Basic Maintenance Module 13 Aircraft Structures and Systems ‘Training Manual, 13.5 Electrical Power (ATA 24) 13.5 Electrical Power (ATA 24) cat:02 135-4- Basic Maintenance ‘Training Manual ‘Module 13 Aircraft Structures and S) “13.5 Electncal Power ( tome (TA 24) DC Generators hare ae two types of eocticiy: state and current State electety produces Stoctie Haise caused by an accumistion of electone tat are not mong. Ca Tentalsetnety a more veel ype causes ty fe movement eleetons in OC {atetcuren) elecresy. the lecrone move trough the croutons Brecon IAC (aternabag current the electrons portly reverse thor recon few ‘Therese ve ways current elecscty canbe gonerated The conversion of em icalenergy. most sgt pressure and magneton ‘eletical energy use in an avra comes fom he scutes he conversion of ‘hemiealeneray and magnetism Storage bates conver shemeal energy no ‘ect for farting he engine anid fr use n emergencies ul he lett fot ronal eporaton'sprosueed by magnet na onoratro alenator Genorator Principles [AC Generator Principles ‘ACs easier to prosuce than DC. Aloop of wre roatesin the magnetic ld. wich ‘ecavsed by ines of magnet fuxtbotweon te two pale poses, The two nds of the logp terminate siping convestes to the extemal seat through carbon brushes, DC Generators and Alternators Al eectrcty produced by magnetic gneraors i AC. th output rected. oF ranged into Bc. There ae Wo ypes of acters mecrania and semicondue tor The ple peces and rtatng 2 are sla fo those ne desenpton of He [AC generat bute and fhe ca are term saodn the two segments of et fing commutator Caron bushes ideo he comma to comet theca othe ner crc “The outpt waveform i ow fequency pulsing DC. By adoing 2 second cll st ‘igh angles ote rat the eauency of he pusavons, cates the ne requency, ISdoubie, andthe terminal vltage men smoother then hat prosuced by a= {je colby adding even more ca, the ple Fequercy i ther eteases and the ouput vag becomes soothe Figure; Rotating collin a magnotic fl cat:02Basic Maintenance Mod 19 Aircraft Structures and Systems ‘Training Manual “35 Elocrea Power (ATA 23) DC Generators and Alternators Figure Stator, Rotor and Carbon Brash DC Generator ve re negro Lamnaadson Field Magnets ueutees Inracialgoreras. the magnet fll is produced by eactonagnts. The on ‘oe ofa pce atm Oc purer nes or emcomognave fs. Toe < np ne rapt he onus he vage poteed bye grea. we Snctined ty tne vcage toplas wich onto Be out Sa Som into tls cel Armature ek ff Praces genet have aruberotcolaouné in se rund a cms cce recon oo ‘ftsmnated sof ron on he armature sat. The angel he cole ae soles ts opper commutator segments which ate slated fam each ater and Wom he srmoture sma Carbon Brushes 1 pi of carbon bushes picks ofthe output cure fom the cating amatureBasic Maintenance ‘Training Manual Module 13 Aircraft Structures and Systems "35 Electrical Power (ATA 24) Gonerator Circuit (Generator cutputcuret is produced in the rotating amature ost ight aeat Use. basicelecrcal system thathas been adapted fom automoble systems The (gererairs and regulators ate senor appearance fo hase vaed in atorabies, But tere are stemal ferences, aftereness n marl, and expecially ier foes inthe inspections used to seriete te componcnt or use m aera is fot permaste fo se an aulomenie eonponentm 2 cericated area even {hough te prs 8 ook aheo CGenarator elds ae se-excited. This means ha he ld curent comes fom the ‘Sature As he votage produced nthe armature es, theft current ses ad auses the armature vote, ad consequent the load cute. to nerease even ‘mote All generators rust Use sore pe of curentWtr aa wel as 2 vane regulator The Acireuts fetes ae connected tothe naa bush lde te goers the vllage equator acls as voiabe tesslor between Pe genet Feld and ground ‘The B-cheut feld cals ave connected to he grounded brush, the votoge regu: Intoracte as vanablereastor between te generator Hols and te amature Figure 6: Generator Exetation Field A-ircut or Bey ne. sine ‘oat 82 