Today's Message Index:
----------------------
1. 09:23 AM - Insulation on Welding Wire (D Fritz)
2. 09:50 AM - Re: Insulation on Welding Wire (jaybannist@cs.com)
3. 09:55 AM - Re: Insulation on Welding Wire (LarryMcFarland)
4. 02:44 PM - Re: Contactor and Crowbar Ratings (Craig Winkelmann)
5. 04:54 PM - Re: Marking Wires? (BobsV35B@aol.com)
6. 07:03 PM - Contactor and Crowbar Ratings (Robert L. Nuckolls, III)
7. 07:05 PM - Re: Re: Alternator excitation - suggested wiring? (Robert L. Nuckolls, III)
8. 07:33 PM - Re: Re: EXP2BUS and non-functioning alternator (Robert L. Nuckolls, III)
9. 07:33 PM - Re: High pitch whine from KLN90 GPS (Robert L. Nuckolls, III)
10. 07:35 PM - Re: Re: Alternator excitation - suggested wiring? (Mike Fontenot)
11. 07:36 PM - Re: Re: Contactor and Crowbar Ratings (Bob McCallum)
Message 1
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| Subject: | Insulation on Welding Wire |
All,
I'm getting ready to buy my main battery cables and would like some advice
on which insulation to choose.- I've read the discussions that say weldin
g cable is good to use for its flexibility and durability, but should I be
worried about the temperature range of the insulation?- The choices seem
to be neoprene welding cable (good to 90C), thermoplastic rubber welding ca
ble (good to 105C), PVC battery cable-(good to 80C), and-"SGX" battery
cable (good to 125C).- Any ideas/insight into which of these is the most
desirable?- The application is-a 24V system in a Velocity (batteries in
the front, engine in the back).- Should I consider using some of the sti
ffer battery cable for the run from the batteries to the firewall-mounted s
tarter contactor and then welding cable from the contactor to the starter m
otor?
-
Also, Waytek has some pretty good prices on these, but only sell in quantit
ies greater than 100ft, does anyone know a good source that won't break the
bank?
-
Thanks,
Dan=0A=0A=0A
Message 2
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| Subject: | Re: Insulation on Welding Wire |
Dan,
I got my welding cable (~30') at Grainger for what I thought was a very reasonable
price.
Jay Bannister
-----Original Message-----
From: D Fritz <dfritzj@yahoo.com>
Sent: Sun, 17 May 2009 11:11 am
Subject: AeroElectric-List: Insulation on Welding Wire
All,
I'm getting ready to buy my main battery cables and would like some advice on which
insulation to choose.? I've read the discussions that say welding cable is
good to use for its flexibility and durability, but should I be worried about
the temperature range of the insulation?? The choices seem to be neoprene welding
cable (good to 90C), thermoplastic rubber welding cable (good to 105C),
PVC battery cable?(good to 80C), and?"SGX" battery cable (good to 125C).? Any
ideas/insight into which of these is the most desirable?? The application is?a
24V system in a Velocity (batteries in the front, engine in the back).? Should
I consider using some of the stiffer battery cable for the run from the batteries
to the firewall-mounted starter contactor and then welding cable from the
contactor to the starter motor?
?
Also, Waytek has some pretty good prices on these, but only sell in quantities
greater than 100ft, does anyone know a good source that won't break the bank?
?
Thanks,
Dan
________________________________________________________________________
Email message sent from CompuServe - visit us today at http://www.cs.com
Message 3
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| Subject: | Re: Insulation on Welding Wire |
Hi Dan,
I think welding wire is a better product for the heavy cable at the
batteries. It's easy to join with silver solder and cupped ring ends.
It's flexible and doesn't
get brittle because of the fine wires.
*January 15 *The order for cable terminals from Wicks came in so the
battery contactor to starter was stripped, inserted and was crimped
once. Flanges were filed off. Silver solder was added to join cable and
terminal and shrink-wrap was added. After refastening it to the
contactor, tie-ties reattached the cable to bus support structures
through the plane. The instrument panel was removed to the worktable and
switches were placed thru the switch template panel to keep them in
order. Wires were revisited to shorten them, provide bundled protection,
and minimize motion.
see link:
http://www.macsmachine.com/images/electrical/full/chargebatteryconnection.gif
Larry McFarland 601HDS at www.macsmachine.com
D Fritz wrote:
> All,
> I'm getting ready to buy my main battery cables and would like some
> advice on which insulation to choose. I've read the discussions that
> say welding cable is good to use for its flexibility and durability,
> but should I be worried about the temperature range of the
> insulation? The choices seem to be neoprene welding cable (good to
> 90C), thermoplastic rubber welding cable (good to 105C), PVC battery
> cable (good to 80C), and "SGX" battery cable (good to 125C). Any
> ideas/insight into which of these is the most desirable? The
> application is a 24V system in a Velocity (batteries in the front,
> engine in the back). Should I consider using some of the stiffer
> battery cable for the run from the batteries to the firewall-mounted
> starter contactor and then welding cable from the contactor to the
> starter motor?
