AeroElectric-List Digest Archive

Mon 07/14/14


Total Messages Posted: 10



Today's Message Index:
----------------------
 
     1. 04:16 AM - Re: Dual master solenoids (tomhanaway)
     2. 04:20 AM - Re: Learning (Tomhanaway)
     3. 05:07 AM - Re: Dual master solenoids (user9253)
     4. 07:45 AM - Re: Re: Dual master solenoids (Robert L. Nuckolls, III)
     5. 08:10 AM - Re: Battery choice (Dj Merrill)
     6. 09:19 AM - Re: Battery choice (Robert L. Nuckolls, III)
     7. 10:01 AM - Re: Battery choice (Dj Merrill)
     8. 12:31 PM - Re: Battery choice (Robert L. Nuckolls, III)
     9. 01:55 PM - Noisy USB Charger (Dennis Johnson)
    10. 04:56 PM - Re: Noisy USB Charger (Sacha)
 
 
 


Message 1


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    Time: 04:16:55 AM PST US
    Subject: Re: Dual master solenoids
    From: "tomhanaway" <tomhanaway1@gmail.com>
    Thanks Joe, Once I started thinking in terms of a relay, this came pretty close to what I was looking for. Interesting use of a starter enable/disable switch to ensure no cranking current through relay. Interesting question ( to me, anyway), are heavy duty continuous service relays any less reliable than mechanical relays? If about the same reliability, what are the reasons that they aren't used more often for a master solenoid? As you stated, the weight differential is pretty significant. Thanks again, Tom -------- RV-10. Built and sold RV-8a. Building Read this topic online here: http://forums.matronics.com/viewtopic.php?p=426622#426622


    Message 2


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    Time: 04:20:23 AM PST US
    From: Tomhanaway <tomhanaway1@gmail.com>
    Subject: Re: Learning
    If you don't find what you want, contact SteinAir and tell them exactly what instruments you'll be installing. They will provide a complete schematic showing where each wire connects to each pin. Great company to do business with. Worth it's weight in gold for those doing their own wiring. Plus, it gives you and any future operator a reference chart for the future. I made a copy of mine and marked off each wire as I installed them Sent from my iPad > On Jul 13, 2014, at 12:21 PM, John Tipton <jmtipton@btopenworld.com> wrote: > > > You are so lucky Jim: over here (UK/Europe) we have to fit to new builds 8.33 radios, and Mode S transponders, and all aircraft by the end of 2015 are to be so equipped - a lot of surplus equipment will be available !!! > > John > > Sent from my iPad > > ----x--O--x---- > >> On 13 Jul 2014, at 04:45 pm, Jim Gilliatt <jim.gilliatt@att.net> wrote: >> >> >> Hi John, >> Not to my knowledge, and I have talked to many people who are well aware of the requirements. >> I hope I'm not showing my ignorance here. >> Jim >> >>> On 7/13/2014 11:33 AM, John Tipton wrote: >>> >>> Hi >>> >>> I take it that 8.33 radios, and mode S transponders are not a (I presume your in) USA requirement for new fits >>> >>> John >>> >>> Sent from my iPad >>> >>> ----x--O--x---- >>> >>>> On 13 Jul 2014, at 04:21 pm, Jim Gilliatt <jim.gilliatt@att.net> wrote: >>>> >>>> >>>> Hi All, >>>> I am installing a Bendix KX155 transceiver, a Bendix KT 76A transponder, a Dynon EFIS D100 and a PM500EX intercom in a Kitfox Series 7 with a Continental IO240. Can anyone supply me with a wiring diagram for this configuration? It has to be plain to a 6 year old; I have all the installation manuals, and they are mostly Greek to the uninformed; I am floundering around like a beginner, which I am. I may have bitten off more that I can chew, but I'll be a monkey's uncle if I'll it give up. >>>> At least I'm learning a whole lot. >>>> Thanks, >>>> Jim Gilliatt >>>> Rhode Island > > > > >


