PDC PROPELLER DE-ICE CONTROLLER

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1 PDC PROPELLER DE-ICE CONTROLLER OPERATIONAL & INSTALL MANUAL Updated: 14 October 2016 Copyright 2016 by VR Avionics

2 Inc. All rights reserved. This User and Installation Guide and the information contained herein is the proprietary data of VR Avionics. No part of this manual may be reproduced, copied, transmitted, disseminated or stored in any storage medium, for any purpose without the express written permission of VR Avionics, Inc. VR Avionics hereby grants permission to download a single copy of this manual and of any revision to this manual onto a hard drive or other electronic storage medium to be viewed for personal use, provided that such electronic or printed copy of this manual or revision must contain the complete text of this copyright notice and provided further that any unauthorized commercial distribution of this manual or any revision hereto is strictly prohibited. Information in this document is subject to change without notice. VR Avionics reserves the right to change or improve its products and to make changes in the content without obligation to notify any person or organization of such changes. Visit the VR Avionics website ( for current updates and supplemental information concerning the use and operation of this and other VR Avionics products. VR Avionics page 2 of 21

3 Table of Contents Introduction...4 System Options...4 Operation...5 Master On (Power-up)...5 Prop Heat Off...5 Prop Heat On...5 Prop Heat On with Fault...6 Prop Heat On First Cycle...7 Installation...8 Slip-Ring Assembly...8 Mounting the Module...8 Electrical Wiring...9 Parts and Tools...9 Electrical Wiring Practices...10 Firewall Forward Power Circuit...11 Firewall Aft Selection & Indication Circuit...13 Maintenance Interface...15 Configuration...16 Introduction...16 Configuration Settings...16 Unit Reference (location)...16 Operation (1:On/Off, 2:High/Low/Off, 3:Alt-On/Off)...16 Combining Outputs for Single Phase Application...16 Enable On-light blinking code according to phase states...16 Low Heat Phase A On-time (seconds)...16 Low Heat Phase B On-time (seconds)...16 Low Heat Phases Off-time (seconds)...17 High Heat Phase A On-time (seconds)...17 High Heat Phase B On-time (seconds)...17 High Heat Phases Off-time (seconds)...17 Working Current Range: Minimum (Amp)...17 Working Current Range: Maximum (Amp)...17 Current (Amp) Calibration...17 Voltage Calibration...18 Low Heat Cycle Count...18 High Heat Cycle Count...18 Fault Code Remembered (for troubleshooting)...18 SetView Software...19 Introduction...19 System Requirements...19 SetView download and Installation...19 Using SetView...19 Viewing and recording parameters...20 Synchronizing with the system...20 Sharing files via Adjusting the Configuration...21 page 3 of 21

4 Introduction This manual describes the installation and operation of the propeller de-ice controller (PDC). System Options The PDC can work standalone or be part of a larger VRX system, in which case this manual must be read in conjunction with the relevant VRX Operational & Installation manual. The diagram below shows how functionality may be expanded. With a VRX multi-function display (MFD) you will obtain a dedicated PDC page as shown to the right. This manual will assume that the user have updated his PDC firmware to version 2.3 or later. You can easily do this by using the SetView program or a VRX multifunction display (MFD). There are two versions of the PDC. The new version II PDC can be recognized by its 13 pin electrical connector with three high-power contacts. The earlier version I PDC has a 25 pin connector with no high-power contacts. Functioning is the same and they run the same firmware. This manual will cover both units. For the general specifications including PDC unit dimensions you can read the PDC Specification Sheet. It covers both versions of the PDC. page 4 of 21

