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Tundra10
Joined: 14 Jun 2010 Posts: 102 Location: Scarborough, Ontario
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Posted: Thu Nov 18, 2010 10:32 pm Post subject: Z13/8 Rev Q comments |
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Bob,
I wonder why the feed paths to the Endurance Bus are different. The
relay from the battery bus is 14 awg and fused, while the diode from
the main power bus is 16 awg and not fused.
Previously, I was planning to use 14 awg and * 6 inches or less wire,
without any fuses for both paths. I have changed my drawing so both
paths include fuses.
Since Z13/8 highlights some new technology with E-Mags, perhaps it
makes sense to replace the Ford regulator with an electronic one that
includes overvoltage protection and low voltage annunication ?
Jeff Page
Dream Aircraft Tundra #10
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nuckolls.bob(at)aeroelect Guest
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Posted: Fri Nov 19, 2010 4:08 pm Post subject: Z13/8 Rev Q comments |
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At 12:15 AM 11/19/2010, you wrote:
Quote: |
Bob,
I wonder why the feed paths to the Endurance Bus are different. The
relay from the battery bus is 14 awg and fused, while the diode from
the main power bus is 16 awg and not fused.
|
Good question. The 16AWG wires are adequate to the
current carrying task assigned to power the e-bus
and you'll note that they're called out as "short"
wires. As "short", potentially sacrificial wires,
we'd like them to fuse open as fast as practical,
hence make them as small as practical. As we discovered
in this experiment on the bench some time back . . .
http://aeroelectric.com/Pictures/Wire/22AWG_20A.pdf
. . . a 20 AMP current through a 22AWG wire didn't
warm it enough to put the 150C insulation at risk.
So we could probably wire the short normal feed path
with 20 or even 18 AWG without 'over stressing' the
the wire.
An e-bus configured to the original idea calls for
punching through a cloud layer at the home airport,
failing an alternator, and flying comfortably to
airport of intended destination battery only. This
called for getting alternator-out endurance-bus loads
down to 2 or 3 amps. Not an terribly difficult task in
the magneto/steam-gage era.
Then came electrically dependent engines and
clusters of panel mounted 'stuff' that increased
the size of a 'minimalist' power requirement.
Okay, add the SD-8 and we've got 8-10 amps of
continuous load without depleting the battery.
Figure 2-3 amps of the original concept on top
of that and one COULD consider an e-bus load of
perhaps 13 amps. Okay, the feeders had to take
a big jump in AWG. Hence the fat feeder
for alternate feed path. If we're to observe
the reverence for crash safety and limit always
hot feeders to 7A or less, then the S704 relay
gets added and the fuse sizes go up to accommodate
the new definition of endurance loads.
This illustrates the thinking behind the disparity
between normal and alternate feed wire sizes.
Quote: | Previously, I was planning to use 14 awg and * 6 inches or less wire,
without any fuses for both paths.
|
How did you arrive at this? When the battery and main
bus fuse blocks are immediately adjacent to each other,
then the no-fuse, 16AWG feeders (or even smaller
as described above) through the diode fits legacy
design goals. But the feeder from the battery
bus to the e-bus is a long conductor that classically
gets either:
(1) 7A or less protection for skinny feeder and no
remote mini-contactor or
(2) a larger feeder and contactor per Z-32. The larger
14AWG wire is appropriate for low voltage drop on longer
wires good for up to 15A and rear mounted batteries. If
your battery is up front, that wire could comfortably
drop to 12AWG.
Quote: | I have changed my drawing so both paths include fuses.
|
Doen't hurt . . . but not necessary by legacy design
goals.
Quote: | Since Z13/8 highlights some new technology with E-Mags, perhaps it
makes sense to replace the Ford regulator with an electronic one that
includes overvoltage protection and low voltage annunication ?
|
As suggested in an earlier post, you are encouraged
to consider the full constellation of available accessories
to put frosting on the Z-13/8 cake. I doubt that no two
OBAM airplanes flying this ARCHITECTURE have the same
frosting. It's my personal goal to suggest the simplest,
lowest cost suite of components that get the job done.
If the builder's design goals and pocket-book goes beyond
those suggestions, great!
Bob . . .
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Tundra10
Joined: 14 Jun 2010 Posts: 102 Location: Scarborough, Ontario
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Posted: Sun Nov 21, 2010 8:28 am Post subject: Z13/8 Rev Q comments |
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Robert L. Nuckolls wrote:
Figure 2-3 amps of the original concept on top
of that and one COULD consider an e-bus load of
perhaps 13 amps. Okay, the feeders had to take
a big jump in AWG. Hence the fat feeder
for alternate feed path. If we're to observe
the reverence for crash safety and limit always
hot feeders to 7A or less, then the S704 relay
gets added and the fuse sizes go up to accommodate
the new definition of endurance loads.