    Message 3


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    Time: 05:07:40 AM PST US
    Subject: Re: Dual master solenoids
    From: "user9253" <fransew@gmail.com>
    > are heavy duty continuous service relays any less reliable than mechanical relays? If about the same reliability, what are the reasons that they aren't used more often for a master solenoid? There are several ways that a relay or contactor can fail. The contacts can develop a high resistance, the coil can burn open, springs or other mechanical parts can break, and etc. I do not know which type is more likely to fail. The current carrying capability determines which relay or contactor to use. Starters can draw a few hundred amps initially to get the engine rotating. A 30 amp automotive relay would not last very long carrying that much current. So why have the starter current go though the master contactor? The starter contactor could be wired directly to the battery. I think the reason is that contactors have been known to fail closed. Having two contactors in series makes sure that the circuit can be opened. Joe -------- Joe Gores Read this topic online here: http://forums.matronics.com/viewtopic.php?p=426626#426626


    Message 4


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    Time: 07:45:32 AM PST US
    From: "Robert L. Nuckolls, III" <nuckolls.bob@aeroelectric.com>
    Subject: Re: Dual master solenoids
    At 07:06 AM 7/14/2014, you wrote: > > > > are heavy duty continuous service relays any less reliable than > mechanical relays? If about the same reliability, what are the > reasons that they aren't used more often for a master solenoid? "Reliability" is a rather soggy concept. It can mean different things to most speakers in a group of conversants. If you write to Stancore/White-Rogers and ask, just HOW reliable is your 70-110 contactor? . . . they MIGHT fire back with a laboratory study that cites cycle-life of the contactor under various loads and perhaps environmental conditions. Write to Tyco about reliability of their Kilovac contactors and you MIGHT get another report. Okay, Tyco's numbers are better than S/W-R numbers . . . now what? As I've been explaining in my writing and presentations for the past 30 years, the elegant design has little, if any, interest in those numbers. Lessons-learned in over a century of building airplanes have demonstrated that the designer's prime directive is to reduce risk for a bad day in the cockpit. To be sure, if money, weight, $time$ to market and cost of ownership were of no concern, then there are virtually limitless ways that hedges against risk can be applied to the system. But applied without the confidence that comes from understanding there is a larger risk that the end-product is burdened with "safety features" that degrade performance to far greater degrees than protecting the airframe and crew. Emacs! My teachers would ask, "Okay, you've selected a whiz-bang part for that location in the airplane, make your case for the decision." Had I whipped out the reliability data sheets for the constellation of choices and said, "See here, look at THOSE numbers!" they might have banished me to purchasing support or perhaps the EMC lab. The first bit of guidance germane to your decision resides in lessons-learned. Question: How many times have pilots experienced a bad day in the cockpit due to in-flight failure of the battery master contactor? I haven't a clue . . . because the incidents have been so few in numbers and so benign as to become completely buried in COMPONENT failures that put the whole SYSTEM at risk . . . The aviation journals are replete with what I have called "dark n stormy night" stories . . . most of which are so lacking in data as to defy understanding of root cause . . . or more illustrative of human weaknesses than those of the airplane. Consider that EVERY contactor is RATED and TESTED in the lab to perform as advertised for tens of thousands of cycles at rated lioad. YOUR battery contactor is going to close/open once per flight cycle . . . perhaps 100 times per YEAR and under nearly zero-load conditions. Were you to conduct laboratory reliability testing for conditions in YOUR airplane, it's unlikely that you would ever see a failure. We HAVE seen some failures here on the List. Detailed analysis revealed failure due to a variety of reasons including manufacturing defects Emacs! moisture ingress, and installation error . . . but in no case were the failures first detected in flight. Carrying lessons-learned a step further we can conduct a failure effects study. You do this by ASSUMING that every part will fail at some point in time. You then analyze how that failure will affect system performance. For failures that pose unacceptable risk, you make some design changes. Except for things like wing struts and prop bolts, the elegant design drives more toward failure TOLERANCE than failure PROOF. See: http://tinyurl.com/ozum5u9 If your studies for optimal design are driving you toward the purchase of high-dollar hardware -OR- adding backup components, then perhaps your confidence born of lessons-learned and artful conduct of failure analysis is shaky. I suggest that crafting any of the Z-Figures chosen to match your mission profiles and hardware will produce an exceedingly failure tolerant system. I suggest further that Z13/8 has more bang for the buck/pound/volume than systems flying in some pretty sophisticated airplanes. The very first example of Z13-8 flying in an OBAM aircraft was in an RV-8 in Connecticut about 25 years ago . . . the father-son build team were delighted with its performance and confidence levels. They could loose a battery master contactor every few months and not suffer a bad day in the cockpit . . . but I'll bet that the Model 70 contactor installed day-on is still flying. Bob . . .