5 Operation Here we describe the PDC propeller de-icing system operation. Master On (Power-up) When at first power is applied both lights (Heat On and Heat Fail) will light up for 3 seconds before going out. If both lights do not light-up during this time it usually indicates a faulty lamp. If Heat Fail remains on after the 3 seconds have passed, power should be turned off (master off) and the system checked out. Both phase A and B are off during the 3 seconds, thereafter the system is ready for use. Prop Heat Off With the selection switch in the Off position, all outputs (phase A and phase B) are off. The PDC will turn off both annunciation lights (Heat On and Heat Fail) to confirm the off-line status. Prop Heat On With Operation = Off/On switching heat selection to On will turn on propeller heating. With Operation = Off/Low/High switching heat selection to either High or Low will turn on propeller heating. The Heat On light will turn on to confirm the on-line status. Turning on propeller heating will immediately start a new heating cycle except if that would result in the max duty cycle to exceed, in which case the start of the heating cycle is delayed until the max duty limit will be met. The max duty cycle is calculated using the High Heat Phase A On-time, the High Heat Phase B On-time and the High Heat Phases Off-time configuration settings. If outputs are not combined (Combining Outputs = 0) a heating cycle executes as follows: 1. Only Phase A is powered for the High Heat Phase A On-time time period unless the heat selection switch is on Low and Operation = Off/Low/High, in which case Phase A is powered for the Low Heat Phase A On-time time period. 2. Only Phase B is powered for the High Heat Phase B On-time time period unless the heat selection switch is on Low and Operation = Off/Low/High, in which case Phase B is powered for the Low Heat Phase B On-time time period. 3. Both Phase A and B are turned off for the High Heat Phases Off-time time period unless the heat selection switch is on Low and Operation = Off/Low/High, in which case Phase B is powered for the Low Heat Phases Off-time time period. If outputs are combined (Combining Outputs = 1) a heating cycle will execute as follows: 1. Both Phase A and B are powered for the sum of High Heat Phase A On-time and High Heat Phase B On-time time period unless the heat selection switch is on Low and Operation = Off/Low/High, in which case both Phase A and B are powered for the sum of Low Heat Phase A On-time and Low Heat Phase B On-time time period. 2. Both Phase A and B are turned off for the High Heat Phases Off-time time period unless the heat selection switch is on Low and Operation = Off/Low/High, in which case both Phase A and B are turned off for the Low Heat Phases Off-time time period. page 5 of 21

6 If no fault is detected during any stage of a cycle, the Heat Fail light will stay off. The Heat On light will however be turned on except for a few blinks when the cycle transitions from one state to another. For example, if Enable On-light blinking code according to phase states is enabled, the Heat On light will blink as follows: Heat On Cycle State Phase A Phase B Phases Off Phase A Should Enable On-light blinking code according to phase states be disabled however, the Heat On light will blink according to the heating cycle selected either High heat (two blinks) or Low heat (one blink) at every state transition. Prop Heat On with Fault While executing a heating cycle the PDC will continuously check for faults. The phase A circuit is checked independently from the phase B circuit. Should a fault be detected on either or both phases, the Heat Fail light will be turned on, while repeatedly blinking either once or twice. Once if only one phase has a fault and twice if both phases have faults. In the example below Heat Fail blinks twice every few seconds, thus indicating faults exists on both phases. Heat Fail Heat On < 2.5 seconds > As shown above in addition to the Heat Fail light coming on, the Heat On light will also blink on and off (once a second) while any fault remains. The PDC checks for the following faults for each output phase: No power on the POWER1 input. It could be that the circuit-breaker as shown in Power Circuit is open. The PDC will thus not be able to supply any power to the boots both phases are affected. A phase output short-circuits to ground. This is detected when attempting to turn a phase on. The fault is latched - the PDC will henceforth not attempt to turn this phase on again unless power is cycled. A component or circuit fault within the PDC itself is detected. This can affect one or both phases. This unit should be sent for repair. The current (Amps) measured on a phase does not fall within the expected range when powered. The working range is controlled by the following configuration properties: Working Current Range: Minimum Working Current Range: Maximum page 6 of 21

7 Prop Heat On First Cycle The first cycle after power-up (Master on) is executed slightly different as shown below. Sw-On Phase A Phase B Heat Fail Heat On Phase B is activated for 1 second before the normal cycle begins with Phase A. This allows us to quickly check for faults 2 seconds after the first activation. Any subsequent heating cycles will execute as normal. page 7 of 21

