DC Generation. 1. General. A. DC Generation

Transcription

1 CIRRUS AIRPLANE MAINTENANCE MANUAL DC Generation CHAPTER -0: DC GENERATION GENERAL -0: DC GENERATION 1. General (See Figure -0-1) This section covers the systems to generate, regulate, control, and indicate DC electrical power. The DC generation portion of the system includes the batteries, alternators (with internal rectifiers), and regulator. Two batteries (battery 1 and battery ) and two alternators (alternator 1 and alternator ) are used in the power generation system on this airplane. Both batteries are used for power storage. The two alternators are very similar in design to each other. The alternators and the batteries are designed to function in parallel or independently. Both alternators are self-exciting which means the alternators become energized as soon as either battery switch is moved to the on position. If an alternator becomes disconnected, the remaining alternator will still function properly, as long as the opposing alternator received initial excitation. If the alternators were initially excited from the batteries, they will continue to generate electrical power if either battery should fail. Because the alternators are self-exciting (not self-starting), the battery switches should never be turned off during flight. A. DC Generation During normal operation, the alternators feed their respective distribution bus independently (ALT 1 feeds Main Distribution Bus 1 and ALT feeds Main Distribution Bus ). The main distribution buses are interconnected by a 60-amp fuse and diode. The diode prevents ALT from feeding Main Distribution Bus 1. Additionally, since ALT voltage is slightly higher than ALT 1 voltage, bus voltage is further assured. The alternators are three-phase AC generator type; each alternator has an internal rectifier. Each alternator uses two diodes for each phase to rectify the output. In addition, these diodes will block reverse current. If a single output diode were to fail, the winding junction will be held to the output potential, reducing the quantity of current the alternator can produce. The alternators are regulated by the MCU and power the MCU via 6 AWG tin plated copper wires. Alternator 1 is protected by an 100-amp fuse within the MCU while alternator is protected by a 80-amp fuse within the MCU. ALT 1 is connected to the Main Distribution Bus 1 and ALT is connected to the Main Distribution Bus. Each alternator system has its own 5-amp alternator circuit breaker located in the circuit breaker panel. Each alternator is individually protected against overvoltage generation by the field control module, located within the MCU. ALT 1 is regulated to 8 volts and ALT is regulated to 8.75 volts. 1 Dec 016

2 CHAPTER -0: DC GENERATION GENERAL CIRRUS AIRPLANE MAINTENANCE MANUAL Voltage output of each alternator is a function of engine RPM, alternator design, and load on the alternator. During low RPM operation, the alternator will require higher engine RPM to provide the same voltage to increased electrical loads. The drop off RPM for each alternator will change whenever the electrical system loads are altered from nominal. Any time an alternator drops off line, a Crew Alerting System (CAS) message will appear on the MFD. If an alternator drops off line due to low engine RPM, the alternator can be restarted by simply increasing engine RPM. When alternator drops off line, alternator 1 will power the Essential Bus through the Main Distribution Bus 1 in the MCU. When alternator 1 drops off line, alternator will power the Essential Bus through the Main Distribution Bus in the MCU. For additional information concerning power distribution, see Electrical Load Distribution. (Refer to -50) Dec 016

3 CIRRUS AIRPLANE MAINTENANCE MANUAL Figure -0-1: Electrical System Schematic F ALT 1 B 100A CHAPTER -0: DC GENERATION GENERAL LANDING LIGHT ALT 1 RELAY ALT 1 SWITCH EXTERNAL POWER VOLT REG EXTERNAL POWER RELAY MAIN DIST BUS 1 7.5A 0A 0A 0A LANDING LIGHT SWITCH 15A BAT 1 BAT 1 SWITCH STARTER STARTER SWITCH F ALT B 5A BAT 1 RELAY STARTER RELAY 60A 80A MAIN DIST BUS 50A 50A 50A 0A 0A 0A ESSENTIAL DIST BUS 0A 0A ALT SWITCH VOLT REG MASTER CONTROL UNIT 0A NON-ESSENTIAL BUS A/C BUS A/C BUS 1 CONS CONV LIGHTS 1 AFT BUS A/C COND ALT 1 1 AFT BUS A/C COMPR CABIN FAN STARTER AVIONICS FAN 1 NAV LIGHTS STROBE LIGHTS PITOT HEAT FLAPS STALL VANE HEAT 8A 8A MAIN BUS MAIN BUS 1 AFT BUS 1 LANDING LIGHTS YAW SERVO EVS CAMERA 1V DC OUTLET MFDA AVIONICS FAN GPS NAV GIA COM ADAHRS FUEL PUMP PFD B ESSENTIAL BUS ESSENTIAL BUS 1 ICE PROTECT ALT ENGINE INSTR STALL WARNING ROLL TRIM PITCH TRIM ESSENTIAL POWER BAT GPS NAV GIA 1 COM 1 ADAHRS 1 STDBY ATTD A PFD A 0A MAIN BUS 1 AVIONICS BUS AVIONICS ICE PROTECT 1 STDBY ATTD B MFD B CABIN LIGHTS FUEL QTY AP SERVOS KEYPADS / AP CTRL CABIN AIR CONTROL DME / ADF AUDIO PANEL DATA LINK/ WEATHER XPONDER TRAFFIC MAIN CIRCUIT BREAKER PANEL AFT CIRCUIT BREAKER PANEL 1 AFT BUS 1 AFT BUS AFT BUS AFT CB SWITCH AFT CB RELAY AVIONICS SWITCH AVIONICS NON-ESSENTIAL RELAY 0A 1 NOTE Serials w/ Perception. BAT BAT SWITCH For each aft circuit breaker bus, connection is made at discretion of Perception system integrator. SR_MM_97A

