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OVM-14 MkIII

 
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finn.lassen(at)verizon.ne
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PostPosted: Thu Sep 21, 2023 5:56 am    Post subject: OVM-14 MkIII Reply with quote

On 9/20/2023 10:47 PM, Robert L. Nuckolls, III wrote:

Quote:
At 12:35 PM 9/20/2023, you wrote:
Quote:
Bob,

I want to turn on an idiot light that indicates an over-voltage trip event.

The attached quick-and-dirty schematic shows what I would like to do, however I have not seen a final schematic for your latest OVM, so I'm working on some assumptions.

� What you've described will work . . . but do you
� NOT have a low voltage warning light? What would
� the ov light tell you that the lv light would not?



� Bob . . .
�
I would love to have an indication telling me why the field breaker tripped. Over voltage or excessive field/voltage regulator current?
I'm still trying to figure out why my breaker sometimes pops when pulling back to low RPMs. I had changed the alternator pulley to prevent excessive RPMs and wear on the alternator, so it may well be field over-current. On the other hand field current with alternator stopped is 3.45A and appears to be next to nothing when running at 3,000RPM and above. 5A breaker. Still working on data logging to figure it out.

Finn


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PostPosted: Thu Sep 21, 2023 6:13 am    Post subject: OVM-14 MkIII Reply with quote

Unless the OV light has a latching function, will it not extinguish as soon as the crowbar trips the Field breaker?

Neal George
Sent from my iPhone

Quote:
do you
NOT have a low voltage warning light? What would
the ov light tell you that the lv light would not?


An over-voltage light will tell the reason for low voltage. There could be other reasons fir low voltage.
I would save troubleshooting for when safely on the ground. But some pilots might find an
over-voltage light helpful depending on the aircraft instrumentation and pilot workload and stress factor.

--------
Joe Gores


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PostPosted: Thu Sep 21, 2023 8:08 am    Post subject: OVM-14 MkIII Reply with quote

At 07:09 AM 9/21/2023, you wrote:
Quote:
--> AeroElectric-List message posted by: "user9253" <fransew(at)gmail.com>


> do you
> NOT have a low voltage warning light? What would
> the ov light tell you that the lv light would not?
>

An over-voltage light will tell the reason for low voltage.

Assuming we subscribe to "aviate, navigate, communicate
and leave tools in the hangar", then knowing why a
low voltage condition exists is not useful while
airborne. Once on the ground, a popped breaker is
as profound as a light annunciating the obvious.

Quote:
There could be other reasons fir low voltage.

Sure 'nuf. The vast majority of low voltage
conditions involve broken belts, broken
wires, worn brushes. Fault on field supply
line which would open the breaker and masquerade
as an ov condition when in fact, no such
condition exists. The PTT feature
helps resolve the paradox.

Quote:
I would save troubleshooting for when safely on the ground. But some pilots might find an
over-voltage light helpful depending on the aircraft instrumentation and pilot workload and stress factor.

I suggest that info is of no value:

LOW VOLTS LIGHT - ON
MAIN ALTERNATOR - OFF
AUX ALTERNATOR (if installed) - ON
PLAN-B LOAD MANAGEMENT - ACCOMPLISHED
LANDING - AS SOON AS PRACTICAL
TOOLBOX - OPEN

Reversion to Plan-B is consistent irrespective
of root cause, i.e. no difference in work-load.


Bob . . .

////
(o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
=================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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PostPosted: Thu Sep 21, 2023 8:24 am    Post subject: OVM-14 MkIII Reply with quote

Quote:
I would love to have an indication telling me why the field breaker tripped. Over voltage or excessive field/voltage
regulator current?

Having an annunciator call out OPEN BREAKER doesn't
help resolve the issue.

Quote:
I'm still trying to figure out why my breaker sometimes pops when pulling back to low
RPMs. I had changed the alternator pulley to prevent excessive RPMs and wear on the
alternator

Were you experiencing alternator failures or
excessive wear with a diagnosis of 'turning
too fast'?

Check with the field service gurus at B&C
to inquire as to their experience over decades
and thousands of alternator installations.
How often do alternators fail due to
mechanical wear?

About 30 years ago, Van's customer service
advice and their design policy for alternators
they supplied called for a special, oversized
pulley to slow down alternator to forestall
'excessive stress'.

