G&M&WIRING
G&M&WIRING
ELECTRICAL
SYSTEMS
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GENERATORS
A generator is any piece of equipment that converts mechanical
energy into electrical energy by electromagnetic induction.
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In a simple generator
1- The magnets are called pole pieces
2- The loop of wire is called the armature.
3- The end of the loop is a slip ring, on which a set
of brushes rides, to complete a circuit through a
load
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The output of an elementary generator is
represented by the sine curve, as a loop
rotates 360 degrees through the lines of
magnetic flux.
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1-The variation in DC voltage is called ripple, and
is reduced by adding more loops.
2-As the number of armature loops increases,
the number of commutator segments must
also increase.
3-increasing the number of turns in each loop
does increase the voltage value.
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Increasing the number of loops in an armature reduces the
magnitude of the ripple in DC voltage.
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The major parts of a DC generator include :
1-the field frame . 2-rotating armature .
3-commutator. 4- brush assembly.
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Tow pole shoes Four pole shoes
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Field coils are form fitted around the pole shoes and are
connected in such a manner that the north and south poles
are in alternate polarity order
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The armature assembly consists of:
1-the armature coils 2- the commutator 3-
other associated mechanical parts.
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1-The commutator is located at one end of the armature.
2-consists of wedge-shaped segments of hard-drawn copper.
3-Each segment is insulated from the other by a thin sheet of
mica. 21
Lap winding connects one end of two coils to each commutator
segment, and the other ends of these coils to adjacent segments.
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Brushes:
1-act as the electrical contact between armature coils
and an external circuit.
2-aflexible braided-copper conductor called a pig-tail.
3-The brushes are made of high grade carbon.
4-Low spring tension can result in brush arcing.
5-Oil or grease must never be 'used on a commutator.
6-extreme care must be used when cleaning a
commutator to avoid marring or scratching its
surface.
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TYPES OF DC GENERATORS:
1- SERIES-WOUND
-The field winding of a series-wound generator is connected
in series with the external load circuit.
- few turns of large wire because they must carry the full
load current.
- poor voltage regulation 26
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2-SHUNT-WOUND
- A generator having a field winding connected
in parallel with the external circuit is called a
shunt-wound generator.
- The field coils in a shunt-wound generator
contain many turns of small wire.
Output voltage = Induced voltage –Voltage drop
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3-COMPOUND-WOUND
A compound-wound generator combines a
series winding and a shunt winding so that
characteristics of each are used.
Flat- compound generator is one in which the
no-load and full-load voltages have the same
value.
under-compound generator has a full-load
voltage less than the no-load voltage.
over-compound generator has a full load
voltage higher than the no-load voltage.
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STARTER GENERATORS
-saves appreciably in weight.
-starter generator consists of at least two sets
of windings and one armature winding.
-When acting as a starter a high current flows
through both sets of field windings and the
armature to produce the torque required to
start the engine.
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ARMATURE REACTION
-Distortion of the main fields by the armature fields.
The bad effects of armature reaction:
1-the commutator becomes pitted. 2-
the wear on the brushes becomes excessive. 3-the
output of the generator is reduced.
To correct this condition:
1- by moving the brushes forward in the direction of
rotation This operation is called shifting the brushes
to the neutral plane
2- interpoles.
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• This generator has four poles and four
interpoles. The interpoles are used to counter
the effect of armature reaction.
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GENERATOR RATINGS
A generator is rated according to its power output.
Amperes/Volts.
A generator's rating and performance data are
stamped on the name plate attached to the
generator.
GENERATOR TERMINALS
B terminal-----positive armature lead.
E terminal-----negative armature lead.
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GENERATOR VOLTAGE REGULATION
- Used to regulate / sense the output voltage of
generator.
- Types of voltage regulators:
1-Vibrating-types.
2-Three- unit regulator.
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3-Carbon –pile voltage regulator.
• A voltage regulator contains three coils: a voltage regulator coil, a
current Limiter coil, and a reverse current cutout coil.
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A carbon pile voltage regulator
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DC GENERATOR SERVICE AND MAINTENANCE
The lOO-hour and annual inspection of a generator should include
the following items:
1-Inspect the generator for security of mounting; check the mounting flange
for cracks and loose mounting bolts.
2-Inspect the mounting flange area for oil leaks.
3-Inspect the generator electrical connections for cleanliness and security of
attachment.
4-Remove the band covering the brushes and commutator. Use compressed
air to blowout accumulated dust. Inspect the brushes for wear, and freedom
of movement. Check tension of the brush springs, using a spring scale.
5-Inspect commutator for cleanliness, wear, and pitting.
