AeroElectric-List Digest Archive

Wed 11/29/06


Total Messages Posted: 17



Today's Message Index:
----------------------
 
     0. 12:34 AM - Just A Few Days Left; Trailing Last Year... (Matt Dralle)
     1. 06:12 AM - Re: Basic Ford alternator wiring questions  (Robert L. Nuckolls, III)
     2. 06:14 AM - Re: 28v diesel engine (George Braly)
     3. 07:06 AM - Re: 28v diesel engine (Robert L. Nuckolls, III)
     4. 07:45 AM - Re: Homebrew AHRS? (Mike@Crossbow)
     5. 08:32 AM - Re: Re: Homebrew AHRS? (Stovall Todd Lt Col AF/A4RX)
     6. 08:50 AM - Re: Homebrew AHRS? (Mike@Crossbow)
     7. 12:27 PM - Re: 28v diesel engine (gordon or marge)
     8. 02:11 PM - Re: ratcheting crimp tool source ()
     9. 03:37 PM - Re: AeroElectric-List Digest: 14 Msgs - 11/28/06 (Martin & Chris)
    10. 03:38 PM - Re: Continental IO-240: Alternator quit working (FlyboyTR)
    11. 04:20 PM - Re: Strobes wiring (Frank Stringham)
    12. 06:51 PM - Re: 28v diesel engine (Robert L. Nuckolls, III)
    13. 06:51 PM - Re: Re: Homebrew AHRS? (Robert L. Nuckolls, III)
    14. 07:31 PM - Re: Re: AeroElectric-List Digest: 14 Msgs - 11/28/06 (Robert L. Nuckolls, III)
    15. 07:33 PM - Re: Re: ratcheting crimp tool source (Robert L. Nuckolls, III)
    16. 09:20 PM - Re: Strobes wiring (Robert L. Nuckolls, III)
 
 
 


Message 0


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    Time: 12:34:19 AM PST US
    From: Matt Dralle <dralle@matronics.com>
    DNA; do not archive
    Subject: Days Left; Trailing Last Year...
    Dear Listers, There are just a few more days left of this year's List Fund Raiser! Response has been very good, but we are behind last year in the number of people that have made a Contribution and as a percentage of the total number of subscribers. Please remember that there isn't any sort of commercial advertising on the Lists and the *only* means of keeping these Lists running is through your Contributions during this Fund Raiser. Please make a Contribution today! http://www.matronics.com/contribution Thank you! Matt Dralle Matronics Email List Administrator