4 CHAPTER -0: DC GENERATION GENERAL CIRRUS AIRPLANE MAINTENANCE MANUAL B. Alternator 1 (See Figure -0-) The front alternator (alternator 1) is mounted directly to the front of the engine on the co-pilots side. Alternator 1 is a 100-amp engine-driven alternator. Alternator 1 is controlled by the ALT 1 switch located in the bolster panel. Battery 1 and alternator 1 are independently controlled and can be alternately connected to Main Bus. Failure or malfunction of alternator 1 will not impair the capability of the main battery to provide power to Main Bus. Failure or malfunction of either or both alternators will not impair the capability of either battery to power the essential load circuits, because each of these power sources feed into the Essential Bus. If either alternator is lost, the other alternator and both batteries are still capable of feeding the Essential Bus. In addition, each alternator or battery can be manually disconnected by switching the appropriate master bolster switch located on the pilot's bolster switch panel. C. Alternator (See Figure -0-) Alternator is a 70-amp belt-driven alternator mounted to the left front of the engine. Alternator supplies electrical power to Essential Bus through a 5-amp circuit breaker located in the circuit breaker panel. Alternator is controlled by the ALT switch located in the bolster panel. If alternator fails while in operation, the Essential Bus will then get electrical power from alternator 1, battery 1, and/or battery. D. Master Control Unit (MCU) (See Figure -0-) (See Figure -0-5) The MCU is an integrated component which ensures proper electrical output over the entire temperature and RPM range of the alternator system by regulating and distributing alternator output. The MCU is mounted to the forward side of the firewall, on the pilot s side. The MCU 10 controls alternator 1, alternator, starter, landing light, and external power. The MCU provides protection for external power reverse polarity and alternator 1 and alternator overvoltage situations. The bus structure of the MCU and the circuit breaker panel allows all power devices to feed into the Essential Bus during emergencies. This action is automatic and does not require pilot intervention. The Main Distribution Bus 1 and Main Distribution Bus are separated via a diode which allows the Main Bus 1 to feed into Main Bus during failures of Alternator. The MCU used on this airplane contains a landing light relay, battery relay, ground power relay, starter Dec 016

5 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION GENERAL relay, 7.5-amp landing light fuse, three buses (one essential and two non-essential), two field control modules, three current shunts, and eight 0-amp distribution feeder fuses. The MCU regulates Alternator 1 to 8 VDC, while Alternator is regulated to 8.75 VDC which ensures the diode separates the buses during normal operation. The pilot has access to the alternator circuit breakers, which are located in the circuit breaker panel, during flight. If the system is generating more than 1.75±0.5 V, the corresponding alternator circuit breaker will open, preventing further power generation by that alternator. The MCU contains a current shunt in the battery bus. This current shunt sends a signal to the GEA 71 engine airframe unit. Diodes in the alternators block reverse current making negative current indication unnecessary. The current value displayed by the MFD corresponds directly to the quantity of power generated by the alternator system. The master switch arrangement, located in the pilot's bolster contains battery 1, battery, alternator 1, and alternator control switches. Each switch disconnects the associated device from the corresponding bus. The switches are located in a side-by-side arrangement and are labeled as to their function. The BAT switch, when closed, connects battery to the Essential Bus. This switch activates a relay located next to BAT, providing the ability to connect and disconnect battery from the aircraft. Ten power distribution buses with associated protection devices are located in the MCU. The buses are designed to ensure essential flight and avionics systems remain powered during a malfunction of any one of the buses. Eight bus wires run from the MCU, through the firewall, and to the circuit breaker panel for overload protection by fuses or circuit breakers. The eight buses are used to power the majority of aircraft loads and supply power to the circuit breaker panel. Three buses are used as distribution feeders from the Main Distribution Bus 1. Three buses are used as distribution feeders from the Main Distribution Bus. Two buses are used as distribution feeders from the Essential Distribution Bus. One bus is used to power the landing light directly from the Main Distribution Bus 1 through a 7.5 amp fuse. One bus is used to power the constant power devices including the interface between the CAPS and the ELT system which is fused at 5 amperes and is not controlled by master switch arrangement. Alternator power flows from alternators into the MCU. Inside the MCU is where the field control module regulates alternators output. Each field control module provides transient suppression and constant voltage regulation of unfiltered alternator power. To protect sensitive instruments, the over-voltage protection system monitors the primary power bus and automatically limits peak voltage to approximately 1.75 volts. Each field control module will cause the corresponding alternator circuit breaker to open in cases of field output overloads, and overvoltage. In the event an over-voltage condition occurs, the corresponding field control module automatically removes alternator field current to shut down the corresponding alternator. Each field control module has been integrated into the MCU case, for durability and reliability. 5 Dec 016

