SAL12-70 INSTALLATION INSTRUCTIONS
WIRING DIAGRAM
WARRANTY Plane Power, Ltd. warranties its alternators and voltage regulators for a two-year period from date of purchase to be in good working order and free of material defects. Plane Power, Ltd. retains the right to rebuild or replace any alternator or voltage regulator if it fails under the terms of this warranty and only if the customer’s original alternator or voltage regulator is sent to Plane Power for evaluation, along with a dated copy of the sales receipt. This alternator or voltage regulator must be shipped directly to Plane Power per instructions found in this warranty agreement at the customers expense for warranty evaluation. If the alternator or voltage regulator is found to have failed under the terms of this warranty, Plane Power will take the appropriate action of either rebuilding or replacing the alternator or voltage regulator. Customers will be responsible for any additional expedited shipping charges. Plane Power, Ltd. reserves the right to insure all alternators and voltage regulators for loss or damage during shipping directly to the customer.
Plane Power, Ltd. makes no warranty as to suitability of its products for the intended application. To be considered eligible for warranty consideration, DO NOT PURCHASE A REPLACEMENT ALTERNATOR OR VOLTAGE REGULATOR FROM A DEALER. Plane Power, Ltd. will not at any time offer a form of a warranty credit for replacement alternators or voltage regulators purchased through a dealer. All warranty claims must be handled directly by Plane Power, Ltd. If you suspect an alternator or voltage regulator to be defective and in need of service, call Plane Power, Ltd. at 877-934-5700 for a return authorization number. Alternators and voltage regulators returned to the factory via UPS with the valid return authorization number will usually be rebuilt or replaced the same day as received. However, other carriers and/or circumstances may increase the turnaround to 1-2 days.
______________________________________________________________________________________ Warranty Details Plane Power, Ltd. warrants its alternators and voltage regulators to be free from defects in material and workmanship under normal use and operation for a period of two years from date of purchase. Plane Power, Ltd. cannot and never will warrant damage to non-alternator or voltage regulator components or related expenses including labor, inconvenience, transportation or loss of business due to any alternator failure.
Plane Power, Ltd. warranty is void if:
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An alternator or voltage regulator is improperly installed.
•
An alternator or voltage regulator is used for the wrong application.
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Customer tries to service the alternator or voltage regulator in the field by removing or replacing any of the components not specifically instructed and/or supplied by Plane Power, Ltd.
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The alternator or voltage regulator is determined to have failed by application of voltage in excess of the amount specified on the data plate.
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The alternator or voltage regulator is damaged by impact, shock or excessive abuse, (i.e. dents, large scratches, bent components) actual physical evidence not in conjunction with defective components, design or workmanship.
346 Howard Clemmons Rd. Granbury, Texas 76048 Phone: 877-934-5700 Fax: 817-573-5716 www.plane-power.com
IMPORTANT NOTICE: COMPLETE IMMEDIATELY
This form may be accessed and filled out electronically at http://www.plane-power.com/STCletter.pdf In compliance with FAA regulation 21.120 the purchaser of this conversion kit must obtain a permission letter from Plane Power, Ltd. In order to use STC SA10682SC please complete the following form and return to Plane Power, Ltd. by one of the following methods: 1. E-Mail to
[email protected] 2. Fax to 817-573-5716 3. Mail to: STC 346 Howard Clemmons Rd. Granbury, Texas 76048 Please Print Clearly Purchaser: Full Name: Address: State:
City: Phone Number:
Zip:
Fax Number:
E-mail: Ensure that aircraft is listed on STC SA10682SC (Visit http://www.plane-power.com/STC.pdf for the latest approved listing.) AIRCRAFT
Registration #: Make: Model: Serial #:
PLANE POWER CONVERSION KIT Model #: Serial number (for single engine kit):
S/N
Serial numbers (for twin engine kit):
S/N
S/N Submit by Email After Completion
Form # STC001
Print Form and Complete for Fax or Mail
Plane Power, Ltd. Dwg. 14-5001 Rev. B
Page 1 of 4
Drawing No.: 14-5001 Belt Driven Alternator Conversion Installation Instructions For Model: SAL12-70 Single- Engine Aircraft with Lycoming Engine Rev. A B
Date 7/19/07
11/19/09
Parts List: Qty Part No. 1 10-1051 1 10-8099 1 R1224 1 ALP-1001 1 ALP-1006 1 14-5001 1 14-1010
By SJK BRJ
Revision History Revisions