    Message 1


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    Time: 06:12:49 AM PST US
    From: "Robert L. Nuckolls, III" <nuckollsr@cox.net>
    Subject: re: Basic Ford alternator wiring questions
    I'm finally free to experiment with my new "Coyote" project with a Lyc. 320. I will be using the regular "Cessna" alternator/VR at least to begin with (day vfr with electric starter/minimal avionics), basically a copy of my Cardinal to start. My confusion starts when I examine the Cessna alternator wiring: My certified Cardinal has the same style alternator, wired as follows (all wires are shielded): #8 from alt. A+ lug to Alt breaker, shield grounded to alt. case only #8 from alt ground lug to firewall bolt, shield at each end tied to end terminal #18 from alt Field lug to VR F lug, shield grounded to alt case and firewall bolt #18 from alt A+ lug to VR A+ lug, shield grounded to alt case and firewall bolt #18 from VR S lug to square metal filter lug to power buss, shield grounded to firewall bolt and again next to filter, shield end at power buss floats The above is per the factory manual, except for the shielded #8 ground wire, the Cessna manual shows an unshielded #18. I assume the factory used shielded wire for abrasion protection and/or noise protection, and that the #8 shielded ground wire was an undocumented later field change? Questions: 1. I understand the Connection to say that shielding alternator/VR wiring is not necessary for noise protection, did I miss something? No, you didn't. I was a tech writer at Cessna when the shielding protocols were first adopted on the single engine alternator installations. A prophylactic combination of "good things" were sprinkled onto some noisy airplanes where alternator noise was heard in the new ADF installations. The noise was reduced or eliminated and the practice adopted. There were NO formal studies as to the operating characteristics or effectiveness of any particular "good thing". The guy doing the work was a PhD physicist but he had no test equipment and zero experience with EMC issues. Nobody in the local industry did. Beech went on to acquire extensive testing facilities and experience but the roots of curiosity never took hold at Cessna's single-engine plant. 2. Does a shielded ground wire create any noise problem potential? If the engine ground straps are in good shape, is there any reason for the #8 ground from alternator to firewall? Or for any separate ground wire from the alternator, inasumch as the alternator is bolted to the engine with all metal bolts (no insulated washers)? Multiple ground wires give rise to dreaded DC GROUND LOOP and while they don't obviously "hurt" in most cases, they never help either. Bolting the alternator to the engine and strapping the engine to a single-point ground on the firewall is sufficient. 3. Is there any reason to run the A+ wire from the alternator to the VR A+, I would prefer to run a shorter wire from the VR A+ to the alternator side of the A+ alternator fuse on the firewall (1 foot of wire on the firewall instead of 4 feet of wire running beside the hot engine)? I presume you're talking about a remote sense wire from the regulator. Cessna adopted remote sensing protocols in their regulator specs in the 80's and attached (+) and (-) sense wires directly to terminals on the alternator. The notion was that should an alternator experience an electrical disconnect downstream, that remote sensing at the alternator would prevent an unstable or runaway condition. Risks for wiring as you've described are not high . . . and you concerns for "wires next to hot engines" are not operable. Tefzel wire is quite content in the engine compartment compared to the nylon/PVC or nylon/dacron/PVC wire we were using before Tefzel. 4. Is there a need for wire protection, by shielding or otherwise, since it runs next to the hot engine from the alternator? No. 5. Skycrafters sells a high temp "Varglass" sleeving advertised as being rated to 200 degrees C. Is this an appropriate protection for the wires? I can't find any information on the internet. There are a variety of sleeving materials offered to satisfy a variety of protection concerns but for Tefzel wire under the cowl there are few if any concerns. Radiant heating from exhaust stacks are the high-stress heat sources. Keep your wires and accessories away from those antagonists and good order will exist under the cowl. 6. What temp rating should I use for the wires running next to the engine? Tefzel is rated for continuous operation at 150C and is quite sufficient for the appplication we're discussing. 7. Simply, is the following good practice for a Ford style alt/vr: all unshielded: #8 "A+" (alt to big fuse); #18 "F" (alt to VR); #18 VR "S" (VR to power buss); #18 VR "A+" (VR to alt side of big fuse)? This seems less complicated than my Cardinal. Thank you. Skip Simpson Keep in mind that what appears to be "more complicated" may have roots in rational design decisions (like the remote sensing at the alternator terminals) while others are wild ass guesses (like the shielding). Just because it has been done on tens of thousands of "certified" airplanes does not validate the science behind the practice. Operational risks for "rewiring" as you've suggested are very low. Shielding any of these wires is a waste of $time$ and empty weight budgets. Bob . . .


    Message 2


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    Time: 06:14:59 AM PST US
    Subject: 28v diesel engine
    From: "George Braly" <gwbraly@gami.com>
    Bob, The fuel injection control system on the diesel engine may require 28 volts for operation. Regards, George -----Original Message----- From: owner-aeroelectric-list-server@matronics.com [mailto:owner-aeroelectric-list-server@matronics.com] On Behalf Of Robert L. Nuckolls, III Sent: Tuesday, November 28, 2006 7:17 AM Subject: AeroElectric-List: 28v diesel engine <nuckollsr@cox.net> >Comments/Questions: Bob, > >I am installing a DeltaHawk diesel engine in my homebuilt and they have >decided to go with a 28 VDC starter and alternator. I have already >purchased most of my avionics in 14 VDC. I can buy a step-down >transformer from Aircraft Spruce, but is there a good way to run parallel >14 V batteries for power and still use the 28 V alternator for >charging? Seems like I'm between a rock and a hard place. Yup, your sure are! There's no graceful way to do this. The best solution is to use 2 batteries in series for cranking, change to parallel for operating and running a 14v alternator. bob . . .


    Message 3


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    Time: 07:06:07 AM PST US
    From: "Robert L. Nuckolls, III" <nuckollsr@cox.net>
    Subject: 28v diesel engine
    At 08:12 AM 11/29/2006 -0600, you wrote: > >Bob, > >The fuel injection control system on the diesel engine may require 28 >volts for operation. > >Regards, George Hmmm . . . so those guys are going electronic too . . . I guess it comes down to a $time$/weights/parts-count issue. Depending on how much current the engine needs, it might be better to use a small 28v battery and step-up inverter as opposed to a 14 volt battery and step down inverter to support already purchased avioncs. To craft decision right may take as much engineering $time$ as the delta-dollars to sell the 14-volt goodies and buy 28-volt versions. Life can get complicated sometimes! I had a weird phone call yesterday from a guy building a Seawind who was planning to install a PT-6 engine. He started out asking where to buy 100A fuses and I steered him onto the usual suppliers. The conversation expanded to wire sizing and system architecture for engines with starter-generators and it was obvious that he had little knowledge and no experience with the issues. Yet as I attempted to steer him in the right direction, he insisted on arguing with my suggestions. I kept telling him that I wasn't going to argue with him and that our conversation was taking time from my work for a paying customer. He kept asking questions and then arm-wrestling with the answers. I finally suggested that he hire a professional to craft a wirebook for his airplane and offered by services at $150/hour. He replied, "For that kind of money I'll do it myself" whereupon I opined, "Then I guess you don't need me" and hung up. That's the first time I've ever had to forcibly terminate a conversation with a builder. I do wish the fellow well but I'm not optimistic! Some of life's complications are truly intractable. Bob . . .