6-Inspect the area around the commutator, and brush assemblies for any
solder particles. The presence of solder indicates that the generator has
overheated and melted the solder attaching the armature coils to the risers.
When this happens, an open is created in the armature
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GENERATOR OVERHAUL
The step involved in the overhaul of a generator are :
1-disassembly.
the manufacturer's overhaul manual.
Specialized tools are used.
2-cleaning.
Using the wrong solvent could remove the lacquer-type
insulation used on field coils and armatures, resulting in
short circuits after the generator is reassembled.
3-inspection and repair.
A growler is used to test the armature of a DC generator for
open circuits.
110-volt test lamp.
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A growler is used to test the armature of a DC
generator for open circuits 41
When a short exists in the armature windings, the hacksaw blade
vibrates vigorously
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When a ground exists between the windings and the armature core, the
test light illuminates. This test may also be accomplished using an
ohmmeter. 43
4-reassembly.
5-testing.
Operational testing of generators is
accomplished on test benches built for that
purpose.
GENERATOR SYSTEMS
the allowable voltage drop in the main power
wires coming off the generator to the bus bar
is 2 percent of the regulated voltage when the
generator is producing its rated current.
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ALTERNATORS
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DC ALTERNATORS
Brushes bring a varying direct current into the field from the DC
exciter and the voltage regulator.
The load current is induced into stationary stator coils.
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D.C alternator –Rotor and stator
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RECTIFIERS
The three-phase full-wave rectifier in an alternator is made up of six
heavy-duty silicon diodes
NOTE:
Because an alternator has several field poles and
the large number of stator windings, most
alternators produce their rated output at a
relatively low rpm.
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A.C convert into D.C
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BRUSH ASSEMBLY
The brush assembly in an alternator consists
of:
1-Two brushes.
2-Two brush springs.
3-Brush holders.
Note: The brushes in an alternator supply
current to the field coils.
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ALTERNATOR CONTROLS
1- The voltage produced by an alternator is controlled
by varying the DC field current.
2-No need for a reverse-current cutout relay.
Since an alternator uses solid-state diodes for
rectification.
3- No need for a current limiter.
since the alternator field is excited by the system bus
with a limited voltage, there is no way an alternator
can yield enough current to burn itself out.
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Solid-state voltage regulator
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DC ALTERNATOR SERVICE AND MAINTENANCE
There are basically two problems that prevent an alternator from
producing electrical power.
1-shorted or open diode in the rectifying
circuit.
2-an open circuit in the field.
Note: Since the diodes in an alternator are connected in parallel,
an open diode cannot be detected with an ohmmeter.
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AC ALTERNATORS
Alternating current has the advantage over
direct current :
1-AC voltage is easily stepped up or down.
2-AC carries current a long distance.
3-AC is conducted through relatively small
wires.
4- weight savings.
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TYPES OF AC ALTERNATORS
1-Single-phase alternator.
2-Two-phase alternator.
3-Three-phase alternator.
Note: Still another means of classifying
alternators is to distinguish between the type of
stator and rotor used:
1-The revolving-armature type(as AC generator)
2-The revolving-field type.
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Single- phase alternator 57
Three- phase alternator 58
Revolving-field alternator 59
A brushless alternator
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BRUSHLESS ALTERNATORS
In a brushless alternator there are actually three
generators: 1-
The permanent magnet generator. 2
-The exciter generator. 3-
the main generator.
NOTE:
very efficient at high altitudes where brush
arcing is often a problem.
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brushless alternators:
1-Utilize a permanent magnet.
2-There is no need to flash the field.
3-Use of a permanent magnet eliminates the
need to carry current to a rotating assembly
through brushes.
ALTERNATOR RATINGS
kilo-volt amperes, or KVA
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CSD(CONSTANT SPEED DRIVE)
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FREQUENCY
The AC frequency produced by an AC
generator is determined by the number of
poles and the speed of the rotor.
F=P/2×PN/60=PN/120
constant-speed drive unit, or CSD: To provide
a constant frequency as engine speed varies
and to maintain a uniform frequency between
multiple generators.
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BATTERIES
Batteries
a device that is composed of two or more
cells, used to convert chemical energy
into electrical energy.
secondary cells (rechargeable):
A- lead acid batteries B-nickel cadmium
batteries
Secondary cells
A- lead acid batteries:
The most commonly used type in a/c
Consist of 6 or 12 cells, each cell give 2.1 volt
Each cell consist of a series of +ve & -ve plates
+ve plate made from grid of lead & antimony filled with lead peroxide(pbO2)
-ve plate made from grid filled with spongy lead(Pb)
+ve & -ve plates interlaced between each other
Electrolyte made from sulfuric acid and water
Battery case made from hard rubber with individual compartment for each
cell
Each cell have holes and covers to provide access to cells for servicing and
inspection.