8 Installation Slip-Ring Assembly The picture below shows a slip-ring assembly at the rear of the propeller hub: Electrical current is applied to the propeller heating elements (or boots) through a slip-ring assembly. The PDC work with either two node or three node slip-rings. See also Firewall Forward Power Circuit. Mounting the Module The propeller de-ice controller (PDC) unit can be located in front of the firewall. It can for example be mounted to an engine mount tube as illustrated below: Two cushioned (MS21919) clamps each with AN3-13 bolts, washers and nuts are used here. page 8 of 21

9 Electrical Wiring The following section describes the wiring requirements. Please follow these instructions explicitly as improper wiring can result in permanent damage to your unit. Parts and Tools The tools and equipment required are: Wire cutters Wire strippers Teflon insulated wire - 12 and 20 AWG Connector components if new PDC version (13-pin mixed layout D-sub receptacle): Description Crimp Connector Shell Crimp Contacts 12 AWG Crimp Contacts AWG Qty 1 25 Part Numbers DBA25SA197FO M24308/10-1 M39029/ Part Numbers M22520/2-01 M22520/2-08 MS1969/1-02 AFM8 (DMC) K13-1 (DMC) DAK 145 Tools for working with High-Power crimp contacts (12 AWG): Description Crimp tool Crimp tool positioner Extraction tool FL13W3S7-120 FMP003S103 M39029/ Tools for working with M24308/10-1 crimp contacts (20-24 AWG): Description Crimp tool Crimp tool positioner Extraction tool Part Numbers DBA13W3SA197F0 DM M24308/10-1 Connector components if older PDC version (25-pin standard D-sub receptacle): Description Crimp Connector Shell Crimp Contacts AWG Qty Part Numbers M300BT (DMC) TP968 (DMC) Recommended Connector backshell: Description D-Sub (MIL-C-24308) backshell Part Numbers 17E page 9 of 21

10 Electrical Wiring Practices NOTE: For all electrical connections, use correct splicing techniques, taking care to properly insulate any exposed wire. A short circuit between any of the wires may cause damage to the PDC and/or your airplane. VR Avionics does not supply connectors or wire for wiring up your PDC. We recommend that standard aircraft grade wiring and connectors be used during installation. 20 gauge wire is sufficient for most lines to the unit. Make sure you protect the power lines with either a circuit breaker or fuse sized appropriate to the wire you select. We recommend you use wire meeting Mil Standard MIL-W-22759/16 (Tefzel insulation) which is available from various suppliers such as Aircraft Spruce. Another option is to use Teflon insulated wire which is available in various colors. We strongly recommend you use machined pin connectors to mate with the PDC connector. Crimp connections have proven to be the most reliable in aircraft installations. D-Sub shells to hold the pins are available from various sources. Buying high quality connectors is a very wise investment in your aircraft. Make sure all connections are secure and all wires are routed and strain relieved to ensure the wires will not chafe against any other object in the aircraft. Electrical installation of the PDC unit is divided into the following sections: Firewall Forward Power Circuit Firewall Aft Selection & Indication Circuit Maintenance Interface page 10 of 21

11 Firewall Forward Power Circuit The diagrams below shows two power circuit options: A) a three slip-ring and B) a two slip-ring assembly. The power circuit handles load currents to the propeller boots of up to 30A. This requires relatively large diameter AWG wires larger diameters (cross-sections) are more efficient. Locating the unit close to both the power source and the slip-rings provides additional efficiency due to shorter wires. A suitable circuit-breaker (or slow-blow fuse) must be installed close to the source (primary bus) to protect the wire as well as isolate similar faults. Option A Diagram Option B Diagram The latest hardware version II of the PDC uses high power contacts that connect directly to the unit as shown below. These contacts must be crimped onto the AWG wire using the proper contact and tool for the wire size used. It can then be inserted into the connector shell at locations A1 for Power1, A2 for Phase A and A3 for Phase B. page 11 of 21

