrostatic Discharge Sensitive Federal Aviation Administration Generator Control Relay Generator Control Switch Generator Control Unit Hertz or Cycles per Second Inside Diameter llustrated Parts List International Standardization Organization Kilogram Killopascals Liter Pounds Line Replaceable Unit | Systems, Lucas Aerospace warranty or service policy INTRODUCTION ©2000 TRW Aeronautical Systems © 24-30-38 Page xxv Oct 02/02Tw Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series mFd MIL mm ms NDT orc OSHA PI POR PP PSIG. PwB PWM RC REF rms ROM RPM sI TTL Veo wow Microfarad Military Specification Millimeter Millisecond Non-Destructive Testing Overcurrent Occupational Safety and Health Act Proportional, integral Control Point of Regulation Peak to Peak Pounds per Square Inch Gauge Printed Wiring Board Pulse Width Modulated Random Access Memory Resistance/Capacitance Reference Root Mean Squared Read Only Memory Revolutions Per Minute ‘Systéme Internationale Transistor — Transistor Logic Volt or Voltage Voltage, Power Supply Working Weight On Wheels Ohm INTRODUCTION Page xxvi ©2000 TRW Asronautical systems 24-30-38 Oct 02/02Tit Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series 1. 2 3. IN. RA Introduction The Model §1509-002 Series DC Static Voltage Regulator and Protection Panel are designed to incorporate all the features of a 28 VOC System in one compact unit. The unit is designed to permit mounting in any attitude. Description ‘The 51509-002 Series contro! units are static-type replacements for the B-3 type control unit and combine (in one package) the functions of generator-regulation and system protection. Provision is included for connecting an external switch for testing the Overvoltage and ground fault circuits without removing the unit from aircraft. ‘The control unit contains three printed circuit boards. The top board incorporates the paralleling and regulator functions. The middie board contains the line contactor and the feverse current controls. The bottom board contains the ground fault protection and the overvoltage circuits. Operation A. Voltage Regulator ‘The upper left-hand quarter of the schematic comprises the voltage regulator portion. The heart of the regulator is an integrated circuit. By using a comparator amplifier with a regulated reference voltage, any difference between the reference voltage and the generator output, as seen by the sensing line, is amplified and supplied to the comparator circuit, which controls the power amplifier stage. The power amplifier stage then controls the shunt field excitation of the generator, Additional protection is provided by a circuit which prevents generator build up with an open field relay until the pilot has placed the generator control switch into the reset position. The field relay is automatically reset, and this “reset” circuit is then isolated to prevent cycling in the event the system is reset into a “fault” condition. Paralleling Control ‘The upper right-hand quarter of the schematic (Figures 2001 and 2002) is the paralleling portion of the control unit. This system incorporates the use ofan integrated circuit The difference between the interpole voltage of the local generator and the equalizer bus is amplified, inverted and filtered. The resultant difference voltage is coupled through weighted input to the “summing junction” of the voltage regulator circuit and the overvoltage circuit. The equalizing circuit is continuously attempting to sum the differences between the voltage across the interpole of the local generator and the equalizer bus to zero. DESCRIPTION AND OPERATION age 1 ©2000 TRW Aeronautica Systems 24*30-38 — Oct 02/02Titi Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series Automatic Line Contactor Control and Reverse Current Protection In the lower left-hand portion of the schematic is the automatic line contactor control and reverse current control consisting of two integrated circuits providing the necessary reverse current and differential voltage sensing functions, (so when the generator has attained an output voltage equalto the bus voltage), these circuits lose the main line contactor. The two circuits monitor the difference in voltage across the open contacts of the main line contactor. When this potential difference becomes less than 0.3 volts, integration Occurs and the line contactor closes. When the line contactor closes, the circuits automatically shift to sensing reverse current. Overvoltage Protection ‘The overvoltage protection circuitry uses integrated circuits similar to those used by the line contactor control and reverse current control The overvoltage circuit includes the