Chemical changes during discharge
When a conductor is connected between +ve & -ve terminals,
electrons flow from –ve to +ve plates.
As electrons leave –ve plates, +ve ions(+Pb) forms and attract
sulfate(-SO4) ions from sulfuric acid(H2SO4-electrolyte) , to form
lead sulfate(PbSO4) on –ve plate.
Electrons that arrive at the +ve plate, will drive oxygen out from
lead peroxide(PbO2) into the electrolyte, this oxygen combines
with hydrogen(H2) that has lost sulfate(SO4) to become
water(H2O).
The +ve lead ions that are left on the +ve plate (+Pb), attract
sulfate(SO4) from electrolyte and become lead sulfate(PbSO4)
Chemical changes during charge
recharged using direct current of proper voltage.
When +ve plates are connected to +ve terminal of the source,
electrons are drawn from +ve plates and forced onto the -ve plates
Electrons arrive at the –ve plates drive the –ve sulfate ions(-SO4) out
of the lead sulfate(PbSO4) back into the electrolyte to combine with
hydrogen to form sulfuric acid(H2SO4) again.
When electrons leave the +ve plates, they left behind(+Pb), this(+Pb)
will attract oxygen from water to form lead peroxide(PbO2) again.
When the battery is fully charged, the electrolyte becomes a high
concentration of sulfuric acid(H2SO4)(30%)
During charging process, hydrogen gas is released from electrolyte
and bubbles to the surface
Chemical changes during charge & discharge
Lead acid battery condition of charge
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SMALL SINGLE-ENGINE AIRCRAFT
BATTERY CIRCUIT
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BATTERY CIRCUIT
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GENERATOR CIRCUIT
An aircraft generator or alternator is the primary
source of electrical energy.
It must have sufficient capacity to :
1-Supply all of the electrical loads
2-keep the battery fully charged.
use a current limiter in the generator control to limit
the current the generator can produce.
For aircraft that typically use a DC alternator, a circuit
breaker is used to limit the current.
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GENERATOR CIRCUIT
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An ammeter installed in battery positive lead.
An ammeter installed in these positions can
show the charge or discharge rate of the
battery.
Aloadmeter is provided to monitor the
electrical load being placed on the system.
The generator and the battery are in parallel
with their common terminal at the main bus.
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ALTERNATOR CIRCUIT
The advantages of more current for less weight
have made the alternator the modern choice
for production of DC electrical power on most
aircraft.
The electrical system master switch:
1-Is an interlocking double-pole single-throw
switch.
2-The battery side of the switch can be turned on
and off independent of the alternator.
3-But the alternator side of the switch cannot be
turned on without also turning on the battery115
ALTERNATOR CIRCUIT
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An over-voltage relay in the field circuit:
1-senses the output voltage.
2- If it becomes excessive the relay will
open the field circuit shutting off the
alternator output.
3-The relay also turns on a warning light on
the instrument panel informing the pilot
that the alternator is off-line because it
has produced an excessively high voltage.
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EXTERNAL POWER CIRCUIT
Power is brought from a battery cart or
rectifier through a standard three-terminal
external power plug.
Two of the pins in the aircraft receptacle are
larger than the third and are also longer.
The reverse-polarity diode is used in the
circuit to prevent an external power source
with incorrect polarity from being connected
to the aircraft's bus
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A diode D2 is in the circuit to prevent the
positive pin in the external power
receptacle from having power, or being
"hot," when no external power plug is
connected.
Diode D1 prevents the external power
relay closing if the power source has the
wrong polarity.
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EXTERNAL POWER CIRCUIT
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STARTER CIRCUIT
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STARTER CIRCUIT
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AVIONICS POWER CIRCUIT
Avionics are very sensitive to voltage spikes
and are protected by being powered from a
bus separate from the main bus.
1-One method of doing this is by means of a
split-bus relay that de-energizes the avionics
bus during the start cycle.
2-Another means of isolating the avionics bus is
to have it controlled by a separate
circuit-breaker switch.
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split-bus relay
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circuit-breaker switch.
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LANDING GEAR CIRCUIT
The landing gear circuit for a typical twin-
engine general-aviation airplane is
hydraulically operated by a reversible DC
electric motor.
The purpose of the squat switch in this
circuit is to prevent the gear from being
retracted while the aircraft is still on the
ground.