12 The older hardware version I of the PDC (with the 25-pin D-Sub connector) uses 4 pins for each of the power connections a) Power1, b) Phase A and c) Phase B to the unit. Each of the 4 pins are crimped to 20 AWG wires then spliced together a short distance from the connector. As shown below slicing is done with a solder-sleeve receiving the 4 wires from one side and the AWG wire on the other side. The relevant pin numbers for hardware version I of the PDC (with the 25-pin D-Sub) are given below: PIN NR. (version I) DIR NAME DESCRIPTION 10, 11, 22, 23 IN POWER1 PRIMARY POWER INPUT (SOURCING PHASE CURRENTS) 8, 9, 20, 21 OUT PHASE A 30A SWITCHED POWER OUTPUT 12, 13, 24, 25 OUT PHASE B 30A SWITCHED POWER OUTPUT The relevant pin numbers for hardware version II of the PDC (13-pin mixed contact D-Sub) are given below: PIN NR. (version II) DIR NAME A1 IN POWER1 PRIMARY POWER INPUT (SOURCING PHASE CURRENTS) A2 OUT PHASE A 30A SWITCHED POWER OUTPUT A3 OUT PHASE B 30A SWITCHED POWER OUTPUT DESCRIPTION page 12 of 21

13 Firewall Aft Selection & Indication Circuit Propeller de-icing with the PDC can work in the basic on-off or in a high-low-off operation setting. The difference is that the latter type have an additional (intermediate) heating cycle. The diagrams below shows you how you can wire for each option. Operation 1 Diagram Operation 2 Diagram Alternatively, simpler wiring for on-off type operation can be realized with the diagram shown below, but only if you have PDC hardware version II. Hardware version I does not support this. Operation 3 Diagram page 13 of 21

14 The relevant pin numbers for hardware version I of the PDC (with the 25-pin D-Sub) are given below: PIN NR. (version I) DIR NAME DESCRIPTION 1 IN POWER2 SECONDARY POWER INPUT 14, 15 GND GROUND AIRCRAFT SYSTEM GROUND 6 OUT 18 OUT HEAT ON 19 IN SW-ON HEAT SELECTION INPUT 1 7 IN SW-OFF HEAT SELECTION INPUT 2 HEAT FAIL 5A SWITCHED GROUNDED OUTPUT 0.5A SWITCHED GROUNDED OUTPUT The relevant pin numbers for hardware version II of the PDC (13-pin mixed contact D-Sub) are given below: PIN NR. (version II) DIR NAME 6 IN POWER2 SECONDARY POWER / HEAT SELECTION INPUT 3 5 GND GROUND AIRCRAFT SYSTEM GROUND 4 OUT HEAT FAIL 5A SWITCHED GROUNDED OUTPUT 10 OUT HEAT ON 5A SWITCHED GROUNDED OUTPUT 7 IN SW-ON HEAT SELECTION INPUT 1 1 IN SW-OFF HEAT SELECTION INPUT 2 DESCRIPTION page 14 of 21

15 Maintenance Interface To be able to perform maintenance operations such as configuring and troubleshooting you should wire a small 9-pin female D-Sub connector into your harness. This enables you to link to a laptop / PC (usually through a USB-to-Serial converter) for maintenance operations which may be required from time to time. The relevant pin numbers for hardware version I of the PDC (with the 25-pin D-Sub) are given below: PIN NR. (version I) DIR NAME DESCRIPTION 2 IN RX-232 RS232 RECEIVE 3 OUT TX-232 RS232 TRANSMIT 14, 15 GND GROUND AIRCRAFT SYSTEM GROUND The relevant pin numbers for hardware version II of the PDC (13-pin mixed contact D-Sub) are given below: PIN NR. (version II) DIR NAME DESCRIPTION 9 IN RX-232 RS232 RECEIVE 3 OUT TX-232 RS232 TRANSMIT 5 GND GROUND AIRCRAFT SYSTEM GROUND page 15 of 21