195-4Basic Maintenance Trai Module 13 Aircraft Structures and Systems "13.5 Electrical Power (ATA 24) Electromagnetic Voltage Regulator ‘The generator contol contans three unis: 2 votage-requlate, a curen-inaer, and Severs curent ult rly. ‘The votage regulator senses the generate output voltage, and ts normaly closes contacts vrata open ana clesed many umes asecara ting ihe amount oto rent hat can fow rough he fel ‘The cuten ters actuates ty a colin seria wih he amature output When the generator pus cut more than fs ated curen. tho current itor normaly [Sosed contacts open ana pus resstance nthe fia erouktolower the generator ‘utp vatage to eve tat wil not produce excessive curent “he reverse-curent cutout asconnect te genetator rom the aera bus when the generator volage drops Blom ha the batry, ans they sutomatealy con ec! bs generator the bus when the ganetate Voltage nses above at fhe Paton. Figure 7: Electromagnatie Generator Control (iano shiny neater nema ead eae ef ection s35-5Basic Maintenance Training Manual ‘Module 13 Aircraft Structures and Systoms “12.5 Electrical Power (ATA 24) Generator System ‘The A-reut type generator sytem 6 typical fr mest single engine gh a= panes The nature tema! ofthe generator connect ote rma of he [Jonraor contol unt The conan oh verse. cirren euout ae Between te Gana'ne Bterminas When the generator cuput eaches species vole, Pe reverse-curent cucu contacts doce sna connoc te generate fp he mar bus Fel current produced in the generator Bows om he fed termina ofthe gener ‘ar hough ie generat sie of he mse’ st so the Formal te con trolunt and throogh the voltage regulator and coments conto ground Heshor the vestag othe arent re oo high one set fnomaly cose contacts ‘pens and hs held current mast few tough ie ressortogrours. The zeo.cet tre‘ammetor shows the amount o curent Rowing her fom te Eatery t Imambus ¢] ortom the generator though tne mar bus io the bate (© Gravee Figure &: DC Generator Circuit cat: 82 t35-6Basic Maintenance Training Manual Module 13 Aircraft Structures and Systems “13.5 Electrical Power (ATA 24) DC Alternators As semiconductor sodes ab fo whstnd the temperature and vibration were de ‘eis the farmoreprasical tomar replaced te generator for proscing a ‘most al automotive and areratleciny DC aerators have thre peenary ‘vaniages over generators ‘Thay have many more sels of fel ples so ey can produce cuenta a lower speed ‘The high curentsproducedin the statonarycomsonent ard Convene doses ed by sem ‘An aerator ystems ighle in weight than a generator system ‘The foto's mage of two end pices afro that farm he magnet ples. Some ‘olrs have four pars of poles an oars have as many as sever pat The vlt ge regula supptes caren hough brushes and sip regs to acl of ulated Capper wie between the fa ena pices fo coral the stengh othe magnets ‘The stator wndngs in hich the ouplcurent i produced conto series of ais wound i sles In lamitea so fon tame. The cols ate avtangea in’ three phase Y connected cteut The AC output athe saa converted lo DE bya sucdede toe phase rete, Curent lowing tom the main bus trough the votage regulator magnatize the rotor As the rotor tors the mulpie pars cf pols meuee a volage the tee ‘haces of the stator winding The trae phase AC conertea me DC byte 6 3+ ‘es and sent fo he man tus byaugh a gh current crout breaker Figure 8: Rotor and Dietrbutes Pote Stator 2 ‘winaings ee ‘tip Rings (yp ) Figure 10: D¢ -Atrnator Schematic Slip in remem ‘cat 62 8-7Basic Maintenance Module 13 Aircraft Structures and Systems ‘Training Manual, "135 Electnoal Power (ATA 24) Solid-State voltage Regulator Figure 11: Voltage Regulator sold state Hoa of te moder systems use asodstat vltage regulator ‘Wher ne aerate ttc stoned onthe fel Tay loses and curent tows ttvoug” Farsstor Tan the ots Fea eo ‘Assoon ashe engine sas, he ater begin o output vokage, and when he ‘tage ses othe equating vue, he zener diode ZO, begins ts corauct The, though he action of ransitor 12-11 shut ofthe feccrant ang he output vat [Spe atone As soon as te voltage Sees 2D reps below te zener vokage and ‘Sp conaucing. 