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The hydraulic pressure switch is used to:
turn off the pump motor in the event
hydraulic pressure exceeds its limits.
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But when the landing gear selector
switch is in the LANDING GEAR
DOWN position and all three gears
are down and locked, the light will be
out.
Also, if the selector switch is in the
LANDING GEAR UP position and all
three gears are in the up position,
the light will be out.
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If the airplane is on the ground with the
squat switch in the GROUND position,
and the landing gear selector switch is
moved to the LANDING GEAR UP
position, the warning horn will sound,
but the landing gear pump motor will not
run.
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LANDING GEAR CIRCUIT
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LANDING GEAR CIRCUIT
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LANDING GEAR CIRCUIT
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ALTERNATING CURRENT SUPPLY
Small aircraft for which DC is the primary
source of electrical power have little use
for alternating current .
Except for certain instruments that
require 26volt, 400-hertz AC.
And some lighting circuits known as
Electro Luminescent Panels.
A rotary inverter is used in some older aircraft
to produce alternating current from direct
current.
because they are noisy, subject to mechanical
problems and are electrically inefficient, in
most cases solid-state inverters are replacing
rotary inverters.
A solid-state inverter uses an oscillator to
produce 400-hertz alternating current that is
amplified so it can drive alternating current
instruments.
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A rotary inverter
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SMALL MULTI-ENGINE AIRCRAFT
The vast majority of light twin-engine aircraft
uses two generators or alternators.
Theses aircraft have their voltage controlled so
that when they are connected together on the
power bus.
paralleling the regulators work together to
keep the output voltages of the two sources
the same.
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PARALLELING WITH VIBRATOR-TYPE
VOLTAGE REGULATORS
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PARALLELING WITH CARBON-PILE VOLTAGE REGULATORS
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PARALLELING TWIN-ENGINE ALTERNATOR
SYSTEMS
Most modern light twin-engine aircraft contain
DC alternator systems for electrical power
generation.
These alternators are typically controlled
through two relatively complex solid-state
alternator control units (ACU).
The alternator control units receive input from
both alternators in order to provide paralleling.
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The ACU also provides voltage and
current regulation as well as over-and-
under voltage sensing and protection.
In the event of a fault condition, the
ACU would automatically isolate the
defective alternator and alert the flight
crew.
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LARGE MULTI-ENGINE AIRCRAFT
There are two basic types of large aircraft
power distribution systems
1-The split-bus power distribution
systems
2-The parallel system power distribution
systems.
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The split-bus power distribution systems
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The parallel system power distribution
systems
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The CSD provides for frequency control by
matching the RPM of each generator to
produce three-phase, 115 volts AC at 400
cycles per second (Hz.).
A gas turbine-powered auxiliary power unit
(APU) located in the wheel well drives a three-
phase, 115- volt.
The APU is used to supply all of the needed
electrical power when the aircraft is on the
ground.
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When the aircraft is operated on the ground,
an internal fan cools the APU.
Unlike some aircraft, the 727's APU cannot be
operated when the aircraft is in the air.
In the event that all three AC generators fail,
the engineer can select the STANDBY position
of the selector switch, and the standby AC and
DC busses are supplied directly from the
battery bus with a standby inverter providing
the AC.
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The Boeing 727 aircraft employs a parallel power
distribution system.
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The APU can be started and the output
monitored from the APU control panel.
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Each of three generators on a Boeing 727
has its own generator control panel.
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The DC electrical panel of the Boeing 727 allows the flight
engineer to select the source of DC power and to monitor
the voltage and current being supplied.
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AC ALTERNATOR DRIVE
Each of the generators is driven through a
hydraulic constant-speed drive unit CSD.
The flight engineer has controls that allow
disconnecting the CSD in case of a generator
or CSD malfunction.
The CSD has its own lubrication system, and
the flight engineer has a low oil pressure
warning light and an oil temperature gauge for
the unit.
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The temperature gauge can either indicate the
temperature of the oil entering the CSD unit,
or it can show the amount of temperature rise
as the oil passes through the drive unit.
Since the generator is cooled by oil spray, it
gives an indication of the load that is being
carried by the CSD.
The voltage is controlled by the generator
control unit to hold the output to 115 volts,
plus or minus 5 volts, and the frequency is
maintained by the CSD.
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The CSD maintains the frequency at 400 hertz,
plus or minus 8 hertz.
The KVAR button causes the selected
generator's KW-KVAR meter to read in
kilo-volt-amps-reactive.
This indicates how hard the generator is
working to supply power for both the resistive
and reactive loads.
The synchronizer lights are lit when the
selected generator and the tie bus are out of
phase.