This illustrates the thinking behind the disparity
between normal and alternate feed wire sizes.
Whether the feed is via the diode or the relay, the load is the same.
Shouldn't the wire capacity be the same ?
Quote: | Previously, I was planning to use 14 awg and * 6 inches or less wire,
without any fuses for both paths.
|
How did you arrive at this? When the battery and main
bus fuse blocks are immediately adjacent to each other,
then the no-fuse, 16AWG feeders (or even smaller
as described above) through the diode fits legacy
design goals. But the feeder from the battery
bus to the e-bus is a long conductor that classically
gets either:
(1) 7A or less protection for skinny feeder and no
remote mini-contactor or
(2) a larger feeder and contactor per Z-32. The larger
14AWG wire is appropriate for low voltage drop on longer
wires good for up to 15A and rear mounted batteries. If
your battery is up front, that wire could comfortably
drop to 12AWG.
My battery will be on the front of the firewall. I planned the
connections between busses, contactors and relays all to be less than
6", so I originally omitted fuses. I am minimizing my inventory by
purchasing only 14, 18 and 22 gauge wire, since the numbers worked out
that I would rarely need 16 and 20 gauge wire. So the 16 awg feeders
changed to 14 awg.
Since my busses will be fuse blocks, it is quite easy to use one of
the fuse positions to feed the bus. However, I would prefer fewer
connections if you think the additional fuses are not needed.
My "Endurance" bus grew. I will be flying IFR. My Plan B for a main
alternator failure is to have a sufficient secondary alternator to
continue to power one Dynon Skyview screen, a Garmin 430W, audio panel
and instrument lights and some indicators. This could be 10A, peaking
to 16A during transmissions. Rather than a load meter, the low
voltage indicator will confirm that the secondary alternator is
carrying the load. The dark and stormy night equipment is my Plan C.
Jeff Page
Dream Aircraft Tundra #10
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fvalarm(at)rapidnet.net Guest
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Posted: Sun Nov 21, 2010 9:13 am Post subject: Z13/8 Rev Q comments |
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Jeff,
If I recall correctly and Bob may confirm, the SD8 aux alt actually puts out
up to 10mp at the rpm we fly. Further, in a main alternator out scenario,
this is to be matched to the continuous draw of your minimum equipment list.
The surge current for transmitting etc can come from the battery.
Therefore, I would think that the SD8 will be sufficient as I'm doing
similar as you.
Bevan
RV7A wiring, not flying yet.
--
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Tundra10
Joined: 14 Jun 2010 Posts: 102 Location: Scarborough, Ontario
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Posted: Mon Nov 22, 2010 5:35 am Post subject: Z13/8 Rev Q comments |
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Quote: | Jeff,
If I recall correctly and Bob may confirm, the SD8 aux alt actually puts out
up to 10mp at the rpm we fly. Further, in a main alternator out scenario,
this is to be matched to the continuous draw of your minimum equipment list.
The surge current for transmitting etc can come from the battery.
Therefore, I would think that the SD8 will be sufficient as I'm doing
similar as you.
Bevan
RV7A wiring, not flying yet.
|
I typically cruise at 2200 rpm. For a Lycoming the pad ratio is
1.3:1. at 2860 rpm, the SD-8 outputs approx 6.2A, which is just a
little shy of what I need. Some items, such as the instrument panel
lights can be turned down or off. The Skyview probably drawsa less
current if it is dimmed as well. The SD-8 will produce more power if
I cruise at a higher rpm. So my Plan B has me doing a little
adjustment to keep the low voltage warning light off.
I would like to include a transponder on my endurance bus, but that
would require the SD-20. More cost and weight for a very unlikely
situation.
Jeff Page
Dream Aircraft Tundra #10
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fvalarm(at)rapidnet.net Guest
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Posted: Mon Nov 22, 2010 10:06 am Post subject: Z13/8 Rev Q comments |
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OK,
I stand corrected on the output of the SD-8.
Good info here. I check my E-buss to see if it's less than 6 amp
continuous.
Bevan
RV7A wiring
--
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nuckolls.bob(at)aeroelect Guest
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Posted: Mon Nov 22, 2010 1:46 pm Post subject: Z13/8 Rev Q comments |
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At 11:10 AM 11/21/2010, you wrote:
Quote: |
Jeff,
If I recall correctly and Bob may confirm, the SD8 aux alt actually puts out
up to 10mp at the rpm we fly.
|
Correct . . . sort of . . . the NORMAL manner in which
alternators are rated calls for supporting the bus
a the design set point. Say 14.2 - 14.6 volts. At the
same time, a battery doesn't deliver significant energy
into the system until the bus sags to 12.5 or so volts.