>
> Also, Waytek has some pretty good prices on these, but only sell in
> quantities greater than 100ft, does anyone know a good source that
> won't break the bank?
>
> Thanks,
> Dan
>
>
Message 4
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| Subject: | Re: Contactor and Crowbar Ratings |
Bob:
These urls
Even the $high$ contactors have bad days
http://tinyurl.com/qmk6gm
If you're loosing sleep over it, consider the
these EV200 series contactors. They feature
automatic coil current reduction after pull-in
to reduce continuous power to keep the contactor
energized. However, they're about 6X the price
of the 70 series device and do generate some
noise that has been a problem for a few builders.
See:
http://tinyurl.com/qazl8t
>
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=244422#244422
Message 5
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| Subject: | Re: Marking Wires? |
Good Afternoon Don,
I borrowed a WWII vintage, hand operated, electric wire marker and printed
a label about every ten inches on every wire I used. It probably caused me
to waste a few feet of wire as I tended to make each wire just a bit longer
than needed, but it sure helps a lot during the assembly and for trouble
shooting.
Using any sort of shrink tube application darn near doubles the diameter of
the small wires we tend to need. I tried that and did not care for the
extra bulk at all.
If I had a very sophisticated airplane to wire, I would watch E-Bay and buy
my own wire marking machine! If it's good enough for Boeing and
Beechcraft, it's good enough for me!
Happy Skies
Old Bob
AKA
Bob Siegfried
Ancient Aviator
628 West 86th Street
Downers Grove, IL 60516
630 985-8502
Stearman N3977A
Brookeridge Air Park LL22
In a message dated 5/15/2009 11:57:50 A.M. Central Daylight Time,
mosquito-56@hotmail.com writes:
I am looking for a way to mark my wires in my Zodiac 601XL. I am just
finishing up the body and will begin engine installation soon.
Can anyone suggest a method to print on shrink sleeving if possible? I
have no idea what one would be called.
I had heard there was a way to use a laser printer to do this in some way
also.
Any other ideas would be welcome.
Don
**************A strong credit score is 700 or above. See Yours in Just 2
Easy Steps!
bcd=Maystrongfooter51709NO115)
Message 6
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| Subject: | Contactor and Crowbar Ratings |
At 04:42 PM 5/17/2009, you wrote:
Bob:
These urls
Even the $high$ contactors have bad days
http://tinyurl.com/qmk6gm
. . . and this 6041 series contactor . . .
in spite of its pedigree had a very
bad day in a King Air about 20 years
ago.
If you're loosing sleep over it, consider the
these EV200 series contactors. They feature
automatic coil current reduction after pull-in
to reduce continuous power to keep the contactor
energized. However, they're about 6X the price
of the 70 series device and do generate some
noise that has been a problem for a few builders.
See:
http://tinyurl.com/qazl8t
. . . and this is an exemplar 21st century
design for a contactor along with a place to
purchase the critter.
These are "Tiny URL" contractions of the
desired address. See:
http://tinyurl.com
Bob . . .
----------------------------------------)
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
----------------------------------------
Message 7
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| Subject: | Re: Alternator excitation - suggested wiring? |
Bob,
I wanted to update you. After getting a new alternator plug that has
the connections I needed, I experimented and rewired the field and
ground leads per your suggestions.
WhaLa, alternator started outputting about 15 volts. Too high, but a
few turns of the LR3C regulator screw has it now outputing 14.2
volts. And if I move the Master Switch to BATT position the
alternator stops producing voltage. Like Hannibal Smith always said:
'I love it when a plan comes together'.
I have a Z19 system, and here are the measured voltages from various
instruments/locations:
Digital meter directly on the main battery: 14.23 v
Digital meter on the Z23 field wire to cockpit: 1.90 v
Digital panel Voltmeter on Ebus: 14.10 v
EM2 engine monitor connected to main bus: 14.44 v
Is that Z23/field voltage what you might expect?
Yes, depending on RPM and system loads, the
field excitation to the alternator can be quite
low. At low RPM and high loads, this reading
will climb until it reaches at or slightly
below bus voltage . . . this is were the alternator
is maxed out. A very low reading says the alternator
is carrying present loads without breaking a
sweat.
Bob . . .
----------------------------------------)
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
----------------------------------------
Message 8
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| Subject: | Re: EXP2BUS and non-functioning alternator |
At 05:08 PM 5/16/2009, you wrote:
>
>I discovered that the IG lead to the alternator was only producing
>12V when measured disconnected. As soon as a load was applied that
>went down to 1.5V. It turns out that some filings had got under
>the legs of an IRF4905 Mosfet and seemed to have shorted the pins.