    Message 4


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    Time: 07:45:00 AM PST US
    Subject: Re: Homebrew AHRS?
    From: "Mike@Crossbow" <msmith@xbow.com>
    Malcolm, I can confirm that we have not seen a repeat of any of the items called out in our service bulletin nor have we seen any new failures in the upgraded units. We have over 30 of these units in the field and have not had any further problems with the NAV425EX. If you are running the NAV425EX, we offer this update for free and will do everything possible to minimize any down time to your aircraft. -------- Michael Smith Application Engineer Inertial Systems Crossbow Technology msmith@xbow.com Read this topic online here: http://forums.matronics.com/viewtopic.php?p=77845#77845


    Message 5


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    Time: 08:32:34 AM PST US
    Subject: Re: Homebrew AHRS?
    From: "Stovall Todd Lt Col AF/A4RX" <Todd.Stovall@pentagon.af.mil>
    Michael, I'm considering purchasing the OP Tech EFIS which uses the NAV420. Has it suffered the same problems as the 425? Thanks, Todd -----Original Message----- From: owner-aeroelectric-list-server@matronics.com [mailto:owner-aeroelectric-list-server@matronics.com] On Behalf Of Mike@Crossbow Sent: Wednesday, November 29, 2006 10:43 AM Subject: AeroElectric-List: Re: Homebrew AHRS? --> <msmith@xbow.com> Malcolm, I can confirm that we have not seen a repeat of any of the items called out in our service bulletin nor have we seen any new failures in the upgraded units. We have over 30 of these units in the field and have not had any further problems with the NAV425EX. If you are running the NAV425EX, we offer this update for free and will do everything possible to minimize any down time to your aircraft. -------- Michael Smith Application Engineer Inertial Systems Crossbow Technology msmith@xbow.com Read this topic online here: http://forums.matronics.com/viewtopic.php?p=77845#77845


    Message 6


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    Time: 08:50:52 AM PST US
    Subject: Re: Homebrew AHRS?
    From: "Mike@Crossbow" <msmith@xbow.com>
    First, I would like to apologize for hijacking the thread. That wasn't my intention. In reference to the original topic, what Malcolm and others have said is completely correct. We are approached by customers occasionally that complain that they could build the unit for far less because the parts are relatively inexpensive. Yes, the parts aren't too expensive but the software is very complicated and you will need to rely upon some sort of aiding (GPS, Kalman filtering, Airspeed, etc..) to improve performance of an AHRS. MEMS gyro's without this aiding are really not accurate enough for aviation in my opinion. By the time you are done creating software and testing a fully functional unit you would have saved a significant amount of money by purchasing a completed solution. Now, if you want to create an AHRS for your personal enjoyment...then yes it's probably worthwhile. In regards to OP Tech, we have not seen any failures with the NAV420's that we shipped to OP Tech, but a very large percentage of the ones that were shipped to OP Tech were already updated with the latest hardware/firmware so we wouldn't expect to see much. The early units that were shipped OP Tech have also come back to be updated and we haven't been informed of any problems with those units. Crossbow is aware of the delay and inconvenience that we have put our NAV425EX customers through and on behalf of Crossbow I would like to personally apologize for the amount of time that it took to get this fix in place. We have been updating these units since May of this year and are confident that the fixes we have in place remedy all noted issues that are stated in the service bulletin. -------- Michael Smith Application Engineer Inertial Systems Crossbow Technology msmith@xbow.com Read this topic online here: http://forums.matronics.com/viewtopic.php?p=77859#77859