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AC ALTERNATOR DRIVE
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The voltmeter and frequency meter on the AC
control panel of the Boeing 727
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GENERATOR INSTRUMENTATION AND
CONTROLS
A push-button beside the voltmeter allows it
to read residual voltage, which is the voltage
produced by the selected generator when no
field current is flowing.
Two synchronizing lights on the panel
illuminate when the selected generator is not
synchronized with the power on the tie bus,
and must not be connected until it is
synchronized.
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AUTOMATED AC POWER SYSTEMS
The use of automated systems has made it possible to
reduce flight crew workloads.
The control units, known as Line Replaceable Units
(LRU) are easily removable to facilitate maintenance.
The current produced from the static electricity, which
is commonly produced by a technician's movements
around the aircraft, could be harmful to the LRD.
It is therefore very important to ground one's self
using an approved wrist strap before touching any
electrical component labeled as Electro Static
Discharge Sensitive (ESDS).
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The generator control unit from a Boeing 757 contains
a 24-character LED display for visual display of system
faults.
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A&P technicians should be certain to use an approved
wrist strap when working on or around equipment
labeled with Electro Static Discharge Sensitive (ESDS)
symbols and placards.
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The simplicity of automated AC power systems, such as
this one on the Boeing 757, helps reduce the flight crew
workload.
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MOTORS AND STARTING SYSTEMS
A DC motor is a rotating machine that
transforms direct-current electrical energy
into mechanical energy.
PARALLEL CONDUCTORS
When two parallel wires have current flowing through them in
the same direction, they are forced in the direction of the
weaker field which is toward each other.
When the flow of electrons in two wires is opposite, the
resulting magnetic fields force the wires apart.
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Torque:The force that produces rotation
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The amount of torque developed in a coil
depends on several factors: 1-
The strength of the magnetic field. 2-
The number of turns in the coil. 3-
The position of the coil in the field.
The right-hand motor rule is used to
determine the direction a current-carrying
wire moves in a magnetic field.
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The right-hand motor rule
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BASIC DC MOTOR
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One way to reverse the current in a coil is to
attach a commutator.
A more effective method of ensuring
continuous coil torque is to have a large
number of coils wound on an armature.
That the commutator must contain several
segments.
The armature is placed between the poles of
an electromagnet instead of a permanent
magnet.
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DC MOTOR CONSTRUCTION
1- The armature assembly.
2-The field assembly.
3-The brush assembly.
4-The end frames.
Armature assembly
1- Soft-iron core.
2-Coils.
3-Commutator mounted on a rotatable steel
shaft.
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The armature of a typical DC motor
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MOTOR SPEED, DIRECTION, AND BRAKING
CHANGING MOTOR SPEED
• Motor speed is controlled by varying the
current in the field windings.
EMF(actual)=emf(applied)-Cemf
• In a shunt motor speed is controlled by a
rheostat that is connected in series with the
field winding.
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A shunt motor with variable speed control uses a rheostat to
control the motor's speed. 171
REVERSING MOTOR DIRECTION
• The direction of a DC motor's rotation is
reversed by changing the direction of current
flow in either the armature or the field
windings.
• methods for reversing the direction of
rotation:
1- A single-pole, double throw switch.
2- double-pole, double throw switch.
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TYPES OF DC MOTORS
1-SERIES DC MOTOR (high starting torque)
In a series motor, the field windings consist of
heavy wire with relatively few turns that are
connected in series with the armature
winding.
The series motor is able to draw a large
starting current because of the winding's low
resistance.
The speed of a series motor depends on the
load applied.
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2- SHUNT DC MOTOR
In a shunt motor, the field winding is
connected in parallel with the armature
winding.
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3- COMPOUND DC MOTOR
The compound motor is a combination of the
series and shunt motors.
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.mechanical losses originate from the friction of various moving parts
TYPE OF DUTY
1- Intermittent operations operated for only short
periods of time.
2-Continuous duty are operable at their rated
power for long periods.
ENERGY LOSSES IN MOTORS
1-Mechanical losses originate from the friction of
various moving parts.
2- Electrical losses:
a- Copper losses form of heat.
b-Iron losses are divided into hysteresis and
eddy current losses. 179
AC MOTORS
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UNIVERSAL MOTORS
1-Fractional horsepower (less than one horsepower)
AC series motors.
2-A unique characteristic of universal motors is
that they can operate on either alternating or direct
current.
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INDUCTION MOTORS
The most popular type of AC motor.
No need for an electrical connection between
the motor housing and the rotating elements.
No brushes, commutators, or slip rings to
contend with.