In fact, slowing the alternator down only
increases field current and reduces cooling
airflow from internal fans. Bearings and
brushes are not significantly affected by
increased operating speeds.

Quote:
. . . so it may well be field over-current.

So how many other choices do you have? Trips occur
only at low rpm? OV conditions can present
at ANY rpm. Did this condition exist before
you increased pulley size?

Quote:
On the other hand field current with alternator stopped
is 3.45A and appears to be next to nothing when running at
3,000RPM and above. 5A breaker. Still working on data
logging to figure it out.

I would start by replacing the breaker . . .
your breaker may be 'soft'. Maybe upsize to
7A. Better yet, put the smaller pulley back on.



Bob . . .

////
(o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
=================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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PostPosted: Thu Sep 21, 2023 8:28 am    Post subject: OVM-14 MkIII Reply with quote

At 09:12 AM 9/21/2023, you wrote:
Quote:
--> AeroElectric-List message posted by: Neal George <neal.george(at)gmail.com>

Unless the OV light has a latching function, will it not extinguish as soon as the crowbar trips the Field breaker?

Neal George

In this case, the light was essentially
across an open breaker. I.e. it would
annunciate a 'breaker open' condition
irrespective of root cause.

Kinda like those whizzy fuses with
built in LEDs that illuminate if the
fuse is blown.

BTW Neal, I got my gmail bouncing issues
resolved with my email server. I think
I may have some messages intended for you
that were never delivered. I'll check
to see if we have any significant
issues 'hung up'.



Bob . . .

////
(o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
=================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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jluckey(at)pacbell.net
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PostPosted: Thu Sep 21, 2023 8:38 am    Post subject: OVM-14 MkIII Reply with quote

Neal - yes, latching is essential and my sketch assumes that it is possible. (and I believe that Bob confirmed that)

Joe - agree with what you said.


Off the top of my head, the alternator field breaker could be tripped for the following reasons:
1. Wiring fault
2. Regulator fault/fail
3. Breaker failure
4. Actual/legitimate over voltage event
5. OVM fault
If we get some kind of indication that the tripped field breaker is due to some action taken by the OVM then that additional info will aid in our diagnosis.

Anecdotally, I just saw a thread on another forum where and aging circuit breaker was nuisance tripping. There was quite a bit of trouble-shooting and back and fourth. After a week or two the breaker was replaced and the problem was fixed.

Another thought, the early adopters of Bob's new OVM will essentially be beta testers. If the OVM is a little "twitchy" and nuisance trips frequently, having an idiot light would immediately confirm that the OVM caused the breaker to trip. (It would not tell you what's wrong with the OVM but just knowing that it is the cause would be extremely helpful.)
I just read further down this thread. To clarify the requirements: The idiot light must indicate that the OVM "fired", not just that the field breaker is open.

-Jeff


On Thursday, September 21, 2023 at 09:15:49 AM PDT, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com> wrote:




At 07:09 AM 9/21/2023, you wrote:
Quote:
--> AeroElectric-List message posted by: "user9253" <fransew(at)gmail.com>


> do you
> NOT have a low voltage warning light? What would
> the ov light tell you that the lv light would not?
>

An over-voltage light will tell the reason for low voltage.

Assuming we subscribe to "aviate, navigate, communicate
and leave tools in the hangar", then knowing why a
low voltage condition exists is not useful while
airborne. Once on the ground, a popped breaker is
as profound as a light annunciating the obvious.

Quote:
There could be other reasons fir low voltage.

Sure 'nuf. The vast majority of low voltage
conditions involve broken belts, broken
wires, worn brushes. Fault on field supply
line which would open the breaker and masquerade
as an ov condition when in fact, no such
condition exists. The PTT feature
helps resolve the paradox.

Quote:
I would save troubleshooting for when safely on the ground. But some pilots might find an
over-voltage light helpful depending on the aircraft instrumentation and pilot workload and stress factor.

I suggest that info is of no value:

LOW VOLTS LIGHT - ON
MAIN ALTERNATOR - OFF
AUX ALTERNATOR (if installed) - ON
PLAN-B LOAD MANAGEMENT - ACCOMPLISHED
LANDING - AS SOON AS PRACTICAL
TOOLBOX - OPEN

Reversion to Plan-B is consistent irrespective
of root cause, i.e. no difference in work-load.