6 CHAPTER -0: DC GENERATION GENERAL CIRRUS AIRPLANE MAINTENANCE MANUAL E. Low Volts Warning Light All annunciations are displayed on the MFD as part of the Crew Alerting System (CAS). If the Essential Bus voltage drops to approximately.5 volts, the GEA 71 engine airframe interface will cause the LOW VOLTS warning light to illuminate on the MFD. Resetting the ALT 1 and ALT switches (from off and back on again) may reset the field control module within the MCU. If the warning light does not illuminate again, normal alternator charging has resumed. If the light illuminates again, a malfunction has occurred. The LOW VOLTS annunciator will illuminate regardless of how many or what types of power sources are connected. Illumination of the LOW VOLTS warning light along with ammeter discharge indications may occur during low RPM conditions with an electrical load on the system, such as during a low RPM taxi. Under these conditions, the light will go out at higher RPM. The battery switches will not need to be recycled since an over-voltage condition has not occurred to de-activate the alternator system. F. ALT 1 and ALT Fail Lights All annunciations are displayed on the MFD as part of the Crew Alerting System (CAS).The GEA 71 engine airframe interface will cause the ALT 1 and ALT warning light to illuminate on the MFD. If either alternator generates less than amps (approximately), a yellow alert will illuminate on the MFD. If either alternator becomes overloaded, a green alert will illuminate on the MFD. G. Volt and Ampere Meter (See Figure -0-6) Main and Essential Bus voltages are shown graphically and as text in the electrical data field located in the mid-right section of the MFD and are also continuously displayed in the voltage parameters field located in the mid-left corner of the PFD. The MFD and PFD receive the voltage signals via the GEA 71 engine airframe interface as measured directly off the Main and Essential Buses. In the event Main Bus voltage is less than.5v or exceeds.0v the MFD will display Check Main Bus in a yellow advisory box in the lower right corner of the MFD. In the event Essential Bus voltage is less than.5v or exceeds.0v the MFD will display Check Essential Bus in a red advisory box in the lower right corner of the MFD. Alternator 1, Alternator, and Battery 1 ampere output are shown graphically and as text in the electrical data field located in the mid-right section of the MFD. The MFD and PFD receive the amp signals via the GEA 71 engine airframe interface as derived from current shunts located in the MCU. In the event Alternator 1 or Alternator ampere output is less than amps for 0 seconds or more, the MFD will display a CAS warning on the MFD. 6 Dec 016

7 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION GENERAL 8 VDC for the digital instrument operation is supplied through the -amp ENGINE INSTR circuit breaker on Essential Bus. H. Battery 1 (See Figure -0-7) Battery 1 is a -volt, valve regulated, lead-acid aviation-grade type battery. The battery is mounted in the engine compartment. The battery is used for engine starting and can also be used as an emergency power source in the event Battery or either alternator fails. Battery 1 provides all the electrical power for starting the aircraft. Battery 1 also supplies the electrical power to the landing light in the event Alternator 1 fails. Battery 1 is independently controlled by the BAT 1 switch, located in the pilot s bolster panel. The BAT 1 switch energizes a relay in the MCU which will connect BAT 1 to the Main Distribution Bus. I. Battery (See Figure -0-8) Battery is a maintenance free rechargeable sealed lead acid battery. The battery consists of two 1-volt, 6-cell, 7-amp-hour batteries connected in series to provide -VDC to the Essential Bus. There is no need to check the specific gravity of the electrolyte or add water to these batteries during their service life. Battery is independently controlled by using the BAT switch, located in the pilot s bolster panel. The BAT switch energizes a relay located just aft of bulkhead in the MCU which will connect BAT to the Essential Bus. The electrical power from BAT reaches the Essential Bus through the circuit breaker panel. Battery is mounted directly behind bulkhead in an acid resistant battery container. Battery is primarily used to power the Essential Bus. The Essential Bus delivers electrical power to the annunciator lights, attitude indicator, stall warning system, and alternator. Failure of the BAT 1 will not affect the ability of BAT to provide necessary power to the Essential Bus. Because of diode protection, a failure or malfunction of the BAT 1 will not affect BAT or either alternator output. NOTE Prior to engine start-up, the pilot must activate only the BAT switch to verify that BAT properly energizes the electrical loads powered by the Essential Bus and that BAT has proper voltage. The voltage is displayed by the MFD and PFD. 7 Dec 016