11 ters bak ,alowog hold current to fom ag Ths sols-siate device proves smooth and censstent contol ofthe system vat age minna moung pate “Th sold state rece used inthe aternator prevents thew of any caren om the load bus back oe afernator stator winding, so teres no neta fr reverse. Curent relay wath an atest “The fs currents aken tom the regulated bus vllage rather han rect tom the aterator ouput and tus makes the tematresitg win retard fu ‘ent oun c9 here no need fora cent iter ‘Thee s anged, however, fo 3 eyo sth nthe aenatr fis o prevent feot owing rough Feld wing when tre engine not unning Th le Isy\or saroning transit yey comtanes inthe vrage regulator er ‘ormaor canal unt Temes booe ea cat: B2 135-8Basic Maintenance Module 13 Aircraft Structures and Systems 13:5 Electncal Power (ATA 28) Twin Engine Aircraft DC Alternator System Figure 12:. The outputeteach aerator goes tthe main busthvough a 100 Acct breaker Fed curentissupoted to each aternatar bough a8 Nereut beste, aiorsior feld ich, sox state over vtage prtecor, and sold state voage epilator ‘ath regulators are connect though tet of paatingteminals. So cHcuts baie Pe reguaors compare Ihe ls waltages one atematorproauaes mare urea than the ster Sed votage s higher Tha dierence i eloctonealy Senseo, and he volage regulator Seceases the fet cent owing tothe Na Spur altenatr and inereases the fd erento the oer Th a3 the Ou putvotages so the aternators snare the load equal “The over votage protect senses the utput-votage of the aternator. this gots too nigh the over votage pretctorapons he fed creut sopping futher cult trom the altemaio: tn soreensatstone. ard ight on the netument pane a minates to show te pct tate ateraior Fas stopped producing eurent Sey Cat: B2 138-8Basic Maintenance ‘Training Manual Module 13 Aircraft St 135 EI Structures and Syatoms lectrical Power (ATA 24) Turbine-Engine Starter-Generator System Smale urine anges installed in busines et aplanes have @ combinaten Ser generator rate: than separate starter and generator. They nave an ext Sot of soros windings The sere mote windings ave srtced na he creat wen the engine started but a s90n a8 runnng,tey are surened tt en the star swe i placed ne START poston the slate lay closes and Slows curent 6 ow fo te starter generat trough ts C+ termina, te cores ‘mole windings, the matte, and the starter generator seras wags ‘ound. the same ime. curen flows trough he qrton-cuot seh he Igniter une tig tre Wel ven ignition achieved, he stat ste is moves to RUN postion The gener 10" tld Vela. costes the fd rly to connect te gorerato Hel othe vaage Tegulaor When generator eld erent ome the generate produces cent AS ‘soon ae tne wotage buss Up 10 the spected valve Ine contacts made the re- ‘verse current cutout rely close and the current produces ne generator Flows from th Be fermnal hugh the reverse-crrent roy to tho bus When te sa ‘tons placed inthe OFF postion the generate ey opens, desomectng ‘he generator fe rom the votage replat. ard he generato” slope proauang lead sent Figure 13: Starter - Generator an cat:B2 435-10Basic Maintenance ‘Training Manual Module 13 Aircraft Structures and Systems 135 Elecincal Power (ATA 24) AC Generation Alternator Atpica AC alternator for ae cra nasa rag of between 40 tg 120KVA ana hat tee phase ouput win the prases rermaty connected ina -arangement posting ac00tis ent There ave wo ae types of atermators uso. SUS fess and ine brushtype Todey sacra yocatyuee te bushes atraior ys. tem empiouing sn nteeate 5 colo Fel elma the heat geeratod dur operation ‘A brushless allemator consists of tee saparate feds, pemanent magnet fala an excer fla, anda main output eld. The parmanent magnets tua the Tagnetc fox to sar the generator peoasing an utpt etre fet current fous. ‘Tha magnstsm reduced by ese magnets induces wooge lean armature tat