DELETED PAGE 5, 6-h UPDATED, PAGE 3 WIRING DIAGRAM UPDATED REMOVED DUPLICATIONS, UPDATED DATA, ADDED ICA
Description Alternator, 12 Volt, with 1/2” V-Belt Pulley. Mounting kit for Lycoming Engine. Alternator Controller (Voltage Regulator) and data sheet 12-1001 Placard, ALT FIELD (Part of Drawing 14-1012) Placard, ALT INOP (Part of Drawing 14-1012) Installation Instructions (This document) Alternator Inoperative Lamp (14 Volt)
READ AND THOROUGHLY UNDERSTAND ALL OF THE INSTALLATION INSTRUCTIONS BEFORE BEGINNING INSTALLATION OF THIS KIT. NOTE: IF AIRCRAFT DOES NOT HAVE A CIRCUIT BREAKER OR CURRENT LIMITING DEVICE IN THE GENERATOR’S OUTPUT AND REGULATOR’S INPUT CIRCUIT THEY MUST BE INSTALLED. Part 1, Installation of Alternator and Regulator 1. Disconnect aircraft battery. 2. Remove Generator and voltage regulator. 3. Install Alternator per drawing on page 3. Tension the belt and torque the AN5H-5A adjusting bolts to 200 in/lb and safety wire with 0.032” diameter safety wire. Torque the AN7-42A mounting bolts to 425 in/lb. 4. Ensure that internal jumper #1 and internal jumper #2 of the R1224 regulator are set for 12V operation (See regulator instructions for location of jumpers). 5. If original output circuit breaker is rated at less than 70-amps and you wish to be able to utilize the increased capacity of the alternator, remove the breaker and replace with suitable breaker up to 70amp maximum size. Ensure wire size from alternator output terminal to output circuit breaker and from output circuit breaker to bus is rated for more than the size of breaker installed per AC43.13-1B. Note: If aircraft has been equipped with an Amp Meter, ensure that it is of adequate size to handle the increased output capability before increasing the output wire and breaker.
Plane Power, Ltd. Dwg. 14-5001 Rev. B
Page 2 of 4
6. Wire the system as follows: a. For regulator wiring instructions view the regulator installation instructions. b. Connect the GRND terminal of the regulator to the common aircraft ground. c.
Leave the ground jumper installed on the F2 terminal of the alternator.
d. Connect the existing generator output wire to the alternator’s 6mm OUTPUT TERMINAL (or install a new wire in accordance with AC43.13-1B) using a MS25171-2S terminal nipple for insulation (Not Supplied). Torque to 50 in/lb. e. Use the original generator field wire or install a new wire, minimum 18AWG, from the alternator F1 terminal to the FLD terminal of the regulator. Torque the alternator’s F1 terminal nut to 20 in/lb. f.
Install, in view of the pilot, placard ALP-1001 (ALT FIELD) adjacent to the field switch for the alternator.
g. Ensure that the FIELD switch/breaker is connected to the aircraft positive bus. h. If the aircraft has a “Generator Inoperative” indicator lamp, it may be used in this step. If the lamp is not currently installed or is not compatible use the supplied lamp P/n 14-1010 Alternator Inoperative Lamp (14 Volt) and install it in pilots clear field of view. i.
Install, in view of the pilot, placard ALP-1006 (ALT INOP) adjacent to the indicator for the alternator. Also run a new wire, minimum 18AWG, from the AUX terminal of the alternator to the AUX terminal of the regulator.
7. Adjust and Test the system: a. Set FIELD switch to OFF. b. Turn on MASTER switch and start the engine. With FIELD switch in OFF position ensure that ALT INOP indicator is illuminated. c.
Turn on the FIELD switch. Check proper charging indication. Check ALT INOP indicator is off. Check aircraft maintenance manual for proper bus voltage (typically 14.0V ± 0.3V). Adjust the regulator to the desired bus voltage at 1200 engine RPM.
d. Recheck and inspect the entire installation. Complete FAA form 337, make log book entry, update aircraft equipment list, and weight and balance.
Mounting Kit Parts List 10-8099 MOUNTING KIT COMPONENTS QTY P/N DESCRIPTION QTY P/N DESCRIPTION 1 AN5H-5A BOLT 1 10-1012 TENSION ARM 1 AN960-516 WASHER 1 10-1009 SPACER BUSHING 1 AN7-42A BOLT 1 10-1002 STARTER STRAP 1 AN960-716 WASHER 1 10-8003 CASE MOUNT BRACKET 1 AN363-720 NUT 1 10-1003 BOSS MOUNT BRACKET
Plane Power, Ltd. Dwg. 14-5001 Rev. B
Page 3 of 4
Part 2, Preparation of FAA Form 337 1. Installed Alternator in accordance with Supplemental Type Certificate No. SA10682SC. Updated Airplane Flight Manual with Plane-Power, Ltd. Airplane Flight Manual Supplement 001 (or later revision). Weight changed (compute weight and balance as necessary). Checked size of wire from Alternator output terminal to alternator circuit breaker and from Alternator circuit breaker to bus and size of Alternator circuit breaker with AC43.13-1B. (Note: use this statement as applicable. If wire and circuit breaker sizes are satisfactory, so state. If not satisfactory, state wire and/or circuit breaker size installed to conform with AC43.13-1B.) 2. Modified aircraft equipment list by removal of generator listed and adding Plane-Power Model SAL12-70 Alternator Kit.
