SAL12-70 - Plane

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:
•
An alternator or voltage regulator is
improperly installed.
•
An alternator or voltage regulator is used for
the wrong application.
•
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.
•
The alternator or voltage regulator is
determined to have failed by application of
voltage in excess of the amount specified on
the data plate.
•
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 STC@Plane-Power.com
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.
8
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.
8
7
6
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.