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CH-47D Electrical System. ACTION: Analyze electrical system malfunctions and prescribe corrective actions. CONDITION: While serving as a Maintenance Test Pilot (MTP) or Flight Engineer. STANDARD: In Accordance With (IAW)

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slide2
ACTION: Analyze electrical system malfunctions and prescribe corrective actions.

CONDITION: While serving as a Maintenance

Test Pilot (MTP) or Flight Engineer.

STANDARD: In Accordance With (IAW)

TM 55-1520-240-Series.

CH-47D Electrical System

Terminal Learning Objective

slide3
Safety Requirements: None.

Risk Assessment Level: Low.

Environmental Considerations: None.

Evaluation: Written examination.

CH-47D Electrical System

Administrative Notes

slide4

CH-47D Electrical System

Introduction

Electricity is a fundamental force found everywhere in nature and has become one of the most powerful tools put to use by mankind.

slide5

CH-47D Electrical System

Overview

  • For the next 4 hours, we will be discussing:
  • The CH-47D AC and DC electrical systems, how they function, some basic components.
  • There are 16 Enabling Learning Objectives (ELO).
slide6

CH-47D Electrical System

ELO A

ACTION: Student read ahead assignment: Identify the basic properties of electricity.

CONDITION: Given a student handout.

STANDARD: IAW TM 55-1520-240-Series.

slide8

CH-47D Electrical System

ELO B

ACTION: Student read ahead assignment: List the six common ways to produce electricity.

CONDITION: Given a student handout.

STANDARD: IAW TM 55-1520-240-Series.

slide10

CH-47D Electrical System

ELO C

ACTION: Identify the electrical symbols used in CH-47D troubleshooting manual schematics.

CONDITION: Given a student handout and

TM 55-1520-240-T-1 and 2.

STANDARD: IAW TM 55-1520-240-Series.

slide11

CH-47D Electrical System

Notes

Pay attention to the notes shown on the electrical schematics in the T-Manuals.

slide12

CH-47D Electrical System

Schematics

  • Standardized and universally accepted methods used to diagram the flow of electricity from one component to the next.
slide13

CH-47D Electrical System

Schematics

Each Component has a unique:

  • Symbol
  • Part number
  • Label
slide15

CH-47D Electrical System

Schematics

Linking components together:

  • Wires
  • Terminal Boards
  • Diodes
  • Ground Points
slide16

CH-47D Electrical System

Schematics

Wires:

  • Have a unique number assigned.
  • Either ink stamped or labeled.
slide17

CH-47D Electrical System

Schematics

Terminal Boards:

  • Provide for the connection of one wire or component to another.
  • Are located throughout the airframe.
slide18

CH-47D Electrical System

Schematics

Diodes:

  • Are one-way streets for electricity.
  • Most visible in the CH-47D connected to relays.
slide19

CH-47D Electrical System

Schematics

Ground Points:

  • Allow a common return path for the flow of electricity.
  • Used for either AC or DC.
slide21

CH-47D Electrical System

Schematics

Linking components together:

  • Switches
  • Relays
slide22

CH-47D Electrical System

Schematics

Switches:

  • Turns on or off the flow of electricity.
  • Used for either AC or DC.
slide23

CH-47D Electrical System

Schematics

Relays:

  • Nothing more than remotely controlled switches.
  • Often used to switch components or circuits with high power requirements.
  • Can be used to set up a “logic flow”.
slide24

CH-47D Electrical System

Schematics

Battery Switch (161S1) and Battery Relay (161K1).

slide26

CH-47D Electrical System

Schematics

Questions ?

slide27

CH-47D Electrical System

Schematics

Press-To-Test Annunciator Lights.

slide28

CH-47D Electrical System

Schematics

Transformers.

slide29

CH-47D Electrical System

ELO D

ACTION: Identify the physical location of components listed on the CH-47D troubleshooting manual schematics.

CONDITION: Given a student handout and TM

55-1520-240-T-2.