Bob . . .

  ////
  (o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
=================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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finn.lassen(at)verizon.ne
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PostPosted: Thu Sep 21, 2023 10:09 am    Post subject: OVM-14 MkIII Reply with quote

On 9/21/2023 12:24 PM, Robert L. Nuckolls, III wrote:

Quote:
Quote:
I would love to have an indication telling me why the field breaker tripped. Over voltage or excessive field/voltage
regulator current?

� Having an annunciator call out OPEN BREAKER doesn't
� help resolve the issue.

Quote:
I'm still trying to figure out why my breaker sometimes pops when pulling back to low
RPMs. I had changed the alternator pulley to prevent excessive RPMs and wear on the
alternator

� Were you experiencing alternator failures or
� excessive wear with a diagnosis of 'turning
� too fast'?
No, purely a preventive measure.
Quote:

� Check with the field service gurus at B&C
� to inquire as to their experience over decades
� and thousands of alternator installations.
� How often do alternators fail due to
� mechanical wear?

� About 30 years ago, Van's customer service
� advice and their design policy for alternators
� they supplied called for a special, oversized
� pulley to slow down alternator to forestall
� 'excessive stress'.

� In fact, slowing the alternator down only
� increases field current and reduces cooling
� airflow from internal fans. Bearings and
� brushes are not significantly affected by
� increased operating speeds.
In my case (Madza 13-B Renesis), cruise is typically 5,000 to 6,000 RPM. So it seems reasonable to slow down the alternator to that speed rather than maybe twice that.
Quote:

Quote:
. . . so it may well be field over-current.

� So how many other choices do you have? Trips occur
� only at low rpm?
Have seen it happen around 3,000 RPM but not as frequent as when quickly pulling back to 1,700 or so. Just need to rule out other possible causes such a intermittent shorts at certain RPMs (chafing at certain vibrations). Got 85 hours on the Hobbs, probably another 30 hours on engine in the airframe.
Quote:
OV conditions can present
� at ANY rpm. Did this condition exist before
� you increased pulley size?
Not that I recall. Certainly not as frequent.
Quote:

Quote:
On the other hand field current with alternator stopped
is 3.45A and appears to be next to nothing when running at
3,000RPM and above. 5A breaker. Still working on data
logging to figure it out.

� I would start by replacing the breaker . . .
� your breaker may be 'soft'. Maybe upsize to
� 7A. Better yet, put the smaller pulley back on.
Already replaced the breaker. New rectifier bridge and regulator in alternator.

Hate the idea of disconnecting the OV crowbar.

My plan is to improve data logging to detect the real cause.

Very recently I installed four current sensors (Kitplane article May 17, 2019) and log their output every second:� Engine bus, Main bus, Alternator field and Alternator output. They are not what I hoped for. Didn't realize how sensitive they are to other magnetic fields. Mounted near battery a few inches from alternator. I may start a new thread with my experience with them, if that would be of general interest.

Finn
Quote:



� Bob . . .

������������������ ////
����������������� (o o)
�� ===========o00o=(_)=o00o=========
�� < Go ahead, make my day . . .�� >
�� < show me where I'm wrong.����� >
�� =================================
�
�� In the interest of creative evolution
�� of the-best-we-know-how-to-do based
�� on physics and good practice.


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PostPosted: Thu Sep 21, 2023 1:28 pm    Post subject: OVM-14 MkIII Reply with quote

Quote:
My plan is to improve data logging to detect the real cause.

Very recently I installed four current sensors (Kitplane article May 17, 2019) and log their output every second:� Engine bus, Main bus, Alternator field and Alternator output. They are not what I hoped for. Didn't realize how sensitive they are to other magnetic fields. Mounted near battery a few inches from alternator. I may start a new thread with my experience with them, if that would be of general interest.

I downloaded May 2019 Kitplanes and couldn't find the article.
Can you refine the source citation?


Bob . . .

  ////
  (o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
=================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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PostPosted: Thu Sep 21, 2023 4:09 pm    Post subject: OVM-14 MkIII Reply with quote

At 11:38 AM 9/21/2023, you wrote:
Quote:
Neal - yes, latching is essential and my sketch assumes that it is possible. (and I believe that Bob confirmed that)

I'm lost . . . with the crowbar OV management
system, an OV event triggers a low resistance
load downstream of the alternator field breaker
forcing it to open thus depriving the alternator
of field excitation.