Note Single-phase induction motors require
some form of starting circuit that
automatically disconnects after the motor is
running(Can not start by it self)
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CONSTRUCTION
The two primary parts of an induction motor are 1-
The stator. 2-The rotor. The
rotor of an induction motor consists of an iron core
made of thin circular laminations of soft steel that are
keyed to a shaft.
Note
1- There must always be a difference in speed between
the rotor and the stator's rotating field.
2-The difference in rotational speed is called motor slip,
and is expressed as a percentage of the synchronous
speed.
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SINGLE-PHASE INDUCTION MOTOR
1-SHADED-POLE INDUCTION MOTOR
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3-capacitor-start motor
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DIRECTION OF ROTATION
The direction of rotation for a three-phase
induction motor is changed by reversing two
of the motor leads.
Two-phase motor by reversing the
connections on one phase.
Single-phase motor reversing the connections
to the start winding reverses the direction of
rotation.
188
SYNCHRONOUS MOTORS
Like the induction motor.
a synchronous motor uses a rotating magnetic
field.
DC current is applied to the rotor winding
producing a second magnetic field.
A synchronous motor is not self-starting.
another AC or DC motor that brings the rotor up
to approximately 90 % of its synchronous speed.
utilizes a second squirrel-cage type winding on
the rotor.
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ELECTRIACAL SYSTEM COMPONENTS
WIRE
When choosing the wire for an electrical system
there are several factors that must be considered:
1- Wire selected must be large enough to
accommodate the required current without
producing excessive heat or causing an excessive
voltage drop.
2-The insulation must prevent electrical leakage
and be strong enough to resist damage caused by
abrasion.
192
WIRE TYPES
1- stranded copper wire manufactured
to MIL-W5086 standards.
2- Where large amounts of current must be
carried for long distances MIL-W-7072
aluminum wire is often used.
Note: While aluminum wire does save weight
when exposed to vibration, but
aluminum wire can crystallize and break.
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WIRE SIZE
Aircraft wire is measured by the American
Wire Gage (AWG) system with the larger
numbers representing the smaller wires.
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An electric wire chart
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The three curves extend diagonally across the
chart from the lower left corner to the right side.
Curve 1 represents the continuous rating of a wire
when routed in bundles or conduit.
If the intersection of the current and wire length
lines falls between curve 1 and 2, the wire can be
used to carry current continuously in free air.
If the intersection falls between curves 2 and 3
the wire can only be used to carry current
intermittently. Intermittent is for two minutes or
less.
197
WIRE MARKING
No standard system for wire identification.
Identification mark is required every 12 to 15
inches along a wire.
The identification marking should identify:
1-The wire with regard to the type of circuit.
2-location within the circuit.
3-wire size.
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WIRING Installation
1-open wiring.
With open wiring individual wires or wire
bundles are routed inside the aircraft
structure without protective covering.
2-conduit.
electrical wiring is put inside either a rigid or
flexible tubing that provides a great deal of
protection.
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OPEN WIRING
The quickest and easiest way to install wiring.
open wiring allows easy access when
troubleshooting or servicing individual circuits.
plastic comb can be used to keep individual
wires straight and parallel in a bundle.
limit the number of wires in a single bundle.
better to keep ignition wires, shielded wires,
and wires not protected by a fuse or circuit
breaker separate from all other wiring.
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ROUTING AND CLAMPING
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CONDUIT
The best mechanical protection for electrical
wiring is to enclose the wiring in:
1-Rigid metal conduit.
2- Flexible metal conduit.
The inside diameter of the conduit must be
25% larger than the maximum diameter of the
wire bundle.
Soapstone talc should be blown through the
tubing first.
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The talc will act as a lubricant between the
wiring and conduit wall.
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SHIELDING
Any time a wire carries electrical current a
magnetic field surrounds the wire.
In magnetic compass a two-conductor twisted wire
is used to carry the current to and from this light.
With twisted wire the magnetic fields cancel each
other.
Prevent interference wires that carry AC or
pulsating DC are often shielded.
shielding in electronic circuit wiring is usually
grounded only at one end to prevent setting up a
loop that could cause electromagnetic interference.
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WIRING TERMINALS
Electrical wiring generally terminated with:
1- solderless terminals .
2-crimped.
Crimping is a term used to describe the
squeezing of a terminal around a wire to secure
the wire and provide a high quality electrical
connection.
There are several different types of terminals:
1-ring terminal. 2-slotted terminal.
3-hook type terminal.
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the ring terminal is used most often because it virtually
eliminates the possibility of circuit failure due to
terminal disconnection.
wire use color-coded insulated terminals.