STANDARD: IAW TM 55-1520-240-Series.

slide30

CH-47D Electrical System

Locating Components

Simple Methodology

  • Using the schematic, start with components unique number.
  • Use the T-Manual to see what the component looks like.
  • Look up the number in the T-Manual to find the physical location.
  • Find the component on the airframe.
slide31

CH-47D Electrical System

Locating Components

Questions ?

slide32

CH-47D Electrical System

ELO E

ACTION: Chart the flow of current through an electrical schematic.

CONDITION: Given a student handout and TM

55-1520-240-T-2.

STANDARD: IAW TM 55-1520-240-Series.

slide33

CH-47D Electrical System

Electron Flow

When tracing electrical flow on a schematic, start at the source of power and go towards ground.

slide34

CH-47D Electrical System

Electron Flow

“Ground”

  • A a point that, if voltage was measured, the reading would be zero volts (DC circuit).
  • A common connection related to all other components in a circuit (AC or DC).
slide35

CH-47D Electrical System

Electron Flow

“De-Energized”

  • Note that most schematics are drawn with the power turned off.
  • When troubleshooting, the mechanic must mentally turn on the circuit and trace the flow.

Note: Using a High-Lighter often helps the beginner.

slide36

CH-47D Electrical System

Electron Flow

Battery plugged in, but not turned on.

slide37

CH-47D Electrical System

Electron Flow

Battery plugged in, and turned on.

slide38

CH-47D Electrical System

Electron Flow

Questions ?

slide39

CH-47D Electrical System

Electron Flow

Practical Exercise

slide40

CH-47D Electrical System

Electron Flow

Searchlight switch turned on, closing relay.

slide41

CH-47D Electrical System

Electron Flow

Searchlight light bulb on.

slide42

CH-47D Electrical System

Electron Flow

Searchlight extending, an example of “Logic”.

slide43

CH-47D Electrical System

ELO F

ACTION: List the sources of AC electrical power for the CH-47D.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide44

CH-47D Electrical System

AC Power Sources

3 Sources of AC Power

  • External Power.
  • Auxiliary Power Unit (APU) Generator.
  • Main Generator.
slide45

CH-47D Electrical System

AC Power Sources

External Power

  • Lowest priority of power.
  • If the APU or a Main Generator is turned on, External Power will be disconnected.
  • “EXT PWR” Caution Light usually illuminated.
slide46

CH-47D Electrical System

AC Power Sources

External Power

  • Usually supplied via AGPU, a GPU, or special hangar power supply.
  • Most commonly used as a source of power during post-phase or post-modification work order (MWO) power-on checks.
slide47

CH-47D Electrical System

AC Power Sources

APU

  • Second highest priority of power.
  • As the APU generator comes on, External Power goes off.
  • The APU Generator will disconnect if a Main Generator comes on-line.
slide48

CH-47D Electrical System

AC Power Sources

The APU is most commonly used for:

  • Start-up and shut-down of the helicopter.
  • Ground check-out and troubleshooting of systems.
  • During an in-flight emergency (dual generator failure).
slide49

CH-47D Electrical System

AC Power Sources

Main Generators

  • Highest priority of power.
  • Turning on a Main Generator will disconnect the APU Generator or External AC Power.
  • Usable when the Rotor RPM is greater than 86%.
slide50

CH-47D Electrical System

ELO G

ACTION: List the major components of the main AC generating system.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide51

CH-47D Electrical System

Main AC System Components

OIL INLET

PORT

PMG

SECTION

EXCITOR /

ROTATING

RECTIFIER

ASSEMBLY

OIL OUTLET

PORT

MAIN ROTOR

WINDINGS

Main Generator

slide52

CH-47D Electrical System

Main AC System Components

Generator Control Unit (GCU)

  • Located in the left and right electrical compartments.
  • Receives power to operate from the PMG section of the Main Generator.
slide53