This even is inherently latching . . . the breaker
is not going to close itself. A light wired across
the open breaker would illuminate until the
breaker is re-closed.

I'm not seeing value in adding circuitry to
sense/latch based on the ov event.



Bob . . .

////
(o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
=================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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PostPosted: Thu Sep 21, 2023 4:28 pm    Post subject: OVM-14 MkIII Reply with quote

On 9/21/2023 5:28 PM, Robert L. Nuckolls, III wrote:

Quote:
Quote:
My plan is to improve data logging to detect the real cause.

Very recently I installed four current sensors (Kitplane article May 17, 2019) and log their output every second:� Engine bus, Main bus, Alternator field and Alternator output. They are not what I hoped for. Didn't realize how sensitive they are to other magnetic fields. Mounted near battery a few inches from alternator. I may start a new thread with my experience with them, if that would be of general interest.

� I downloaded May 2019 Kitplanes and couldn't find the article.
� Can you refine the source citation?


� Bob . . .

"Hall of Fame" article by Jim Weir� May 17, 2019. In Kitplanes July 2019 mag.

Attached my version. The four outputs go to analog inputs on an Arduino Mega 2590 and a SDRAM shield for logging. Not shown the hall sensors also fed by the Mega 2590's 5V power output. But shouldn't I start a new thread for this?

Finn


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PostPosted: Thu Sep 21, 2023 5:11 pm    Post subject: OVM-14 MkIII Reply with quote

I posted this under a new title but I should have posted in this thread...


Simple "OVM has Fired" Idiot Light
Here's a circuit that does the trick using a $2 latching relay. Please check it for errors. I just corrected a few and re-sent the latest version to Google Drive.

See OVMTripIndicator_SA.pdf
OVMTripIndicator_SA.pdf


On Thursday, September 21, 2023 at 05:15:46 PM PDT, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com> wrote:




At 11:38 AM 9/21/2023, you wrote:
Quote:
Neal - yes, latching is essential and my sketch assumes that it is possible. (and I believe that Bob confirmed that)

I'm lost . . . with the crowbar OV management
system, an OV event triggers a low resistance
load downstream of the alternator field breaker
forcing it to open thus depriving the alternator
of field excitation.

This even is inherently latching . . . the breaker
is not going to close itself. A light wired across
the open breaker would illuminate until the
breaker is re-closed.

I'm not seeing value in adding circuitry to
sense/latch based on the ov event.



Bob . . .

  ////
  (o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
=================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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PostPosted: Thu Sep 21, 2023 6:23 pm    Post subject: OVM-14 MkIII Reply with quote

Just send me back to my corner and crayon snacks 😊.

I looked at the proposed circuit, but didn’t study it, and in not studying, didn’t grok it – I can look at the simplest of schematics for an eternity and still not get it.  Not pairing the words with the proposed schematic, I imagined one light, multiple functions (I seem to remember a device (LR3x, maybe?)  that could set a lamp ON for over-voltage, blinking for low voltage).

Mea Culpa… didn’t mean to roll a grenade.

Neal


At 11:38 AM 9/21/2023, you wrote:

Quote:

Neal - yes, latching is essential and my sketch assumes that it is possible. (and I believe that Bob confirmed that)


I'm lost . . . with the crowbar OV management
system, an OV event triggers a low resistance
load downstream of the alternator field breaker
forcing it to open thus depriving the alternator
of field excitation.

This even is inherently latching . . . the breaker
is not going to close itself. A light wired across
the open breaker would illuminate until the
breaker is re-closed.

I'm not seeing value in adding circuitry to
sense/latch based on the ov event.


Bob . . .

////
  (o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
  =================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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PostPosted: Fri Sep 22, 2023 10:22 am    Post subject: OVM-14 MkIII Reply with quote

Crayons? I like crayons. I do some of my best work with crayons Wink... and snacks? Who doesn't like snacks?
-Jeff


On Thursday, September 21, 2023 at 07:29:44 PM PDT, Neal George <neal.george(at)gmail.com> wrote:





Just send me back to my corner and crayon snacks 😊.