8 CHAPTER -0: DC GENERATION. Maintenance Practices CIRRUS AIRPLANE MAINTENANCE MANUAL A. Alternator 1 (See Figure -0-) (1) Removal - Alternator 1 (a) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (b) Remove engine cowling. (Refer to 71-10) (c) Disconnect battery 1. (Refer to -0) (d) Disconnect cables and wires from alternator terminals. (e) Remove nuts and washers securing alternator to engine. Remove alternator from airplane. (f) Discard old gasket and remove residual gasket material from alternator and engine. () Disassembly - Alternator 1 (a) Refer to the manufacturer s approved Instructions For Continued Airworthiness for alternator inspection and maintenance. () Assembly - Alternator 1 (a) Refer to the manufacturer s approved Instructions For Continued Airworthiness for alternator inspection and maintenance. () Installation - Alternator 1 (a) (b) Position alternator and new gasket to engine. Hand tighten washers and nuts in an alternating pattern securing alternator to engine. Torque nuts 180 to 0 in-lb (0. to.8 Nm) in an alternating pattern. (Refer to 0-60) CAUTION Cable shielding could be installed to the Power and/or Field wire harness. If installed, attach cable shielding wire(s) to 8

9 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION ground terminal on alternator. Do not install cable shielding wire(s) to AUX power terminal. (c) Connect cables and wires to alternator terminals. (d) Connect battery 1. (Refer to -0) (e) Install engine cowling. (Refer to 71-10) 9

10 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL Figure -0-: Alternator NOTE Torque nut to in-lbs ( Nm). 11 DETAIL 1 A LEGEND 1. Alternator, 100 Amp. Nut. Lock Washer. Washer 5. Gasket 6. Cable 7. Ground Strap 8. Bolt 9. Screw 10. Power Terminal 11. Terminal Cover 1. Terminal Cover Retainer SR_MM_ 10

11 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION B. Alternator (See Figure -0-) (1) Removal - Alternator (a) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (b) Remove engine cowling. (Refer to 71-10) (c) Disconnect battery 1. (Refer to -0) (d) Remove screws and washers securing alternator baffling. (e) Loosen upper alternator mounting bolt and belt tension adjustment bolt. (f) Remove drive belt from alternator pulley. (g) Remove bolts and washers securing alternator lower mounting boss to engine. (h) Remove bolt, washers, and nut securing alternator upper mounting boss to engine. Remove alternator from airplane. (i) Identify and disconnect wires from alternator terminals. () Installation - Alternator (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Borroughs Belt Tension Gauge BT--7F (or equivalent) Any Source Set belt tension. (b) (c) (d) (e) (f) (g) Connect alternator wires to appropriate terminals. Position alternator upper mounting boss to engine bracket and loosely secure with bolt, washers, and nut. Position alternator lower mounting boss to engine bracket and secure with bolts and washers. Position belt over alternator pulley. Using belt tension gauge, set belt tension at center of span between drive sheave and alternator to 50 to 70 lb ( to kg) of belt tension. The belt should deflect no more than 0.11 inch (.79 mm) with a 5 lb (. kg) load. Re-tension after 5 hours of operation. Torque upper alternator mounting bolt 00 to 50 in-lb (5.1 to 50.8 Nm). (Refer to 0-60) 11

12 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL (h) Torque lower alternator mounting bolt and belt tension adjustment bolt 00 to 75 in-lb (.6 to 1.0 Nm). (Refer to 0-60) (i) Install screws and washers securing alternator baffling. (j) Connect battery 1. (Refer to -0) (k) Install engine cowling. (Refer to 71-10) 1

13 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION Figure -0-: Alternator 6 BRACKET (REF) 5 CABLE (REF) CABLE (REF) 9 NOTE Torque bolt to in-lbs ( Nm). Torque bolt to in-lbs ( Nm) LEGEND 1. Alternator. Bolt. Washer. Nut 5. Drive Sheave 6. Sheave Adapter 7. Pulley 8. Mounting Boss 9. Drive Belt 10. Terminal Cover 11. Terminal Cover Retainer SR_MM_ 1

14 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL C. Master Control Unit (See Figure -0-) The MCU is field repairable to the extent provided for in Chapter -00, Electrical Power Troubleshooting. (Refer to -00) Field repair is limited to replacing the following components: current sensors, logic module, fuses, and field control modules. The MCU part number may be determined from a placard located on the MCU chassis. (1) Removal - Master Control Unit (a) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (b) Remove engine cowling. (Refer to 71-10) (c) Disconnect battery 1. (Refer to -0) (d) Remove nuts and washers securing grounding strap to MCU chassis. (e) Disconnect P180, P181, P18, and P18 connectors. (f) Remove nuts and washers securing starter cable assembly to bus bar stud. (g) Remove nuts and washers securing alternator 1 cable assembly to bus bar stud. (h) Remove nuts and washers securing battery 1 cable assembly to bus bar stud. (i) Remove nuts and washers securing alternator cable assembly to bus bar stud. (j) Remove bolts and washers securing MCU to firewall. Remove MCU from airplane. () Installation - Master Control Unit (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose High Temperature Silicone Sealant RTV 76 Dow Corning Sealant. (b) (c) (d) (e) Position MCU to firewall and secure with bolts and washers. Apply sealant over bolt heads. Install washers and nuts securing alternator cable assembly to bus bar stud. Install washers and nuts securing battery 1 cable assembly to bus bar stud. Install washers and nuts securing alternator 1 cable assembly to bus bar stud. 1