Weight and Balance Removed generator installation: Weight _______ Arm _______ (Refer to Aircraft Equipment List)
Removed regulator installation: Weight _______ Arm _______ (Refer to Aircraft Equipment List)
Installed SAL 12-70 alternator kit consisting of: (1) 10-1051 alternator (1) 10-8099 mounting kits. (1) R1224 Voltage Regulator (1) ALP-1001 Placard (1) ALP-1006 Placard (1) 14-1010 Lamp
wgt. 10.0lbs._ 1.0 lbs.__ 0.3 lbs.__ Negligible Negligible Negligible
Plane Power, Ltd. Dwg. 14-5001 Rev. B
Page 4 of 4
Part 3, Instructions for Continued Airworthiness PERIODIC MAINTENANCE: 1. It is recommended that the operation of the Plane Power, Ltd., SAL12 -70 alternator be checked every 100 hour inspection or every annual inspection which ever comes first. 2. ANNUAL/100 HOUR INSPECTION: a. Remove drive belt and turn alternator rotor to check condition of bearings for abnormal noise or roughness. b. Each annual/100 hour inspection, the alternator and its associated wiring should be checked for secure electrical connections and physical connection to the airframe. The belt drive tension should be re-set to the aircraft manufacturer’s specification. 3. 5 YEAR OR 1000 HOUR INSPECTION a. Repeat the Annual/100 hour inspection. b. Remove field brush assembly and inspect brushes for excess wear. Replace brush assembly if brushes extend less then 0.250 inches from edge of holder case. AIRWORTHINESS LIMITATIONS There are no mandatory replacement limits. There are no mandatory structural inspection intervals. THE AIRWORTHINESS LIMITATIONS SECTION IS FAA APPROVED AND SPECIFIES MAINTENANCE REQUIRED UNDER SEC. 43.16 AND 91.403 OF THE FEDERAL AVIATION REGULATIONS UNLESS AN ALTERNATIVE PROGRAM HAS BEEN FAA APPROVED.
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7
6
R1224 & R1224B REV. C
4
5
3
SUPERCEDED VERSION SEE STEP 7
LTR.
D E F
FAA PMA PLANE POWER, LTD For eligibility see www.plane-power.com/catalog or call 1-877-934-5700
WT: 0.3 Lbs. Model Number: R1224 F L D
E N A B L E
G
Rev: Serial Number:
DATE 7/17/07
ADDED PAGES 3 & 4 UPDATED INSTALLATION STEPS 1, 5, 6, 7 UPDATED INSTALLATION INSTRUCTIONS, COMBINED DWGS 12-1001, 12-1001B & 37003-06
10/18/07
SJK SJK
7/9/08
SJK
8/20/09
BRJ
A U X
L A M P
DUAL ALTERNATOR ONLY O I U N T
DETAIL A 28VOLT JUMPER POSITION
INCREASE FAA PMA
PLANE POWER, LTD For eligibility see www.plane-power.com/catalog or call 1-877-934-5700
Rev: C Serial Number:
WT: 0.3 Lbs. Model Number: R1224 E N A B L E
F L D
28VOLT JUMPER POSITION
14V OV16V
28V OV32V G R N D
A U X
L A M P
DUAL ALTERNATOR ONLY O I U N T
D
N/C
VOLTAGE ADJUST C
APR.