>
>So, new question: Does anyone know how to test whether the cleaned
>up IRF4905 still works, and what the pinouts might be. There are
>three legs, but nothing I've read tells me what leg does what.
See:
http://www.irf.com/product-info/datasheets/data/irf4905s.pdf
>Would I have to remove the IRF4905 from the board to test it's output?
I wouldn't think so . . . but I'm mystified as to how
an IRF4905 might be used to control an alternator. This
is a really husky device. Far larger than necessary
to effect control of the IG lead of an alternator. Do
you have a schematic of the EXP2BUS product? I wasn't
able to find anything useful on the website.
Bob . . .
----------------------------------------)
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
----------------------------------------
Message 9
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| Subject: | Re: High pitch whine from KLN90 GPS |
At 09:43 AM 5/16/2009, you wrote:
>
>I recently installed a KLN90 GPS (I know its old, but it is better
>than my old loran) and it has a high pitch whine. I noticed the
>whine when I was wiring the gps on the bench, thinking I would not
>hear the noise in the plane-wrong. Would some kind of filter
>eliminate this or does it need to go to the shop ? I can hear the
>whine thru the headsets also and it gets annoying. Any ideas ?
You need to deduce the propagation mode
for the noise as described in chapter 16.
Bob . . .
----------------------------------------)
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
----------------------------------------
Message 10
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| Subject: | Re: Alternator excitation - suggested wiring? |
Bob,
Thanks again for the information on regulators (pull up/pull down), and the
way to wire it up. Sure feels good to have the system really working. This
list is great!
Mike
On Sun, May 17, 2009 at 8:04 PM, Robert L. Nuckolls, III <
nuckolls.bob@aeroelectric.com> wrote:
> nuckolls.bob@aeroelectric.com>
>
>
>
> Bob,
>
>
> I wanted to update you. After getting a new alternator plug that has the
> connections I needed, I experimented and rewired the field and ground leads
> per your suggestions.
>
>
> WhaLa, alternator started outputting about 15 volts. Too high, but a few
> turns of the LR3C regulator screw has it now outputing 14.2 volts. And if I
> move the Master Switch to BATT position the alternator stops producing
> voltage. Like Hannibal Smith always said: 'I love it when a plan comes
> together'.
>
>
> I have a Z19 system, and here are the measured voltages from various
> instruments/locations:
>
> Digital meter directly on the main battery: 14.23 v
> Digital meter on the Z23 field wire to cockpit: 1.90 v
> Digital panel Voltmeter on Ebus: 14.10 v
> EM2 engine monitor connected to main bus: 14.44 v
>
>
> Is that Z23/field voltage what you might expect?
>
> Yes, depending on RPM and system loads, the
> field excitation to the alternator can be quite
> low. At low RPM and high loads, this reading
> will climb until it reaches at or slightly
> below bus voltage . . . this is were the alternator
> is maxed out. A very low reading says the alternator
> is carrying present loads without breaking a
> sweat.
>
>
> Bob . . .
>
> ----------------------------------------)
> ( . . . a long habit of not thinking )
> ( a thing wrong, gives it a superficial )
> ( appearance of being right . . . )
> ( )
> ( -Thomas Paine 1776- )
> ----------------------------------------
>
>
--
Mike
===============================
Mike Fontenot
Apex Consulting & Services LLC
Lakewood, Colorado
303 / 731-6645
mikef AT apexconsultingservices DOT com
===============================
Message 11
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| Subject: | Re: Contactor and Crowbar Ratings |
Craig;
Both those URL's work fine for me.
Bob McC
Do not archive
> -----Original Message-----
> From: owner-aeroelectric-list-server@matronics.com
[mailto:owner-aeroelectric-list-
> server@matronics.com] On Behalf Of Craig Winkelmann
> Sent: Sunday, May 17, 2009 5:43 PM
> To: aeroelectric-list@matronics.com
> Subject: AeroElectric-List: Re: Contactor and Crowbar Ratings
>
<capav8r@gmail.com>
>
> Bob:
>
> These urls
>
> Even the $high$ contactors have bad days
>
> http://tinyurl.com/qmk6gm
>
> If you're loosing sleep over it, consider the
> these EV200 series contactors. They feature
> automatic coil current reduction after pull-in
> to reduce continuous power to keep the contactor
> energized. However, they're about 6X the price
> of the 70 series device and do generate some
> noise that has been a problem for a few builders.
> See:
>
> http://tinyurl.com/qazl8t
>
> >
>
>
>
>
>
> Read this topic online here:
>
> http://forums.matronics.com/viewtopic.php?p=244422#244422
>
>
>
>
>
>
>
> _-
> =====================================================
> =====
> _-
> =====================================================
> =====
> _-
> =====================================================
> =====
> _-
> =====================================================
> =====
>
>
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