15 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION (f) Install washers and nuts securing starter cable assembly to bus bar stud. (g) Connect P180, P181, P18, and P18 connectors. (h) Connect battery 1. (Refer to -0) (i) Perform Operational Inspection - Master Control Unit. (Refer to -0) (j) Install engine cowling. (Refer to 71-10) () Operational Inspection - Master Control Unit WARNING In order to perform the following check the engine must be operating. Do not stand or let anyone else stand close to the arc of the airplane s propeller while conducting this check. (a) (b) (c) Verify all circuit breakers are set. Toggle BAT switch to ON position and verify the following occurs: 1 Flap position light off. Serials w/o MD0 Standby Attitude Module: Standby attitude gyro low voltage flag hidden. Serials w/ MD0 Standby Attitude Module: MD0 Standby Attitude Module powers up. PFD powers up. 5 MFD is off. 6 Essential Bus voltage (indicated on PFD) is to 6 volts. 7 ALT 1 and ALT caution annunciations on PFD. Toggle BAT 1 switch to ON position and verify the following occurs: 1 Flap position light illuminates. MFD powers up. Pull PFD A circuit breaker and verify PFD remains on. Reset PFD A circuit breaker. 5 Serials w/o MD0 Standby Attitude Module: Pull STDBY ATTD A circuit breaker and verify standby attitude gyro voltage flag remains hidden. 6 Serials w/ MD0 Standby Attitude Module: Pull STDBY ATTD A circuit breaker and verify MD0 Standby Attitude Module remains powered up. 7 Reset STDBY ATTD A circuit breaker. 8 Pull MFD B circuit breaker and verify MFD remains on. 9 Reset MFD B circuit breaker. 10 Switch on Landing Light and verify Landing Light illuminates. 11 Switch off Landing Light. 15

16 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL 1 Serials w/ Fan or Air Conditioning: Turn on Cabin Fan and verify fan is on. 1 Serials w/ Fan or Air Conditioning: Turn off Cabin Fan. 1 ALT 1 and ALT caution annunciations on PFD. 15 BAT 1 current indicator shows slight discharge. (d) Start Engine and set engine speed at 1000 RPM. (e) Switch ALT 1 ON and ALT ON. (f) Verify landing light, pitot heat, avionics, strobe lights, and navigation lights are on. (g) Increase RPM to (h) Check that BAT 1, ALT 1, ALT, ESS BUS, M BUS 1, and M BUS caution and warning annunciations are off. (i) Increase RPM to 00. (j) Check that BAT 1, ALT 1, ALT, ESS BUS, M BUS 1, and M BUS caution and warning annunciations are off. (k) Switch ALT 1 ON and ALT OFF. Verify and record operating values from MFD. Bus Volts (V) Current (A) ESS M1 M ALT 1 ALT BAT 1 = M1-0.7 (±0.) 7.0V - 8.V = M1-0.7 (±0.) A - 7A 0A 0 - Pos (l) Switch ALT 1 OFF and ALT ON. Verify and record operating values from MFD. Bus Volts (V) Current (A) ESS M1 M ALT 1 ALT BAT 1 = M (±0.) V - 6V 8.1V - 9.1V 0A A - 50A Neg - 0 (m) Switch ALT 1 ON and ALT ON. Verify and record operating values from MFD. Bus Volts (V) Current (A) ESS M1 M ALT 1 ALT BAT 1 = M (±0.) 7.0V - 8.V 8.1V - 9.1V Pos < 7A A - 50A 0 - Pos (n) Switch ALT 1 OFF and ALT OFF. Verify and record operating values from MFD. 16

17 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION Bus Volts (V) Current (A) ESS M1 M ALT 1 ALT BAT 1 V - 6V V - 6V = M1-0.7 (±0.) 0A 0A Neg - 0 (o) Shut down engine. () Inspection/Check - Master Control Unit (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose High Temperature Silicone Sealant Cotton Cloth (clean and lint free) RTV 76 Dow Corning Sealant. - Any Source General Cleaning. Isopropyl Alcohol 99% or higher purity Any Source Solvent clean. Corrosion Inhibitor (aerosol) MIL-C-8109 Type III Any Source Prevent corrosion. (b) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (c) Remove engine cowling. (Refer to 71-10) (d) Disconnect battery 1. (Refer to -0) (e) Remove MCU cover. (Refer to -0) (f) Visually inspect inside MCU for evidence of water. If water if found, dry MCU and components with a clean cotton cloth. NOTE Evidence of surface corrosion does not require replacement of MCU components. If corrosion is found, verify MCU operation by performing Operational Inspection - Master Control Unit. 17

