Troubleshoo*ng

Aircra2 Charging Systems

by
Herb Spenner

Teaching Environment
Documents on line
Lecture, handouts, worksheets and manuals
General loca*on - hhh.gavilan.edu/hspenner
This lecture hhh.gavilan.edu/hspenner/05-16-11

Expect students to take notes - slower pace

References to class text books
Reword for beNer understanding

Topic
Solid State Voltage Regulators and Alternators
Most common solu*on
Piston engine

Not covered (because of *me limita*ons)

BaNery problems
Generators
Mechanical regulators
Turbine charging systems
Rebuild alternator
Cheaper to buy a new or rebuilt unit

Troubleshoo*ng Steps
1.
2.
3.
4.

Setup
Connec*ons
Electrical Components
Finish Up

Setup
Avionic must be turned o
Protects them from damage

Master switch On when checking voltage

Master switch O when checking
resistance
Select mul*-meter range before measuring
Secure item before running engine

Connec*ons
Check circuit breakers
If tripped, nd out why
Remind customer of Special Airworthiness
Informa*on Bulle*n (SIAB) CE 11-10
Electrical: Fire Hazard in Reseang Circuit Breakers

Check grounding straps

Refer to AC 43.13-1B 11-188
Use Low Ohm Meter (LMO) to check connec*ons
Standard mul*-meter not sensi*ve enough
See Prac*cal Low Resistance Measurement Bob
Neckolls

Connec*ons

Check all mechanical connec*ons are *ght

Cleanup all corrosion
Check for damaged insula*on
Recommend customer replace old aluminum
baNery cable
BeNer cold starts
Save money through longer component life

Check alternator belt

Insure alternator bearings work smoothly

Typical Charging System

Power Bus Bar

Alt Fld

Alt Fld
Breaker

Main
Switch

Black

Main
Solenoid

Shunt
Resister

Orange

Alt
Switch

LO/OV
Light

Alt Out
Breaker

Amp
Meter

Red

Over
Voltage
Sensor

Alt Out

BaNery

I
S

Voltage
Regulator/
ACU

A
F

ALT

Electrical Components
Voltage Tes*ng Setup (Voltage On)
Master switch (Bat & Alt) - On
Alternator eld switch On
Alternator eld and Main alternator breaker On
To generate a load, turn landing lights on

Check Amp Meter with load on

If needle deects, it is OK
If no deec*on plus voltage on connec*ons and
shunt resistor, replace meter

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 eld
shorted

If Pin F is high, check alternator

Voltage Regulator
If Pin A is low
Usually a connec*on problem

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

Check bulb and wiring

Alternator
Disconnect alternator leads and check
alternator voltage o
Check resistance between F (eld lead) and
ground connec*on
Range 3 to 6 ohms
If low, eld coil is shorted - replace alternator
If high
Service brushes and clean commutator
Resistance s*ll high, eld coil is broken - replace
alternator

Alternator
Check for open Stator by measuring resistance
between B (baNery lead) and ground
If high, stator is open and alternator needs to be
replaced

Check for shorted diode bridge

Place a mul*-meter in series with alternator B
lead to measure leakage current
If leakage current is over 0.5 ma, bridge is bad
replace alternator

Alternator
Check for open diode bridge
Power on, engine at 1500 RPM and lights on
Check AC voltage on B lead
If over 0.5 V, bridge is bad replace alternator

Alternator
Check alternator output
Install mul*-meter to measure current in to F lead
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 Regulator handout

Finish Up
Do a nal complete system test with engine
running and lights on
Charge/test baNery
Remember Diamond DA42 crash

Reinstall and *ghten all components

Clean aircra2
Return aircra2 in as-good or beNer shape than
you received it

Complete logbook entry and work order

Troubleshoo*ng Steps
1.
2.
3.
4.

Setup
Connec*ons
Electrical Components
Finish Up