arrentnecurentia generator convalunt,o°GCU Here te AG rected and Sent the exctor ld winding The exer tet then educes volage no ees hor cutput wining The cuput fom the excte faced bys dees, andthe fesulong DG flows hreugh te auout eld wining From hal, voltage = novced Ino me man outpat cots The permanent mapret, oxcer eutbutwnding. sd es! ana ouput fed winding ae al outed on the general shat and rotate [SS unt The twee phase ouput sat windings are wound nets a aerntor rousing Tho tree hase output of AC aerators typcaly ave a voltage of 120 vos {cross cach af the phase windings, and wi the winaings connected Ina, he ‘utp betwoen aach ote terminalia 208 ots Tne common end ol the 3 wind ‘ages conactodtothe areraissructure Tne nea curentfloms via Shue AC Voltage Regulator The complex nate of AC power sytams n'a arc requres more consider: tons fr votage tegulaton than ae required for DU systems. The votage canal {reas mast sense the votage cup al wee phases inthe aamate and ‘ey ae nl equal anc wih ts. agust them aozoranly There must be Bo ‘sens in the equator to reduce the stermator vlogs the oqueney sop be iw a spectied evel andthe contol sytem most have povisons fr equstzig Sesh the real an the teat toads among tne goneraors Many acre use & (Generator Cont Uni (CU) to perorm ese Rnctens 26 well as poring Stem festng and felt soahon Figure 14: Brushless Generator Figure 38:3 Phase Alternating Curent Voltages Le I Lat bt once cat 82 seBasic Maintenance ‘Training Manual Module 13 Aircraft Structures and Systems “{3'5 Electrical Power (ATA 24) Constant Speed Drive (CSD) Its essential that he aternator output have a nominal equency of 400 net wih ‘tolorance ualy tom 380 t9420 ner Thee assorplshedfraugrout the er ‘gre operating speed range by using 8 hyrauicaly operated constant speod Srve unt between the engine aha the aerator ‘A CSO consists ofa variaie tereue pum and motor, connected ogeter so thatregardess ofthe angie seed, the CSO ouput mlbeconstartTheconetant Speed's required fr the aerator to have an ouput of 400 het. Mary mo ‘erat employ an integrates Drive Generator (106) whi contains baie ar fajr ana CSD mene compact unt ithere ean generator er CSO fare he pot (CSD and Generator Configuration + Fiat the CSD ist cate betwen he engine driven gearbox an the gene: or Te generator nas tobe rereved br feplacng the CSD + Second The CSD secated on opposite sige a he gearbox. CSD inputon Dutoceure via coonal arrangemontahats Gach conponents can be replaced Seporaty + Last the i ntgrsted Orve Generate i rosuens toa singe component Figure 17: Evolution of Generator Drive Tray sisonnedt te mputenak fom the deve seven any damage “en Figure 16: CSD controling the Generator Speed Gear Hydro Mechanica! — ae ‘Speed Converter { nsvac i _soredonve i © Integuted Drive Genera seagreire + GEAR} og BOX congeargn A pense eel aatiBasic Maintenance ‘Training Manual Module 13 Aircraft Structures and Systems “12.5 Electrical Power (ATA 24) (C80 Principle “The constant speed drive converts varabe engine input speed to a constant out put speed whch enablos the generator to produce aacv'el power ats constant Frequency of 400 her ‘The constant speed sive adc to or subrats fom the variable engine input ‘peed through convaleggiferentl action to produce a constant cuput speed Governoring System ‘Te governor assembly senses the ouput speed arc regulates the supply pres sue achieve tne equred contol posture at te cont eynder othe varaoie Bump Maran he cote pressure level the contolcyinde provides co Stantoutput seed Normal Governing ‘The tyweights ae connected to the ‘olating sha As output speed changes, 2 change in conttga force causes the tywreigts to pvt on es aos. Te hy \weight oes act aganst 9 Beaing on te governor stom which compresses the ‘pring ang moves the stam ‘nen the proper ouput speed is achaved. a balance exists betwesn the saneg land fywelgh force Ths tance ponbons the stom to mater ne supply praeeae {achieve te requred contol possure Figure 18; C80 Principle ‘Diterental Gear output leonstant Spood Pump Mot PHM Flow Conver ‘Constant Speed trve CSD Figure 19: Governor PrincipleBasic Maintenance Training Manual Module 13 Aircraft Structures and S; toms “135 Electncal Powar (ATA 24) Integrated Drive Generator The DG converts te varying eng: accessory gearbox speeds of 4500 129.120, ‘evolutions per ina 9 constant genet speedo! 