18 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL (g) Apply corrosion inhibitor as follows: 1 Cover surrounding components and structures to prevent inadvertent application of corrosion inhibitor to these areas. Apply a thin coat of corrosion inhibitor to MCU circuit board, internal components, and connectors per the manufacturer s instructions. (h) Verify security of MCU chassis to firewall. (i) Visually inspect cable assemblies and connector wires for chafing and security. (j) Install MCU cover. (Refer to -0) (k) Connect battery 1. (Refer to -0) (l) Install engine cowling. (Refer to 71-10) 18

19 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION Figure -0-: MCU FIREWALL (REF) P18 (REF) 7 P180 (REF) 10 5 P18 (REF) P181 (REF) 1 11 DETAIL A LEGEND 1. Master Control Unit (MCU). Bolt. Washer. Lock Washer 5. Starter Cable 6. Battery 1 Cable 7. Alternator 1 Cable 8. Alternator Cable 9. Ground Cable 10. Nut 11. Wire Loom 1. Cable Tie SR_MM_5 19

20 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL D. MCU Cover (See Figure -0-5) (1) Removal - MCU Cover (a) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (b) Remove engine cowling. (Refer to 71-10) (c) Disconnect battery 1. (Refer to -0) (d) Remove screws securing MCU cover to chassis. Remove MCU cover. () Installation - MCU Cover (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Corrosion Inhibitor (aerosol) MIL-C-8109 Type III Any Source Prevent corrosion. (b) Apply corrosion inhibitor as follows: 1 Cover surrounding components and structures to prevent inadvertent application of corrosion inhibitor to these areas. Apply a thin coat of corrosion inhibitor to MCU circuit board, internal components, and connectors per the manufacturer s instructions. (c) Position MCU cover to chassis and secure with screws. (d) Connect battery 1. (Refer to -0) (e) Install engine cowling. (Refer to 71-10) E. Midi Fuse (See Figure -0-5) The midi fuses, integral to the MCU, are installed in two locations on the power board assembly. 0

21 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION (1) Removal - Midi Fuse (a) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (b) Remove engine cowling. (Refer to 71-10) (c) Disconnect battery 1. (Refer to -0) (d) Remove MCU cover. (Refer to -0) (e) Remove screws and washers securing fuse to power board assembly. () Installation - Midi Fuse (a) Position fuse to power board assembly and secure with screws and washers. (b) Install MCU cover. (Refer to -0) (c) Connect battery 1. (Refer to -0) (d) Perform Operational Inspection - Master Control Unit. (Refer to -0) (e) Install engine cowling. (Refer to 71-10) F. Blade Fuse (See Figure -0-5) The blade fuses, integral to the MCU, are installed in 1 locations on the power board assembly. (1) Removal - Blade Fuse (a) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (b) Remove engine cowling. (Refer to 71-10) (c) Disconnect battery 1. (Refer to -0) (d) Remove MCU cover. (Refer to -0) (e) Remove blade fuse from fuse holder. () Installation - Blade Fuse (a) Insert blade fuse into fuse holder. 1

22 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL (b) Install MCU cover. (Refer to -0) (c) Connect battery 1. (Refer to -0) (d) Perform Operational Inspection - Master Control Unit. (Refer to -0) (e) Install engine cowling. (Refer to 71-10) G. External Fuse (See Figure -0-5) The external fuse, integral to the MCU, is located on top of the MCU chassis. (1) Removal - External Fuse (a) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (b) Remove engine cowling. (Refer to 71-10) (c) Remove external fuse from fuse holder assembly. () Installation - External Fuse (a) Insert external fuse into fuse holder assembly. (b) Perform Operational Inspection - Master Control Unit. (Refer to -0) (c) Install engine cowling. (Refer to 71-10) H. Field Control Module (See Figure -0-5) The ALT 1 and ALT field control modules are integral to the MCU. The ALT 1 field control module is located on the upper chassis. The ALT field control module is located on the lower, RH side of chassis. (1) Removal - Field Control Module (a) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (b) Remove engine cowling. (Refer to 71-10) (c) Disconnect battery 1. (Refer to -0)

23 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION (d) Remove MCU cover. (Refer to -0) (e) Disconnect wire harness from field control module. (f) Remove nuts securing field control module to chassis. Remove field control module from airplane. () Installation - Field Control Module (a) Position field control module to chassis and secure with nuts. (b) Connect wire harness to field control module. (c) Install MCU cover. (Refer to -0) (d) Connect battery 1. (Refer to -0) (e) Perform Operational Inspection - Master Control Unit. (Refer to -0) (f) Install engine cowling. (Refer to 71-10)

24 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL Figure -0-5: MCU Components - Serials w/ Perspective+ Avionics DETAIL A LEGEND 1. Master Control Unit (MCU). Screw. Washer. Nut 5. Midi Fuse 6. Blade Fuse 7. External Fuse 8. ALT 1 Field Control Module 9. ALT Field Control Module 10. MCU Cover 11. Gasket SR_MM_6