1-Terminals with red insulation are used on wire
gauge sizes 22 through 18.
2-Blue insulation identifies a terminal used on 16-
and 14gauge wires.
3- yellow insulation it is used for 12 and
10 gauge wires.
4- Wires larger than 10-gauge typically use
uninsulated terminals.
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stripping the wire: by cutting the insulation and
gently pulling it from the end of the wire.
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When a ratchet-type crimping tool is used, its
handles will not release until the jaws have
moved close enough together to properly
compress the terminal barrel.
Pneumatic crimping tools are often used on
wire gauge sizes 0 through 0000 because of
the force required to properly crimp the wire.
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CONNECTORS
o Connectors are usually installed on wiring that is frequently
disconnected.
o The most common connector used in aircraft:
o 1-AN (Army-Navy).
o 2- MS (Military Specification).
o The ground side of an electrical power conductor is
typically connected to a male connector(pins).
o The power side of the conductor is attached to the female
connector(sockets).
o This is done to reduce the chance of an accidental short
between the power side of a circuit and any conductive
surface when the mating connectors are separated.
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o Another, less common, type of connector plug
requires the wires to be soldered into each
end of a connector.
o Tinning the wires: using an appropriate
soldering iron, solder, and flux, apply a small
amount of solder to the stripped portion of
each wire.
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TERMINAL STRIPS
• A terminal strip consists of a series of
threaded studs that are mounted on a strip of
insulating material.
• A typical terminal strip is made of a plastic or a
paper-based phenolic compound that
provides a high mechanical strength as well as
good electrical insulation properties.
• barrier :prevent shorting between terminal
connectors.
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JUNCTION BOXES
Made of stainless steel or a heat resistant aluminum
alloy.
Junction boxes for aircraft use must be constructed in
a way that no oil canning exists since this is
considered to be a shorting hazard.
Junction boxes are mounted in a way that minimizes
the possibility of water getting into the box and
causing electrical shorts or corrosion.
junction boxes in powerplant compartments are
mounted vertically to help prevent small hardware
from becoming lodged between terminals and
causing a short circuit or electrical fire.
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BONDING
Bonding is a process that grounds all components in an
aircraft together electrically.
This prevents a difference in potential from building to the
point that sparks jump from one component to another.
Any electrical component which uses the aircraft structure
as the return path for its current must be bonded to the
structure.
The resistance of the bonding strap should not exceed 3
milliohms (.003 ohms).
A bonding strap must be long enough to allow free
movement of a component.
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CIRCUIT PROTECTION
Electrical circuit protection devices are
installed primarily to protect circuit wiring.
The protection devices should be located as
close as possible to the electrical power
source bus.
Two types of circuit protection devices that
are used on aircraft are:
1- circuit breakers.
2- fuses.
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A current limiting device should open an electrical
circuit before its conductors become hot enough to
emit smoke.
Circuit breakers are used rather than fuses because
it is so much easier to restore a circuit in flight by
simply resetting the circuit breaker than it is to
remove and replace a fuse.
There are three basic types of circuit breakers used
in aircraft electrical systems:
1-The push-to reset.
2-The push-pull type.
3-The toggle type.
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All aircraft circuit breakers must be of the trip-
free type which simply means that the breaker
contacts will remain open as long as a short-
circuit exists regardless of the actuating
control position.
Automatic reset circuit breakers are not
allowed in aircraft installations.
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FUSES
A fuse is simply a piece of low-melting-point alloy
encased in a glass tube with metal contacts on
each end.
There are two types of fuses used in aircraft
circuits :
1-The regular glass tubular fuse.
2-The slow blow fuse.
has a larger fusible element that is held under
tension by a small coil spring inside the glass tube.
will pass a momentary surge of high.
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SWITCHES
The purpose of a switch is to interrupt the
flow of current to the component it controls.
Each switch is rated with regard to the voltage
it can withstand and the current it can carry.
Derate switches: a switch must be rated to
sustain more voltage and current than what
the circuit normally carries continuously.
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two-position "on-off" switches should be
mounted so that an upward or forward
movement of the toggle obtains the "on"
position.
Switches that control movable aircraft
components such as landing gear or flaps should
be installed so the switch moves in the same
direction as the desired motion of the
component.
an emergency switch normally enclosed in a
cover that must be lifted before the switch can
be actuated.
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RELAYS AND SOLENOIDS
very small switch can be used to control the
current needed to operate an aircraft engine
starter or other high-current device.
A relay has a fixed soft-iron core .
A solenoid has a movable core.
Due to the movable core, solenoids respond
quicker and are stronger than relays.