    Message 5


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    Time: 08:10:12 AM PST US
    Subject: Re: Battery choice
    From: Dj Merrill <deej@deej.net>
    On 05/22/2014 09:18 PM, Dj Merrill wrote: > $44 including shipping from Amazon for the UB12220 battery, 12v 22Ah in > the same form factor. > A plus is that it is 9 lbs lighter than the 25 Ah battery it will be > replacing (a B and C model BC110-1). > > Bob, > I will report back to the list as to how it performs. I have a low > compression 150hp Lycoming O-320 with a light weight starter, so it > should hopefully turn it over with no difficulty. Finally got the plane back together yesterday from the panel upgrade, and am reporting back to the list with the results. I installed one of these as the main battery: http://www.amazon.com/gp/product/B001G8FY38/ref=oh_aui_detailpage_o07_s00?ie=UTF8&psc=1 and one of these as the aux battery: http://www.amazon.com/gp/product/B004J2TAZQ/ref=oh_aui_detailpage_o07_s00?ie=UTF8&psc=1 I was only able to do taxi testing yesterday due to weather, however, the UB12220 battery turned the engine over just as fast as the previous B&C battery, so no issues with cranking power (in summer at least). I'll let you know more as I test further. On a somewhat related note, do contactors normally get very hot when in use? After running the engine and taxiing around for 15-20 mins yesterday, I stuck my hand back behind the baggage area to feel the battery and listen to see if I could hear it "boiling" (it was not hot or boiling). I happened to touch the contactor, and it was very hot, almost to the point of burning my hand, but not quite. Hot enough so that it was very uncomfortable keeping my hand on it for more than a few seconds. Is this is normal? Thanks, -Dj -- Dj Merrill - N1JOV - VP EAA Chapter 87 Sportsman 2+2 Builder #7118 N421DJ - http://deej.net/sportsman/ Glastar Flyer N866RH - http://deej.net/glastar/


    Message 6


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    Time: 09:19:45 AM PST US
    From: "Robert L. Nuckolls, III" <nuckolls.bob@aeroelectric.com>
    Subject: Re: Battery choice
    On a somewhat related note, do contactors normally get very hot when in use? After running the engine and taxiing around for 15-20 mins yesterday, I stuck my hand back behind the baggage area to feel the battery and listen to see if I could hear it "boiling" (it was not hot or boiling). I happened to touch the contactor, and it was very hot, almost to the point of burning my hand, but not quite. Hot enough so that it was very uncomfortable keeping my hand on it for more than a few seconds. Is this is normal? Yes. "Hot" is a relative term. While the outside surface of the contactor may become too warm to keep your fingers on it, this condition is normal. http://tinyurl.com/mpcgp3t http://tinyurl.com/k6bwdqo Internal components of the contactor are rated for much higher levels. An RG battery in distress doesn't 'gurgle' but it does whistle. Finished some tests on a really big RG battery a few months ago wherein a Schumacher charger failed to perform as advertised . . . the battery was 'singing' as pressures exceeded settings on the vent valves. Bob . . .


    Message 7


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    Time: 10:01:27 AM PST US
    Subject: Re: Battery choice
    From: Dj Merrill <deej@deej.net>
    On 07/14/2014 12:18 PM, Robert L. Nuckolls, III wrote: > Yes. "Hot" is a relative term. While the outside > surface of the contactor may become too warm to > keep your fingers on it, this condition is normal. Excellent, thank you! > An RG battery in distress doesn't 'gurgle' but > it does whistle. I was listening for any sort of weird noise coming from the battery. I've also had a Schumacher charger go wonky on me (it is sitting on my bench right now), and from one RG battery I could clearly hear what sounded like "boiling/bubbling", and from another the "hissing/singing" as you describe. The voltage from the charger was getting up to 15.7 or so. I haven't had the time to tear it apart to see if it can be adjusted down. The other charger that seems to be working correctly puts out 14.5 volts. The UB12220 battery has a label on the top that says it can handle up to 14.7 volts, and my alternator is putting out 14.2, so I am hopeful this battery will work fine in the plane. The essential bus diode is dropping 0.6v across it, giving 13.6 v on the e-bus, which seems reasonable. -Dj -- Dj Merrill - N1JOV - VP EAA Chapter 87 Sportsman 2+2 Builder #7118 N421DJ - http://deej.net/sportsman/ Glastar Flyer N866RH - http://deej.net/glastar/