    Message 7


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    Time: 12:27:01 PM PST US
    From: "gordon or marge" <gcomfo@tc3net.com>
    Subject: 28v diesel engine
    -----Original Message----- From: owner-aeroelectric-list-server@matronics.com [mailto:owner-aeroelectric-list-server@matronics.com] On Behalf Of Robert L. Nuckolls, III Sent: Wednesday, November 29, 2006 10:04 AM Subject: RE: AeroElectric-List: 28v diesel engine At 08:12 AM 11/29/2006 -0600, you wrote: >--> <gwbraly@gami.com> > >Bob, > >The fuel injection control system on the diesel engine may require 28 >volts for operation. > >Regards, George Hmmm . . . so those guys are going electronic too . . . I guess it comes down to a $time$/weights/parts-count issue. George/Bob: The fuel injection system on the Deltahawk is mechanical (unless they have changed recently} so there are no electrical requirements other than starting. Gordon Comfort N363GC


    Message 8


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    Time: 02:11:30 PM PST US
    From: <jtpackard@usfamily.net>
    Subject: Re: ratcheting crimp tool source
    For those looking for an inexpensive crimp tool that appears identical to the one sold by B & C, check out Harbor Freight- item 93977. I bought one today for $15 TJ --- http://USFamily.Net/dialup.html - $8.25/mo! -- http://www.usfamily.net/dsl.html - $19.99/mo! ---


    Message 9


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    Time: 03:37:26 PM PST US
    From: "Martin & Chris" <av.8@bigpond.com>
    Subject: RE: AeroElectric-List Digest: 14 Msgs - 11/28/06
    I just came across this information regarding an auto starter motor adaptor. Has any on the list seen this or used the plans ? http://abianconi.hypermart.net/Starter-Adapter.html Martin in Oz


    Message 10


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    Time: 03:38:58 PM PST US
    Subject: Re: Continental IO-240: Alternator quit working
    From: "FlyboyTR" <flyboytr@bellsouth.net>
    I pulled the engine today for access to the alternator. There was one nut (top) that was almost impossible to remove (ended up removing the starter for easier access) on the alternator. The drive gear on the end of the alternator shaft rotates freely! I have emailed Drake Air (also left them a voice mail...have heard back from them) regarding their rebuilt units. This does not look like a field serviceable part as shown in the Aircraft spruce book (doesn't look the same)! I would welcome any contact names for parts suppliers/rebuilders that would carry this part. I also realized today that I need to replace the motor mount bushings! Thanks again! Travis :) -------- Travis Rayner Mobile, AL Skystar Vixen N-789DF Read this topic online here: http://forums.matronics.com/viewtopic.php?p=77940#77940


    Message 11


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    Time: 04:20:08 PM PST US
    From: "Frank Stringham" <fstringham@hotmail.com>
    Subject: Strobes wiring
    I am in the process of wiring the tail / wing strobes. I have grounded each wire at the power pack location by bundeling them together and securing them to the strobe power pack base. Now the ??? At the strobe end should the ground wire be grounded at this point or taken back to the fairwall ground block. Also the foil shield does it get any special treatment or just terminated at each end with no attachment to the airframe. TIA Frank @ SGU and SLC wiring / fiberglassing RV7A _________________________________________________________________ Stay up-to-date with your friends through the Windows Live Spaces friends list.


    Message 12


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    Time: 06:51:38 PM PST US
    From: "Robert L. Nuckolls, III" <nuckollsr@cox.net>
    Subject: 28v diesel engine
    At 03:25 PM 11/29/2006 -0500, you wrote: > > >-----Original Message----- >From: owner-aeroelectric-list-server@matronics.com >[mailto:owner-aeroelectric-list-server@matronics.com] On Behalf Of Robert L. >Nuckolls, III >Sent: Wednesday, November 29, 2006 10:04 AM >To: aeroelectric-list@matronics.com >Subject: RE: AeroElectric-List: 28v diesel engine > >At 08:12 AM 11/29/2006 -0600, you wrote: > > >--> <gwbraly@gami.com> > > > >Bob, > > > >The fuel injection control system on the diesel engine may require 28 > >volts for operation. > > > >Regards, George > > Hmmm . . . so those guys are going electronic too . . . > I guess it comes down to a $time$/weights/parts-count > issue. > > George/Bob: The fuel injection system on the Deltahawk is mechanical >(unless they have changed recently} so there are no electrical requirements >other than starting. Good to know. That makes integration of that engine a whole lot easier! Thanks Gordon. Bob . . .