16 Configuration Introduction This chapter describes the configuration settings of the PDC that are accessible in one of two ways, either: 1) through a Windows computer running our SetView software, or 2) through a VRX multi-function display. See the SetView Software chapter later in this manual about how to do it through your Windows computer / laptop. The relevant VRX Operational & Installation manual (which can be downloaded from our website) describes how to do it through the VRX multi-function display. Configuration Settings In this section we describe the various configuration properties of the PDC. See Adjusting the Configuration about how to alter any of these settings via SetView. Unit Reference (location) This configuration property is for future use only. Operation (1:On/Off, 2:High/Low/Off, 3:Alt-On/Off) Set to 1 if you are using the basic on/off operation as illustrated in the Operation 1 diagram. Set to 2 for the high/low/off operation as illustrated in the Operation 2 diagram. Set to 3 if using the alternative on/off operation as depicted in the Operation 3 diagram. Combining Outputs for Single Phase Application Set to 1 if you want to combine phase A with phase B outputs for single phase application (Option B diagram). Set to 0 if you require normal two phase operation (Option A diagram). Enable On-light blinking code according to phase states Set to 1 if you prefer the ON-light single blink at the start of phase A, two blink for phase B and three blink code at the start of all phases off operation. Set to 0 for normal blinking single blink for low heating and two blinks for high heating at every phase transition. Low Heat Phase A On-time (seconds) This is used only when the High/Low/Off (3 position) operation is selected. It defines the time phase A will be powered when the prop-heat switch is in the Low position. Low Heat Phase B On-time (seconds) This is used only when the High/Low/Off (3 position) operation is selected. It defines the time phase B will be powered when the prop-heat switch is in the Low position. page 16 of 21

17 Low Heat Phases Off-time (seconds) This is used only when the High/Low/Off (3 position) operation is selected. It defines the time both phases will be switched Off when the prop-heat switch is in the Low position. Note: A heat cycle will begin by powering phase A only then move to powering phase B only and then switching both phases off for a time before the next cycle begins. High Heat Phase A On-time (seconds) When High/Low/Off (3 position) operation is selected this property defines the time phase A will be powered when the prop-heat switch is in the High position. When On/Off (2 position) operation is selected this property defines the time phase A will be powered when the prop-heat switch is in the On position. High Heat Phase B On-time (seconds) When High/Low/Off (3 position) operation is selected this property defines the time phase B will be powered when the prop-heat switch is in the High position. When On/Off (2 position) operation is selected this property defines the time phase B will be powered when the prop-heat switch is in the On position. High Heat Phases Off-time (seconds) When High/Low/Off (3 position) operation is selected this property defines the time both phases will be switched Off when the prop-heat switch is in the High position. When On/Off (2 position) operation is selected this property defines the time both phases will be switched Off when the prop-heat switch is in the On position. Note: A heat cycle will begin with powering phase A only then move to powering phase B only and then switching both phases Off for a time before the next cycle begins. Working Current Range: Minimum (Amp) The PDC measures the current flowing to the propeller heaters when a phase is powered. This property defines the minimum current (Amps) that will not trigger a Prop Heat Fail annunciation. In other words any Amp value lower than this setting when either phase is powered will trigger the Prop Heat Fail indicator. Working Current Range: Maximum (Amp) The PDC measures the current flowing to the propeller heaters when a phase is powered. This property defines the maximum current (Amps) that will not trigger a Prop Heat Fail annunciation. In other words any Amp value higher than this setting when either phase is powered will trigger the Prop Heat Fail indicator. Current (Amp) Calibration This setting calibrates the PDC's current measurement. Adjustment of this property should only be attempted with a proper amp-meter that has itself been calibrated. page 17 of 21

18 Voltage Calibration This setting calibrates the PDC's voltage measurement. Adjustment of this property should only be attempted with a proper volt-meter that has itself been calibrated. Low Heat Cycle Count This is a counter that increments each time a Low Heat cycle completes. High Heat Cycle Count This is a counter that increments each time a High Heat cycle completes. Fault Code Remembered (for troubleshooting) If a fault was detected during the last activation of propeller heating this value provides feedback as to the cause of the fault. The fault code can be a two digit value the first (rightmost) digit is for phase A and second (leftmost) digit for phase B. A value of zero means no fault. Fault codes are as follows: Description Fault Code No fault on this phase 0 Phase current fell outside configured min. and max range 1 Fault with unit internal component used by this phase 2 Fault with unit internal component used by this phase 3 Short circuit to ground was detected on this phase 4 Insufficient voltage on POWER1 input (or circuit-breaker open) 5 Fault codes 2 and 3 would most probably be the result of a problem within the PDC unit itself - it can be sent to VR Avionics for inspection, testing and repair. Fault codes 1, 4 and 5 are most probably the result of something outside of the PDC unit. You may want to check circuit-breakers / fuses, wiring, slip-rings, and heating boots. page 18 of 21