25 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION I. Low-Volts Warning Light (Refer to 1-50) J. ALT 1 and ALT Fail Lights (Refer to 1-50) K. Volt / Amp Meter (See Figure -0-6) NOTE Voltage and amperage are displayed on the screens of the MFD and PFD. (1) Operational Test - Volt / Amp Meter (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Set BAT 1 and AVIONICS switches to ON positions. Verify BAT 1 current indicates between 0 and 10 amps. Verify Essential Bus voltage indicates 6± VDC. Verify Main Bus 1 voltage indicates 6± VDC. Verify Main Bus voltage indicates 6± VDC. Verify ALT 1 indicates zero amps. Verify ALT indicates zero amps. Turn on large electrical loads (landing light, navigation lights, pitot heat, etc.) to ensure more amps are drawn when larger electrical loads are introduced. Verify ammeter indicates an increase in amperage. Set BAT 1 and AVIONICS switches to OFF positions. 5

26 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL Figure -0-6: Amp Meter Indication 1 % Pwr RPM 0 Man "Hg 0.0 F L R 1.0 Gal FFlow GPH Gal Used 1.6 Oil F 15 Oil PSI Batt 1 A Ess Bus V TAS 10 KT 9.0 AFCS TRAFFIC HDG T 0 KT E GPS TERM S 1 CRS 187 V BARO MIN 110 FT IN ALT ALT 1 FUEL QTY M BUS M BUS CHT F 0 XTK 1.01NM N W EGT F 1610 ENGINE 0 PFD w/ ENGINE DISPLAY 1 Anti Ice - TKS L R Time Rem (H+MM) MAX 0+00 High Norm Gal 0.0 Range NM Density Alt 8000 Ft Oat 1 F -1 C (ISA +0 C) MFD w/ ENGINE DISPLAY LEGEND 1. Amp Meter SR_MM_7 6

27 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION L. Battery 1 (See Figure -0-7) (1) Removal - Battery 1 WARNING All electrical circuits must be off, prior to disconnecting battery cables. Always remove the negative battery cable first, then the positive cable. Insulate cable ends and battery terminals to prevent accidental re-connection. Remove all jewelry before servicing the battery. Metal objects may fuse to electrical connections and cause severe burns. Wear face shield and protective clothing when servicing battery and/or handling electrolyte. Neutralize electrolyte spills with a solution of baking soda and water, then rinse with clean water. NOTE The battery box should be washed out thoroughly and dried each time the battery is removed. Use a non-metallic bristle brush to clean the battery. The battery vent hose should be inspected periodically for obstructions. (a) To disconnect battery 1: 1 Verify ignition switch is in OFF position and remove the key. Set BAT 1, BAT, and AVIONICS switches to OFF positions. Pull BAT circuit breaker. Remove upper engine cowling. (Refer to 71-10) CAUTION After battery disconnection, insulate cable ends and battery terminals to prevent accidental connection. 5 Remove negative battery cable from battery terminal. 6 Remove positive battery cable from battery terminal. 7 Insulate cable ends and battery terminals. (b) To remove battery 1: 1 Remove bolts and washers securing hold-down bracket to battery mounting tray. Remove battery hold-down bracket and battery from airplane. 7

28 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL () Installation - Battery 1 (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Bicarbonate of Soda (baking soda) - Any Source Neutralize electrolyte. Contact Cleaner - Any Source Clean terminals. Acid Resistant Bristle Brush (non-metallic) - Any Source Clean terminals. Petroleum Jelly VV-P-6 Any Source Prevent corrosion. (b) To install battery 1: 1 Rinse battery with fresh water and wipe clean with a dry cloth. Visually inspect battery box for corrosion and spilled electrolyte. CAUTION Do not allow bicarbonate of soda to enter battery cells or permanent battery damage will result. If necessary, clean battery with a solution of bicarbonate of soda and clean water. Using contact cleaner and bristle brush, remove dirt and corrosion from battery terminals. CAUTION Ensure hold-down bracket is installed to prevent damage to battery. 5 Install battery into battery mounting tray, and position battery hold-down bracket to top of battery. 6 Install bolts and washers securing battery hold-down bracket to battery mounting tray. Torque bolts 10 in-lb (1.1 Nm) greater than accepted nut drag. Maximum torque not to exceed 5 in-lb (5.1 Nm). (Refer to 0-60) (c) To connect battery 1: CAUTION Connecting cables in reverse (positive to negative and negative to positive) can cause serious damage to the electrical system. Connect the negative cable last. 1 Connect positive battery cable to positive terminal. Connect negative battery cable to negative terminal. To prevent corrosion, apply petroleum jelly to battery terminals. 8

29 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION Install engine cowling. (Refer to 71-10) 5 Reset BAT circuit breaker. 6 Verify operation of electrical system. () Inspection/Check - Battery 1 Capacity NOTE A fully charged battery is considered serviceable if it meets 85% of the nominal rated capacity (C1) shown on the label. (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose -Volt Battery Capacity Tester - Any Source Test battery condition. (b) Verify ignition switch is in OFF position and remove the key. (c) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (d) Pull BAT circuit breaker. (e) Remove battery 1. (Refer to -0) (f) Perform capacity test as instructed by the manufacturer. (Refer to 5-00) (g) If battery fails capacity test, replace battery. (h) Install battery 1. (Refer to -0) (i) Reset BAT circuit breaker. () Inspection/Check - Battery 1 Charging If the airplane is parked for long periods of time, the battery may become discharged. The battery may be recharged using a constant potential charger. CAUTION Do not charge battery in airplane or within 10 feet of a fuel servicing area. (a) Acquire necessary tools, equipment, and supplies. 9