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ELECTRICAL CONTROL PLACARDS
When electrical control components
such as switches or circuit breakers are
installed, it is important to make sure
that the device is placarded to indicate
its function.
These placards, or labels, should be
readily visible to the flight crew in day or
night time conditions, and should also
indicate any special operating
considerations 241
AIRCRAFT LIGHTS
Interior lighting systems are needed to
illuminate most areas of the aircraft,
from cargo compartments to the pilot's
instrument panel.
Exterior lights are required to ensure
safety by illuminating landing and taxi
environments, and to provide
recognition or position indications to
other aircraft. 242
EXTERIOR LIGHTS
Include:
1- Position lights .
2-landingand taxi lights.
3-Anti collision lights .
4- Wing inspection lights.
Types of lamps:
1-incandescent lamps.
2-Halogen lamps.
3-xenon lamps.
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1-INCANDESCENT LAMPS
The most popular types.
Use a small coil of tungsten wire, called a
filament which is surrounded by a sealed bulb
containing an inert gas.
Many technicians rely on a visual inspection to
determine if the lamp is good.
The best way to check an incandescent lamp is
to conduct a continuity test of the filament
using an ohmmeter.
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2-HALOGEN LAMPS
Halogen lamps are often used on the
exterior of an aircraft for such items as
flashing beacons and illumination lights.
These lamps is to avoid bare-hand
contact with the bulb since oil from the
skin can burn into the bulb during
operation.
This decreases the lamp's intensity and
can also lead to premature failure.
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3-XENON LAMPS
Xenon lamps are used primarily on the exterior of an
aircraft for flashing anticollision lights commonly
referred to as strobes.
A strobe is a compact unit that develops a flash of
white light that has a much greater intensity than can
be developed with an incandescent lamp.
It is difficult to determine if the lamp is burned out.
the only way to test these lamps is to swap a
questionable lamp with a good one, or to use special
test equipment from the manufacturer.
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Navigation lights
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POSITION LIGHTS
Position lights are used to indicate the location
and movement of an aircraft during night
operations.
By noting different colors of position lights the
operator of an aircraft can detect if an aircraft
is stationary or moving and then safely
navigate around that aircraft.
Hence position lights are often referred to as
navigation lights.
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POSITION LIGHTS
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Rotating Beacon Light
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Strobe-Type anticollision Light
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LANDING AND TAXI LIGHTS
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WING INSPECTION LIGHTS
If the pilot suspects the formation of ice the wing
can be illuminated to allow a visual inspection from
inside the aircraft.
Many aircraft are equipped with anti-ice or de icing
equipment.
The purpose of this equipment is to remove or
prevent the buildup of ice on critical surfaces such
as the wing's leading edge.
Wing inspection lights are typically flush mounted
on the fuselage or engine nacelle and are directed
toward the leading edge of the wing.
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INTERIOR LIGHTS
Including-------
1- Instrument lights.
2- Overhead lights.
3-Step lights.
4-Reading lights.
These lights can be divided into two basic
categories:
1- incandescent
2- fluorescent.
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1-INTERIOR INCANDESCENT LIGHTING
These lamps are often made dimmable by
using a solidstate transistorized circuit to
control the current in the lighting circuit.
They are normally installed in a heat sink
which aids in dissipating the heat from the
transistors.
Fluorescent lights are made of a gas-filled
glass tube that glows when a high AC voltage
is applied to electrodes at each end.
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Incandescent lamps
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2-FLUORESCENT LIGHTS
Fluorescent lights can operate in a bright
or dimmed position.
The fluorescent tube is in the dim
position when a lower voltage is provided
to the ballast transformer through a
potentiometer.
In the bright position the potentiometer
is bypassed providing more current to the
fluorescent tube.
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Electra Luminescent (EL) panel.
An EL panel contains a fluorescent paste
sandwiched between two layers of plastic.
The paste glows when an AC voltage is
applied to the panel.
The light glows through the unpainted areas
of the plastic, typically displaying the etched-
in lettering.
Since Electra Luminescent panels operate only
with alternating current, most light aircraft
with EL systems use a solid-state static inverter
specifically installed for the panel. 259
Fluorescent- type lamp
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MAINTENANCE AND INSPECTION OF
LIGHTING SYSTEMS
Most lighting circuits are relatively low
maintenance items.
Periodic inspections of the wire for chafing
and hardware security corrosion of
components and general condition of the
circuit should be performed during routine
inspections.
Avoid electric shock.
The best resource for troubleshooting
information is obtained from the aircraft
manufacturer's maintenance manual. 261