use of an operational amplifier, a silicon controlled rector (SCR) and.a separate power supply permitting the overvoltage circuit to be ‘completely independent of any other circuits in the control unit. ‘The operational amplifier senses any difference between the reference voltage and the input voltage. If the generator voltage (as seen at the overvoltage sensing line) starts to exceed the reference voltage, the unit begins an integration which causes the output to decrease until it reaches a predetermined fixed voltage. When attaining this level, the SCR triggers, causing the field relay to open. This, in-turn, opens the equalizer circuit, the main line contactor, de-energizing the generator. Start Up Ground Fault Protection ‘The ground fault circuits are containedin the lower right-hand quarter of the schematic. For primary detection of a ground fault within the generator-to-line-contactor during build up, a self-sustaining circuit measures the voltage across the interpole windin before the line contactor has nally closed. ifthe current present ig equal fo one-halt ‘or more of the generator’s rating, the line contactor circuits will be “disabled” while a Special input fo the overvoltage integrator wil cause the cult to de-energize the generator, Ground Faults Protection During Operation The operational ground fault sensing circuits check conditions at the input to the line contactor and af the retum to the génerator by means of two current transformers. When a differential current is sensed between the two current transformers (CT’s), the differential current wil fire an SCR, trip the field relay, and de-excite the faulted generator. DESCRIPTION AND OPERATION Page 2 ©2000 TRW Aeronautical Systems: 24*30-38 oct 02/02Titi Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 1509-002 Series 1 G. Leading Particulars Characteristic 5150 Height 4.86 in. (123.44 mm) max. Width 3.77 in. (85.6 mm) max., (4.42 in.(112.27 mm) including base) Length 6.36 in. (161.54 mm) max. Weight 2.8 lbs. (1.27 Kgram) max. Table 1 - Physical Characteristics ! Figure 1 - DC Static Voltage Regulator and Protection Panel, 51509-002 Series DESCRIPTION AND OPERATION Page 3 ©2000 TRW Aeronautical Systems 24-30-38 — oct 02/02Titty Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with Illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series 2enrposmion PATE 44 gecepracue Wis soekes-29P ~ MATING CONNECTOR t ms3102R2e20s 492 CHOUrAgE AOWSTMENT nes = wire Locke per msa3s40 AND SEALED Figure 2 - DC Static Voltage Regulator and Protection Panel, 51509-002 Series, Installation DESCRIPTION AND OPERATION Page 4 ©2000 TRW Asronautical systems 2430-38 — oct 02/02TR Aeronautical Systems, Lucas Aerospace Component Maintenance Manual with illustrated Parts List DC Static Voltage Regulator and Protection Panel, 51509-002 Series 1 STING AND Fi introduction WARNING: THE GENERATOR CAN PRODUCE AN OUTPUT CURRENT CAPABLE OF CAUSING SHOCK. MAKE SURE ALL POWERIS SHUT OFF TO UNIT BEFORE REMOVING OR REPLACING TEST EQUIPMENT, INSTRUMENTS, OR ASSEMBLIES. TAKE EXTREME CARE WHEN PERFORMING “LIVE CIRCUIT” TESTS AND FAULT ISOLATION PROCEDURES. CAUTION: THIS EQUIPMENT CONTAINS PARTS THAT ARE ELECTROSTATIC DISCHARGE SENSITIVE (ESDS). THESE PARTS CAN BE DAMAGED BY ELECTROSTATIC DISCHARGE. USE ESDS PRECAUTIONARY, PROCEDURES WHEN TOUCHING, REMOVING OR INSERTING ESDS PARTS OR ASSEMBLIES. CAUTION: ALL PRINTED WIRING BOARDS (PWB'S) AND WIRING BOARD. 5 COMPONENTS CAN BE DAMAGED BY SEEMINGLY UNDETECTABLE ELECTROSTATIC DISCHARGE. CARE MUST BE EXERCISED DURING HANDLING OF THESE ITEMS. USE ESDS PRECAUTIONARY PROCEDURES. Perform the following tests upon overhaul, rebuilding, replacement of components or acceptance. Various tests are outlined to diagnose and locate malfunctions. There is no established test sequence as testing must be accomplished to fit exact requirements. Conaiti 7 Parameter ‘Operating Conditions Environment No special conditions. ‘Ambient Temperature 50 to 104°F (10° to 40°C) Cooling Air None required. Ambient air velocity must be less than 5 mph actual air speed. Mounting Unit must be mounted so that unit base is down and horizontal. Line Impedance Line impedance between generator output terminal and point of regulation (POR) must be such as to give no more than 7.0 volt drop at full-ated generator load, Generator shall be operated within iis respective generating speed range. Voltage regulator tests shall be conducted using a TRW Aeronautical Systems, Lucas Aerospace generator meeting MIL-G-6162 requirements. Table 1001 - Performance Test Conditions TESTING AND FAULT ISOLATION Page 1001 ©2000 TRW Aeronautical Systems. © 24-30-38 oct 02/02