19 SetView Software Introduction The SetView software connects to the PDC and allows you to do the following: Update firmware View and record parameters View and adjust configuration / settings Share configuration and recordings via System Requirements Operating System: Windows 7 or higher One available serial port. If no serial port is available, a USB port together with a USB-to- Serial converter can be used. SetView download and Installation Find the latest version of SetView on our website ( and install it onto your Windows computer or laptop: Click on the SetView Software link found at ( Click on Install and run the setup.exe until all is successfully installed. Bundled with the latest software are the latest firmware for all VR units in your system (EIU, TSLM, PDC, FSM, etc.). This new firmware may provide new features or have corrected old problems. Using SetView Through the Maintenance Interface the PDC can link with your computer / laptop connecting either directly to your computer s serial port or via a USB-to-Serial converter. Plug in your USB-to-Serial converter (if you are using one) in your Laptop. If this is the first time it have been plugged into a specific USB port, wait for Windows to recognize it and successfully install its driver. Connect the USB-to-Serial converter serial port to the Maintenance Interface. Run the SetView Software. Select from the main menu System > Serial Port. Confirm you have a COM port selected and that it is the right one. Power the PDC module (by switching on the aircraft s master switch). Reasons for failing to establish communication could be: Power was not applied to the PDC, or The serial cable between the unit and the laptop is not connected properly, or The correct serial port was not selected, or The USB-to-Serial converter driver was not properly installed. If you have bought a new USB-to-Serial converter, you first need to get it to work with Windows on your computer. Plug only the USB-to-Serial converter into the laptop / PC, let Windows recognize it and install the relevant driver first. Only when this is complete and Windows tells you that the device is ready to be used, should you plug it into the PDC, start the SetView software and switch the power on. page 19 of 21

20 Viewing and recording parameters After running the SetView software, selecting the correct serial port and applying power to the system, the SetView program should start showing the following parameters: Here we see annunciation for HEAT ON, HEAT FAIL, PHASE A and PHASE B showing the status of these PDC outputs. Also shown are SW-ON, SW-OFF and POWER2 annunciation for similarly named PDC inputs. Then we have readings for V-PWR, A-PWR showing respectively voltage and current into the POWER1 input. TMR gives the time in seconds before the next switchover. FAULT-CODE shows the Fault Code. Then SWA1 and SWA2 shows the current via respectively solid-state switch #1 and #2 directed to the Phase A output, and SWB1 and SWB2 similarly to the Phase B output. To make a recording select from the main menu System > Record Parameter Stream. To stop recording thereafter select System > Stop Recording Parameter Stream. The recording will then be saved to a file and shown in graph format for you to view. Synchronizing with the system By synchronizing (menu > system > synchronize) SetView will first check the firmware version of the PDC and any other VR units in your system (connected via CAN bus). If there is a new version SetView will in each case ask you if you want to update. Only if you select Yes it will update the particular unit to the new version. A synchronize will also make SetView read the PDC's configuration as well as those for the other VR units in your system. The bundled configuration settings will be saved to file and can be viewed by simply clicking on the Config tab at the bottom of SetView. page 20 of 21

21 Sharing files via If you have made a recording and/or done a synchronize which will read the PDC configuration, you can easily share these files with others via (menu > Share). If troubleshooting and you require support from VR Avionics, you may your recording and configuration to us so we can better be able to assist you. Adjusting the Configuration To make adjustments to the configuration (such as Working Current Range: Minimum (Amp)), select from the main menu System > Adjust Configuration... The system will take a second or two to enable configuration adjustment as shown below. To modify any specific configuration item, scroll to the item and hit <SPACE BAR> or double-click on it. A dialog box will appear where you can assign a new value to that configuration property When done click the Update button to change the configuration item setting. page 21 of 21

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