    Message 8


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    Time: 12:31:47 PM PST US
    From: "Robert L. Nuckolls, III" <nuckolls.bob@aeroelectric.com>
    Subject: Re: Battery choice
    The UB12220 battery has a label on the top that says it can handle up to 14.7 volts, and my alternator is putting out 14.2, so I am hopeful this battery will work fine in the plane. The essential bus diode is dropping 0.6v across it, giving 13.6 v on the e-bus, which seems reasonable. -Dj Some weeks ago, a Lister published a reply from Odyssey in response to a query about his PC680 battery life. The response spoke to the holy-watered manner in which Odyssey batteries should be recharged . . . the letter also stated that "no Schumacher chargers are approved". I've been a follower of SOME Schumacher products for a dozen years or more. In particular, I've owned a number of 1562, 2A charger/maintainers. For the most part, every 1562 I've tested produced a recharge profile that mirrored this plot. Well within the recommended profile suggested by Hawker-Enersys. http://tinyurl.com/pwo2oxv I do have a 1562 charger around here that was sent to me for testing . . . but it got 'swallowed up' in a re-organization of my shop digs perpetrated by a grandma/grand-daughter conspiracy . . . the charter is not lost, I just don't know where it is right now . . . the shop looks nice. A few weeks ago I spoke to my disappointment for the demonstrated performance of a new Schumacher XC75W charger with lots of push buttons and a digital display. Three successive recharge cycles of the same battery produced these profiles . . . Emacs! The first recharge was in the "AGM" mode, consistent with the configuration of battery. As you can see, this profile peaked at over 15.5 volts . . . The next time I tried the "STD" mode with similar results. Finally a recharge cycle in the "GEL" mode produced a perfectly acceptable performance . . . I forwarded this data to Schumacher asking for an opportunity to talk with an engineer . . . I have yet to hear from them. From this experience I must conclude that any tendency toward blind faith in Schumacher's ability to produce a well crafted recharge profile is not well placed. I was surprised that Odyssey put the evil eye on Schumacher some years ago . . . they did the same thing to Battery Minder. I would like to see the data upon which their displeasure stands but the data above suggests that Odyssey's displeasure may be standing on solid physics . . . You spoke to an observed output of 14.2 volts . . . which is in no way abusive to the battery. But the Rest Of the Story speaks to the complete recharge profile as plotted in the data cited above. I'm doing a study of both lithium batteries and suitable chargers . . . watch this space. I have no doubt that the 12220 battery will perform well when knew. If it suffers any weakness, it will manifest in poor service ilfe . . . Bob . . .


    Message 9


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    Time: 01:55:39 PM PST US
    From: "Dennis Johnson" <pinetownd@volcano.net>
    Subject: Noisy USB Charger
    Hi Sacha, You asked for a Wal-Mart.com link to the USB charger that I'm using that doesn't create "noise" on my comm radio. Sorry, but I can't find it on Wal-Mart's web site. I bought it in the store. Here is the info printed on the charger; you might be able to find it on eBay or locally from a different store. I think it's manufactured by ONN Model #: ONA12WI268 Input: 100-240 VAC Input: 12-24 VDC Output: 5.0VDC 2.1A There is an additional number that might be some kind of certification: E347649 It has two input specs because it can be plugged into a cigar lighter or into a house wall socket. It also has two USB sockets that can charge both at 2.1 A simultaneously. Dennis


    Message 10


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    Time: 04:56:54 PM PST US
    Subject: Re: Noisy USB Charger
    From: Sacha <uuccio@gmail.com>
    Thanks Dennis for that. I guess the different Walmart stores carry different products cos I couldn't find it in the one I went to.




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