CH-47D Electrical System

Main AC System Components

Generator Control Unit (GCU)

Monitors operation of the generator for:

  • Over-Voltage.
  • Under-Voltage.
  • Under-Frequency (an MTP check).
  • Feeder Fault.
slide54

CH-47D Electrical System

Main AC System Components

GCU – Feeder Fault Protection

slide55

CH-47D Electrical System

Main AC System Components

Main Generator Contactor

  • Located in the respective PDP.
  • Allows Generator to connect to Bus.
  • Relay power comes from GCU (28 VDC).
  • Permits Cross-Tie.
slide56

CH-47D Electrical System

ELO H

ACTION: List the components of the APU AC system.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide57

CH-47D Electrical System

APU AC System Components

APU Generator

  • A 20 KVA, air cooled Generator mounted on the APU.
slide58

CH-47D Electrical System

APU AC System Components

APU Generator – 3 Sections:

  • A PMG section.
  • An Exciter section.
  • A main generator section (rotor and stator).

Functions similar to the Main Generator.

slide59

CH-47D Electrical System

APU AC System Components

APU Generator Control Unit (GCU):

  • Located in right electrical compartment.
  • Receives power from the PMG.
  • Requires a conversion plug.
slide60

CH-47D Electrical System

APU AC System Components

APU (GCU) provides protection for:

  • Under-Voltage.
  • Over-Voltage.
  • Under-Frequency.
  • Feed Fault.

Functions similar to Main Generator System, voltages are slightly different.

slide61

CH-47D Electrical System

APU AC System Components

APU Generator Slave Relay:

APU Generator Slave Relay

  • Located in # 2 PDP.
  • Requires 28 VDC from APU GCU to operate.
  • Provides Cross-Tie.
slide62

CH-47D Electrical System

APU AC System Components

APU Generator Contactor:

  • Located in # 2 PDP.
  • Connects APU Generator to the Bus.
  • Requires 28 VDC from APU GCU to operate.
  • Provides Cross-Tie.
slide63

CH-47D Electrical System

APU AC System Components

APU Generator Contactor:

slide64

CH-47D Electrical System

ELO I

ACTION: List the components of the External AC Power System.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide65

CH-47D Electrical System

External AC Power System Components

External Power Receptacle:

  • Located just forward of the left electrical compartment.
  • AC power plug utilizes the lower connector.
slide66

CH-47D Electrical System

External AC Power System Components

External Power Monitor:

  • Located in the Left Electrical Compartment.
  • Monitors for:

- Proper Voltage, Frequency,

and Phase Sequence.

slide67

CH-47D Electrical System

External AC Power System Components

External Power Contactor:

  • Located in the # 1 PDP.
  • Connects External AC Power to the Bus.
  • Provides AC Cross-Tie.
slide68

CH-47D Electrical System

External AC Power System Components

External Power Contactor:

slide69

CH-47D Electrical System

ELO J

ACTION: Analyze the application of External AC Power to the aircraft electrical system.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide70

CH-47D Electrical System

Analyze External Power Application

slide71

CH-47D Electrical System

Analyze External Power Application

slide72

CH-47D Electrical System

Analyze External Power Application

slide73

CH-47D Electrical System

Analyze External Power Application

slide74

CH-47D Electrical System

Analyze External Power Application

slide75

CH-47D Electrical System

ELO K

ACTION: Analyze the application of the # 1 Main Generator AC Power to the aircraft electrical system.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide76

CH-47D Electrical System

Analyze #1 Generator Power Application

slide77

CH-47D Electrical System

Analyze #1 Generator Power Application

slide78

CH-47D Electrical System

Analyze #1 Generator Power Application

slide79

CH-47D Electrical System

Analyze #1 Generator Power Application

slide80

CH-47D Electrical System

Analyze #1 Generator Power Application

slide81

CH-47D Electrical System

ELO L

ACTION: List the sources of DC power for the CH-47D.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide82