30 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL Description P/N or Spec. Supplier Purpose Battery Charger (constant potential) 1 Advanced Power Products Charge Battery 1. CAUTION Some battery chargers will destroy the battery. Contact manufacturer for determination of equivalent equipment. (b) Verify ignition switch is in OFF position and remove the key. (c) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (d) Remove battery 1. (Refer to -0) (e) Ensure battery charger is turned off. (f) Connect battery charger positive lead to positive terminal. (g) Connect battery charger negative lead to negative terminal. (h) Set battery charger switch to ON position. (i) Charge battery at 8. volts constant potential until charge current stabilizes for 1 hour. (j) Set battery charger switch to OFF position. Unplug battery charger. (k) Disconnect battery charger negative lead. (l) Disconnect battery charger positive lead. (m) Install battery 1. (Refer to -0) 0

31 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION Figure -0-7: Battery 1 FIREWALL (REF) LEGEND 1. Battery. Bolt. Washer. Battery Cable, Ground 5. Nut 6. Battery Mounting Tray 7. Battery Cable, Power 8. Hold-Down Bracket 9. Adel Clamp SR_MM_8 1

32 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL M. Battery (See Figure -0-8) (1) Removal - Battery CAUTION All electrical circuits must be off, prior to disconnecting battery cables. If battery becomes damaged and electrolyte is spilled, neutralize the spill immediately with a solution of baking soda and water, then rinse with clean water. (a) Verify ignition switch is in OFF position and remove the key. (b) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (c) Remove access panel RE. (Refer to 6-00) (d) Disconnect vent hose from battery enclosure. (e) Remove cable ties securing wire harness service loop to empennage. (f) Remove screws, washers, and spacers securing battery enclosure to mounting tray. (g) Position battery enclosure near access panel opening. (h) Remove screws, washers, and nuts securing upper battery enclosure to lower battery enclosure. (i) Disconnect negative battery cables from battery terminals. (j) Disconnect positive battery cables from battery terminals. (k) Remove batteries from lower enclosure. (l) CAUTION Do not use abrasive cleaners or materials to clean battery terminals. Visually inspect battery terminals for dirt or corrosion. Clean or replace terminals as necessary. () Installation - Battery (a) (b) (c) Position batteries to lower battery enclosure. Connect positive battery cables to battery terminals. Connect negative battery cables to battery terminals.

33 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION (d) (e) (f) (g) Position upper battery enclosure to lower battery enclosure and secure with screws, washers, and nuts. Position battery enclosure to mounting tray and secure with screws, washers, and spacers. Position wire harness service loop to fuselage and secure with cable ties. Connect vent hose to battery enclosure. (h) Install access panel RE. (Refer to 6-00) () Inspection/Check - Battery Top-Charging The battery will discharge at approximately % per month when storage temperature is maintained at 68 F (0 C). Self-discharge rate will vary with storage temperature and the remaining capacity. If the battery is going to be stored for extended periods of time, the battery should be top-charged periodically with a constant-voltage charger. CAUTION Do not charge batteries in airplane or within 10 feet of a fuel servicing area. (a) Acquire necessary tools, equipment, and supplies. (b) Verify ignition switch is in OFF position and remove key. (c) Set BAT 1, BAT, and AVIONICS switches to OFF positions. (d) Remove battery. (Refer to -0) (e) Ensure battery charger is turned off. (f) Connect battery charger positive lead to positive terminal. (g) Connect battery charger negative lead to negative terminal. (h) Set battery charger switch to ON position. (i) (j) Description P/N or Spec. Supplier Purpose Battery Charger (constant-voltage) Volt Any Source Charge Battery. CAUTION In higher temperature areas, the battery should be charged at the lower voltage of.5 volts per cell. Charge battery at a rate of.5 to.7 volts per cell (each battery has 6-cells). Set battery charger switch to OFF position. Unplug battery charger.

34 CHAPTER -0: DC GENERATION CIRRUS AIRPLANE MAINTENANCE MANUAL (k) Disconnect battery charger negative lead. (l) Disconnect battery charger positive lead. (m) Install battery. (Refer to -0)

35 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER -0: DC GENERATION Figure -0-8: Battery LEGEND 1. Battery. Washer. Nut. Bracket 5. Mounting Tray 6. Battery Enclosure, Lower 7. Seal 8. Screw 9. Relay 10. Vent Tube 11. Circuit Breaker 1. Bulkhead Fitting 1. Connector 1. Cable Tie 15. Cable Tie Anchor 16. Grommet 17. Battery Enclosure, Upper 18. Tab Washer 19. Spacer 0. Bolt DETAIL A SR_MM_9 5

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