    Message 13


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    Time: 06:51:38 PM PST US
    From: "Robert L. Nuckolls, III" <nuckollsr@cox.net>
    Subject: Re: Homebrew AHRS?
    At 08:50 AM 11/29/2006 -0800, you wrote: > >First, I would like to apologize for hijacking the thread. Nobody "hijacks" anything if they have good data to share . . . > That wasn't my intention. In reference to the original topic, what > Malcolm and others have said is completely correct. We are approached by > customers occasionally that complain that they could build the unit for > far less because the parts are relatively inexpensive. Yes, the parts > aren't too expensive but the software is very complicated and you will > need to rely upon some sort of aiding (GPS, Kalman filtering, Airspeed, > etc..) to improve performance of an AHRS. MEMS gyro's without this > aiding are really not accurate enough for aviation in my opinion. By the > time you are done creating software and testing a fully functional unit > you would have saved a significant amount of money by purchasing a > completed solution. Now, if you want to create an AHRS for your personal > enjoyment...then yes it's probably worthwhile. > >In regards to OP Tech, we have not seen any failures with the NAV420's >that we shipped to OP Tech, but a very large percentage of the ones that >were shipped to OP Tech were already updated with the latest >hardware/firmware so we wouldn't expect to see much. The early units that >were shipped OP Tech have also come back to be updated and we haven't been >informed of any problems with those units. > >Crossbow is aware of the delay and inconvenience that we have put our >NAV425EX customers through and on behalf of Crossbow I would like to >personally apologize for the amount of time that it took to get this fix >in place. We have been updating these units since May of this year and >are confident that the fixes we have in place remedy all noted issues that >are stated in the service bulletin. Mike, thanks for monitoring the List and for joining this conversation. Did we meet at Raytheon's Missiles Division when Crossbow came out to propose an AHRS for our AQM-37D target upgrade? I looked for my business cards from those meetings but they were now quite some time ago . . . about 10 years I think. bob . . .


    Message 14


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    Time: 07:31:42 PM PST US
    From: "Robert L. Nuckolls, III" <nuckollsr@cox.net>
    Subject: Re: RE: AeroElectric-List Digest: 14 Msgs - 11/28/06
    At 09:36 AM 11/30/2006 +1000, you wrote: > > >I just came across this information regarding an auto starter motor adaptor. >Has any on the list seen this or used the plans ? > >http://abianconi.hypermart.net/Starter-Adapter.html > >Martin in Oz I've .pdf'ed the data package and posted at: http://www.aeroelectric.com/Reference_Docs/Starters/Lycoming_Starter_Adapter.pdf If anyone has a chance to try this out, please post your discoveries here on the List. Bob . . .


    Message 15


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    Time: 07:33:35 PM PST US
    From: "Robert L. Nuckolls, III" <nuckollsr@cox.net>
    Subject: Re: ratcheting crimp tool source
    At 04:07 PM 11/29/2006 -0600, you wrote: >For those looking for an inexpensive crimp tool that appears identical to >the one sold by B & C, check out Harbor Freight- item 93977. I bought one >today for $15 >TJ That's a good tool. I've checked them against similar and it appears to be a member of the clones for this style of tool. They're on sale right now on the Harbor Freight website for $10. Bob . . . --------------------------------------------------------- < What is so wonderful about scientific truth...is that > < the authority which determines whether there can be > < debate or not does not reside in some fraternity of > < scientists; nor is it divine. The authority rests > < with experiment. > < --Lawrence M. Krauss > ---------------------------------------------------------


    Message 16


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    Time: 09:20:17 PM PST US
    From: "Robert L. Nuckolls, III" <nuckollsr@cox.net>
    Subject: Strobes wiring
    At 05:18 PM 11/29/2006 -0700, you wrote: ><fstringham@hotmail.com> > >I am in the process of wiring the tail / wing strobes. I have grounded >each wire at the power pack location by bundeling them together and >securing them to the strobe power pack base. I'm not sure which wires your're referring to. The cables from each tube assembly are usually 20AWG twisted trios with a foil shield and drain-wire. You ground each drain wire to the strobe power supply base. All other wires ought to drop into pins on connectors > Now the ??? At the strobe end should the ground wire be grounded at this > point or taken back to the fairwall ground block. Also the foil shield > does it get any special treatment or just terminated at each end with no > attachment to the airframe. Nothing attaches to the airframe at the tube end of each cable. What does the installation drawings for the strobe system show? The drawings should be very explicit as to how each conductor in their system is connected. Bob . . . --------------------------------------------------------- < What is so wonderful about scientific truth...is that > < the authority which determines whether there can be > < debate or not does not reside in some fraternity of > < scientists; nor is it divine. The authority rests > < with experiment. > < --Lawrence M. Krauss > ---------------------------------------------------------




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