CH-47D Electrical System

DC Power Sources

3 DC Power Sources:

  • External DC.
  • Transformer-Rectifier.
  • Battery
slide83

CH-47D Electrical System

DC Power Sources

External DC Power:

  • Highest priority of DC power.
  • Supplied by AGPU, GPU, or hangar power supply.
slide84

CH-47D Electrical System

DC Power Sources

Transformer-Rectifier (T/R):

  • Second highest priority of DC power.
  • Normally powers the Bus when a Generator is on-line.
  • Will power all DC Buses except Battery Bus.
slide85

CH-47D Electrical System

DC Power Sources

Battery:

  • When no other source is available, the Battery will power –

The Battery Bus, the Switched Battery Bus, and the Essential Bus.

slide86

CH-47D Electrical System

ELO M

ACTION: List the components of the Transformer-Rectifier system.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide87

CH-47D Electrical System

T/R System Components

  • Transformer-Rectifier (T/R).
  • Reverse Current Cutout (RCCO).
slide88

CH-47D Electrical System

T/R System Components

Transformer-Rectifier:

  • Located in the Left and Right Electrical compartments.
  • Converts 115 VAC to 28 VDC via a step-down transformer and a rectifier (diode) circuit.
  • Can supply up to 200 amps.
slide89

CH-47D Electrical System

T/R System Components

Reverse Current Cutout (RCCO):

  • Located in the respective PDP.
  • Protects the T/R from reverse current (voltage).
  • Connects T/R output to the DC Bus.
slide90

CH-47D Electrical System

ELO N

ACTION: List the components of the battery and charging system.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide91

CH-47D Electrical System

Battery and Charging System Components

  • Battery Charger (NICAD only).
  • Battery (NICAD).
  • Battery (SLAB).
slide92

CH-47D Electrical System

Battery and Charging System Components

Battery Charger (NICAD only):

  • Located in the Left Electrical Compartment.
  • Monitors and controls the state of charge.
  • Converts 115 VAC to 28 VDC
  • Is slowly being phased out.
slide93

CH-47D Electrical System

Battery and Charging System Components

Battery Charger monitors Battery for:

  • Over-temperature.
  • Cell imbalance.
  • Open circuit.
  • Charger fault.
slide94

CH-47D Electrical System

Battery and Charging System Components

Battery (NICAD):

  • Located in the Left Electrical Compartment.
  • It is a nickel-cadmium battery that uses potassium hydroxide (base) as an electrolyte.
slide95

CH-47D Electrical System

Battery and Charging System Components

Battery (SLAB):

  • Newest Battery used in Army aviation.
  • Sealed Lead Acid Battery (SLAB) utilizing sulfuric acid as the electrolyte.
  • Different design, same rating as NICAD.
  • Lower maintenance requirement.
slide96

CH-47D Electrical System

ELO O

ACTION: List the components of the DC External Power System.

CONDITION: Given a student handout and TM

55-1520-240-Series.

STANDARD: IAW TM 55-1520-240-Series.

slide97

CH-47D Electrical System

DC External Power System Components

External Power Receptacle:

  • Used to connect External DC (or AC) power.
  • Located on the forward side of the Left Electrical Compartment.
slide98

CH-47D Electrical System

DC External Power System Components

4 DC Relays provide a Logic circuit:

  • External Power Relay (161K7).
  • External Power Control Relay (161K9).
  • Both RCCO Relays (161K3 and 161K4).
slide99

CH-47D Electrical System

DC External Power System Components

Reverse DC Polarity Protection (Blocking) Diode:

  • Prevents voltage with incorrect polarity from being applied to the DC Bus.
  • Won’t allow 161K7 and 161K9 to operate.
slide100

CH-47D Electrical System

DC External Power System Components

Practical Exercise:

Complete the final Practical Exercise in the Student Handout at your leisure.

slide101

CH-47D Electrical System

Summary&Questions?

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