DESCRIPTION PAGE 3 DELETED
14V OV16V
28V OV32V G R N D
1
REVISIONS
DETAIL A
D
2
S E N S E
JUMPER#2 SHOWN IN 14 VOLT POSITION
2
JUMPER #1 SHOWN IN 14 VOLT POSITION
C
1
NOTE: JUMPERS 1 & 2 MUST BE IN THE SAME VOLTAGE POSITION FOR OPERATION AT SELECTED VOLTAGE. AS SHOWN BY DETAIL A
2.75
B
B FAA PMA
PLANE POWER, LTD For eligibility see www.plane-power.com/catalog or call 1-877-934-5700
1.75
WT: 0.3 Lbs. Model Number: R1224
Rev: C Serial Number: 14V OV16V
28V OV32V G R N D
A
F L D
E N A B L E
A U X
L A M P
DUAL ALTERNATOR ONLY O I U N T
S E N S E
NAMEPLATE MATERIAL TO BE ADHESIVE BACKED SILVER POLYESTER WITH PERMANENT THERMAL PRINT
PLANE POWER, LTD. GRANBURY, TEXAS
STANDARD TOLERANCES ALL DIMENSIONS IN INCHES UNLESS SPECIFIED DECIMALS .XX +/- .030, .XXX +/- .010 ANGLES +/- 1DEG. FRACTIONS +/- 1/16 CONCENTRICITY .005 METRIC TOLERANCES .X +/- 0.2, .XX+/- 0.02 PARENTHESIS ARE REFERENCE DIMS.
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5
4
A
R1224 ALTERNATOR REGULATOR INSTALLATION INSTRUCTIONS DRAWN BY: MATERIALS:
B. JOWERS
DATE:
8/08/06
DWG. NO.
REV.
12 - 1001 3
2
1
G
REGULATOR INSTALLATION 12 - 1001
Page 2 of 3
Single Engine
READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE APPLYING POWER TO UNIT 1. Remove existing regulator and solid-state over-voltage module (if installed). 2. Install R1224/R1224B Regulator in same location as regulator being replaced. If mounting holes do not align add mounting holes as required using acceptable methods, techniques and practices. 3. Connect GRND terminal to aircraft ground. It is critical that the regulator ground is connected to airframe ground. Without this ground, the regulator and its internal overvoltage protection cannot function. 4. Connect the FLD terminal to the FIELD (brush) terminal of the alternator. 5. Connect the ENABLE terminal to the regulator/field power source (the wire from the cockpit ALTERNATOR FIELD switch which is fed from a 7.5 max amp breaker). Note: In order for the over voltage protection circuit to operate the enable terminal must be connected to an operational circuit breaker. (In the event of an over-voltage condition the over-voltage protection circuit will cause the circuit breaker to trip removing all power from the regulating circuit.) Do not install R1224/R1224B in any aircraft that has an automatic resetting circuit breaker in the enable line. 6. If the regulator being replaced has a connection to the AUX terminal on the alternator, connect this wire to the AUX terminal. If not, install a jumper wire between AUX and ENABLE. Note: No connection to AUX terminal is necessary if an alternator out lamp is not installed. 7. If the installer wishes to sense voltage at a source other than ENABLE terminal: remove jumper between ENABLE terminal and SENSE terminal. Connect SENSE terminal to desired location. For superceded versions of the R1224/R1224B (Rev B & previous) indicated by silver label, step 7 does not apply and no sense terminal exists. Wiring of a ‘Sense’ terminal on these regulators will result in damage to the regulator 8. If an ALTERNATOR out lamp is installed in the aircraft and is to be actuated by the R1224/R1224B regulator Connect the negative wire of the lamp to the LAMP terminal of the R1224/R1224B regulator. 9. Remove the regulator cover and ensure that the internal jumper #1 and jumper #2 are set to the proper voltage for the aircraft system. Refer to the picture on page 1. 10. With the engine running and the alternator switch turned on, using a small screwdriver, set the regulator’s voltage adjustment so that the buss voltage, as measured at the ENABLE terminal is the desired value. Refer to aircraft maintenance manual or battery manufacturer’s data for proper voltage setting. 11. Reinstall the R1224/R1224B cover. Multi-Engine 1. For both regulators, perform steps 1-11 of the Single Engine procedure above. 2. Choose one regulator as the MASTER. It can be either. Connect the OUT terminal of the MASTER Regulator to the IN terminal of the other Regulator. NOTE: Both regulators must be the same part number. Adjustments to the voltage setting of each regulator may be made by turning the other alternator switch off.
Page 3 of 3
Instructions For Continued Airworthiness It is recommended that the operation of the Plane Power, Ltd. Voltage Regulator be checked every 100 hour inspection or every annual inspection which ever comes first. If the regulator is operating at the required voltage level, no adjustment is necessary. If the voltage level does not meet the Aircraft Manufacturer’s requirement, adjust the voltage per instructions. Each 100 hour inspection, the regulator and its’ associated wiring should be checked for secure electrical connections and physical connection to the airframe. To maintain the inherent protection from HIRF and lightning, as well as over voltage protection of the aircraft electrical system, ensure the ground connection between terminal 1 (GRND) and airframe ground is less than 0.1 OHM. No special tools are required.