I looked at the proposed circuit, but didn’t study it, and in not studying, didn’t grok it – I can look at the simplest of schematics for an eternity and still not get it. Not pairing the words with the proposed schematic, I imagined one light, multiple functions (I seem to remember a device (LR3x, maybe?) that could set a lamp ON for over-voltage, blinking for low voltage).

Mea Culpa… didn’t mean to roll a grenade.

Neal


At 11:38 AM 9/21/2023, you wrote:
Quote:

Neal - yes, latching is essential and my sketch assumes that it is possible. (and I believe that Bob confirmed that)

I'm lost . . . with the crowbar OV management system, an OV event triggers a low resistance load downstream of the alternator field breaker forcing it to open thus depriving the alternator  of field excitation. This even is inherently latching . . . the breaker is not going to close itself. A light wired across the open breaker would illuminate until the breaker is re-closed. I'm not seeing value in adding circuitry to sense/latch based on the ov event.
Bob . . .   //// (o o)   ===========o00o=(_)=o00o========= < Go ahead, make my day . . .  > < show me where I'm wrong. > ========   In the interest of creative evolution of the-best-we-know-how-to-do based on physics and good practice.


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PostPosted: Sat Sep 23, 2023 3:52 pm    Post subject: OVM-14 MkIII Reply with quote

Quote:
I looked at the proposed circuit, but didn’t study it, and in not studying, didn’t grok it – I can look at the simplest of scchematics for an eternity and still not get it. Not pairing the words with the proposed schematic, I imagined one light, multiple functions (I seem to remember a device (LR3x, maybe?)  that could set a lamp ON for over-voltage, blinking for low voltage).

Does it really do that? All the data I have
here says that light is ALWAYS flashed and
ONLY in response to a detected low voltage.

Due to the nature of LR3 crowbar ov protection,
an OV event is followed milliseconds later
by a LV event. There would not be any time
to sense, display and perceive an OV condition.


Bob . . .

  ////
  (o o)
===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
=================================

In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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PostPosted: Sun Sep 24, 2023 1:13 pm    Post subject: OVM-14 MkIII Reply with quote

Does it really do that?

Probably not.  I may have mentioned that I have an unreliable memory.

Due to the nature of LR3 crowbar ov protection,
an OV event is followed milliseconds later
by a LV event. There would not be any time
  to sense, display and perceive an OV condition.

That behavior I /do/ remember, from years of you repeating it (so that we dullards might learn it).  And that’s what spurred my comment – the way I understood the OV event in a Z-figure environment, OV would occur and be terminated before the lamp could heat up; the chances of pilot notice are exceedingly small.  Other annunciations would be necessary to indicate that an OV event preceded the LV condition.
Neal


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nuckolls.bob(at)aeroelect
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PostPosted: Mon Sep 25, 2023 9:50 am    Post subject: OVM-14 MkIII Reply with quote

Quote:
Due to the nature of LR3 crowbar ov protection,
an OV event is followed milliseconds later
by a LV event. There would not be any time
to sense, display and perceive an OV condition.



That behavior I /do/ remember, from years of you repeating it (so that we dullards might learn it). And that’s what spurred my comment – the way I understood the OV event in a Z-figure environment, OV would occur and be terminated before the lamp could heat up; the chances of pilot notice are exceedingly small. Other annunciations would be necessary to indicate that an OV event preceded the LV condition.

Neal

Exactly so my friend. Having been both designer
and producer of ov management components in both TC
and experimental markets for decades there was only ONE
device conceived that featured both OV and LV
warning. I designed it for B&C in response to
some demand from the ultralight community. Seems
it is still offered.

https://bandc.com/product/over-under-voltage-sensor/

In this instance, potential for a runaway
alternator to quickly drive bus voltage to
dangerous heights was small . . the alternator
would struggle for some time to push the battery
above 16.0v

Further, these airplanes almost never had
panel mounted, bus drive avionics . . . radios
were hand-held. I wonder how many of these
got installed on more complex airplanes . . .
not a problem. But if the alternator is
judiciously configured, the OV warning
light would never be noticed.


Bob . . .

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===========o00o=(_)=o00o=========
< Go ahead, make my day . . . >
< show me where I'm wrong. >
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In the interest of creative evolution
of the-best-we-know-how-to-do based
on physics and good practice.


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