12.000 = "20 revolutions petite The genet operates a constant utp Hegeney o 400 # + ‘Variable space shat powers provided othe IDG input shat whichis direct cou Deda tne camer ana n etornta Toe vanate Saplacement avout unt ‘Scrvon oy te camer shat tact rato cf the nt speed The varani de Davement hyarauc unis nydralicaly coupes to aed ryaraule una wich Imechanicaly connected t te put ng gear of the cifras. The speed and Srecton ef tne input ng ges” = eonvalag oy an ouput spend sens ng governor ‘hich conzols ie cplacement ofthe varie Myatauic Unt ‘Speed summing is accomplished inthe diferent! by adding subtracting tm Sfesd Planet geore se used fo transmt the sped the out! tog gar ncn {oltes ata corsant speed as 3 esulof he speedsummeg. The ouut rg get 'Sengagea win te ganeatr dive gear So the ganerator alte rates a eon Figure 20; IDG Blocksiagram oer | sere oe mse a Generator Contr ge Sota tar The ganeratar sconces by the caesponding generator pustbuton When posse ita generate speed sigh evaugn fe goversor senergsed tha Eiveed paramere at ced. ine Geneat Une Conacr (L8) es Sippy te ewe Figure 21: Disconnect Mechanism The Goreraor Fel lah comes on when any generator parameters ot corect sega ‘or when the Generator Line Contactor ss open. ‘Fo “7 Sy, 106 bisconection = Incase ofl overeat o hop of ol peste, the abe IDG FAULT ight comes Wel |e Cand ne Eealt yom rtrgpered Ta acannet he IDG Hom he acess Tomtn ot I Searoor he OG susbon most be posed veneer [LL IDG Reconnection fe eee Spline | Ing, IDG dsconnectonis reverse. The syste can ny be conn on iz the Sours win engees ant own av darage he Give sat cu de mete] Use'A mechan reset anal (ng)tastoma 0G ansbes he tne tere. op) Oonected wns he engine tora on te grand 3 OTE On etre bG wan henge rig i da "CO ge he lbG aaconnneion mecsonsmy Seem cat: B2 135-14Basic Maintenance ‘Training Manual Module 19 Aircraft Structures and Systems “35 Elects Bower (ATA 28) IDG Hydraulic System Gener “Te constant spe0d die hydrate system consists of two pump ang metor ae Tesuies.» meckaniea governor 4 seavenge pump. stage and scavenge Burp, vacuum beak valve, a scavenge ee valve a a Me. pressure aie Entalisiestor_ an extemal exeutbypace va. a charge rele vas, 2 cnarge pressure switch, 8 scavenge presute sch, anda otaingdeaeratar Govern: ‘and Support The governor is a sprng-oades, tyweight operates, mysraulle contol valve whose arvng gear in mash wih te affarenbe output nna gear twougy the “Scavenge pump gear The goverma’ senses CSD cutputapeed and eonvels neo: fresie te cantelcyiner maaning a constr Opt spe 17.090 Pump and Motor Assembli ‘The lotinaed a rgh-hand pump andimotor assembles bol consi of fed Unt asa vata int The fea Um ncidee aed wobble’ pate and 3 Synge bloc wih nine pistons eper asses. The varable Ln conass oF & ‘uabie wobblor anda eyinder bios sontanns pon sipper assembles Each ump and motor assemaly aso contains a pon Ble Figure 2: Hydromechanicl Gear Train Por Pate a Spline Pesta cat 82 135-18Basic Maintenance Module 13 Aircraft Structures and Systems Training Manual 4135 Electrical Power (ATA 24) 106 Example (A320) ‘Table 4:1DG Charactristcs Votage 118200 vac Frequency 400 +S He Input Speed 44500-9120 RPM Generator Speed 12000 RPM ol Temperature The colapaing magnets fed ro {ces in the cola shot pulse or spk, of very han vtlage whose pola t= {pposie o that ofthe baer The amount nauoed vag s deters by the fate atahicn he magnetic eld cute aos the conductor The faster he Curent thenges. the great’ the induced vollage. This volape spike can Gamage any "lecronc equement connected tothe este when the mater swtsh pened Iean aso damage the master swich by causing an acto jump across fe com ‘acts a ey are opening Figure 5: Voltage spike protection by a freewheu! diode Contactor To proven this ind of damage, a reverse basedsode or reowheol code i con- rnecied szross the contactor col Dung normal speaton no eurent ean ew FRreugh t bt the high-voltage spe ta spruces when tne masts swtch opened trwarsiases the cde, andthe nduced cue fows back hrougr Me Eortator col ands dsipoted. The nduced crrentwifow me same arecton [a5 the how of curren that produced te aged hls, Split-Bus Circuits for Avionics Protection To prevent damage to aco equpment, all radio equipment shouldbe ned off before tha engine shut down, ana a cate check made tobe sure at 11s {Umnas of telore ine engine stated Mest adem aera camy 20 much ex tone equpent hat ts posse alto tum of some ystem when the crate Is sted shut down, when tha extemal power source m connected te a {at Toprevert kind of damage, moder practice so connec aloe vo fge-sonaive eectonc and avionics equipment toa seporata bus aha conic fis bus ome man bus win eifier a swich‘ype crcut Breaker or 2eay Figure 54: Switchable Avionics Power Bus Ayes #L-canmiitn BL aston ‘Te gue shows a popuar system that uses aswch-type crcutbreakr to con ‘ext avons bus tothe main bus Belo starting or hating down te engine, the pict opens he eres breaker ana allo the aiones equpment east rom the main bus Any soxes of igh woage ae abcorbed oy hebatey. an thee ro danger of damage otis equipment cat: 82 135-36Basic Maintenance Module 13 Aircraft Structures and Systems Training Manual 13:5 Electrical Power (ATA 24) Differential Current Protection Figure 88: Principle “Theresa dangercf shot cru teteen wo generator nes or ane generate ne {hd ground. Ais an insulation alr fhe generar feeders cangerous sas wi curent Trenstormer Carrent Generator Line ‘Te aifeentapctectonsrevents the damages ofthe electra wig and the generate windings between ts two detection caren ansormers. One phase ‘irentranstoemer locates sude he generator and reads he eurent ithe aitfernce between the current alte generals arth curentto the power Consumers affers @ceran amount the Generate Line Coniaclr Wi Open ahd {he gonetater excaion feds turned ot “Te tree-nle cunent ansfoimer contains 9 torial transformers one or the sch af the power feode” cables The curent warstomer sends signal Who fs ‘ropornal ote crtet ins feeder cables to Ne Generator convo unt Ife curent am the generator i ot equa tthe current wha laws othe power Coneomars that nears nee must bea fare nie the generate windings ot ‘he generator eacer abies uno binge he power rom the generator tothe pow ‘Sematon centrnsde ne aver Other Protections Incommeteial accra thre are addon elecrea protector devices nthe gen ‘rator ana power supply system such 3s (Over and under equency (ver and under votage Inconet phase sequence pen phase (Generator overions cat: 82 138-36Basic Maintenance Module 13 Aircraft Structures and Systems ‘Training Manual, “12.5 Electrical Power (ATA 24) Avionics Equipment Ventilation Figure 87: Avionics eqtipment ventilation Systm (A230 simpiies) ‘big ameunt of heat sroduced i al avoncs system has tobe taken aay fom the temperature sensitve eectones, The system ensures the veblaon of he vines equipment im order fo quaraniee a high elabily evel The main ers of auipment when ate vertated a Inthe cock 2 Dip Units (Overhead Pane! Inthe avons comparment lecvones Racks Batteries oma Sh ==, | iam S = [seen seven eons esena tn t o e + cc Bowing 58 System ‘or Outboard "The requre blowing alow ig bled rom the bina contining sytem ot + Enact Sub - System ‘The at used forthe avons equipment venta is entiacted by means of the exrac fan. The a ted ether though he undertoor sac ale ot the overboard extract vave Ensure thatthe avionics equipment ventilating system Is operating, as long the alreraft is powered ‘Damage of expensive components ora fire may occur.