The "normal" rating for the SD-8 is 8A. However, the max load
you can support with an SD-8 without taxing the battery
closer to 10A because the bus voltage can be allowed to sag.
This is why I don't show low-voltage warning on the E-bus.
Even with an SD-8 powering it (as in Z-13/. A satisfactory
operating design point voltage is probably below the trip
point for a l3v warning light driver.
Quote: | Further, in a main alternator out scenario,
this is to be matched to the continuous draw of your minimum equipment list.
The surge current for transmitting etc can come from the battery.
Therefore, I would think that the SD8 will be sufficient as I'm doing
similar as you.
|
If we were comfortable with the idea of taxing
a battery for a minimum endurance during alternator
out operations, the act of adding an SD-8 on top
of the battery does not convert the battery's stored
energy into a sacred commodity.
If you needed to support a 13A endurance bus under
some conditions, why not? The points to be pondered
are minute details for how "plan-b" or perhaps even
a "plan-c" are implemented. What preventative
maintenance tests to the battery will be religiously
conducted to insure support for your "worst case"
but planned-for scenario.
Building an OBAM aircraft is a mixed bag. There's
a LOT of planning supported by a lot of understanding
that is NOT covered in a holy-watered POH for your
project.
You're on your own to make sure you've got "the plan" and
understanding that meets your design goals. Well,
not entirely on your own . . . there IS the AeroElectric
List.
This discussion highlights the importance of both
load analysis and failure mode effects that drive
configuration of both hardware and your "plan-b".
Bob . . .
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nuckolls.bob(at)aeroelect Guest
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Posted: Tue Nov 23, 2010 6:41 am Post subject: Z13/8 Rev Q comments |
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At 10:21 AM 11/21/2010, you wrote:
(Me from earlier post) This illustrates the
thinking behind the disparity between normal
and alternate feed wire sizes.
Whether the feed is via the diode or the relay, the load is the same.
Shouldn't the wire capacity be the same ?
Wire sizes may be based on a constellation of
considerations. The legacy convention for 22 AWG
on 5A breakers, 20AWG on 7A breakers, etc. is
EXCEEDINGLY conservative and produces a system
with low voltage drops and temperature rises.
In this special case, we're considering the RARE
but not-zero probability that the normal feed
path wire could also be a fusible link. If we
embrace the legacy policy of allowing wires of 6"
or less to burn as along as they don't put other
wires at risk, then the two short wires I've
shown can be smaller because their voltage drops
are short and their temperature rises very small.
The smaller the wire, the faster they'll fuse.
My battery will be on the front of the firewall. I planned the
connections between busses, contactors and relays all to be less than
6", so I originally omitted fuses. I am minimizing my inventory by
purchasing only 14, 18 and 22 gauge wire, since the numbers worked out
that I would rarely need 16 and 20 gauge wire. So the 16 awg feeders
changed to 14 awg.
I can send you a chunk of any other size . . . but
it would be better to go down as opposed to up
in size for the un-fused, short wires. 20AWG would
be fine. Use REAL PIDG terminals on these wires.
Since my busses will be fuse blocks, it is quite easy to use one of
the fuse positions to feed the bus. However, I would prefer fewer
connections if you think the additional fuses are not needed.
Okay, 20AWG and no fuses it is.
My "Endurance" bus grew. I will be flying IFR. My Plan B for a main
alternator failure is to have a sufficient secondary alternator to
continue to power one Dynon Skyview screen, a Garmin 430W, audio panel
and instrument lights and some indicators. This could be 10A, peaking
to 16A during transmissions. Rather than a load meter, the low
voltage indicator will confirm that the secondary alternator is
carrying the load. The dark and stormy night equipment is my Plan C.
Okay, does your SD-8 drive pad give you 4000 rpm
at engine red-line? Even then, you won't keep a low
voltage warning light OFF during endurance operations.
The SD-8 may be too small for your plan-b loads in
an un-limited endurance mode. You may have to up-size
the alternator or plan for using significant battery
energy to support the e-bus. This is STILL much better
than a battery-only scenario but might call for a
comfortable plan-b endurance of 1 hour or so. You'll
want to measure your REAL plan-b loads as soon as
all the goodies can be fired up.
Bob . . .
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longg(at)pjm.com Guest
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Posted: Tue Nov 23, 2010 7:50 am Post subject: Z13/8 Rev Q comments |
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IMO the SD-8 works well for the main power out scenario. I have the same
setup, but with a G530. One needs to ask oneself how many primary power
blackouts will ye observe on dark and stormy nights in flight.
Murphy says, there will be at least one. If you fly one every week, your
system has real issues and your preparedness is terrible. That would
also mean your planning is also terrible.
I find that with my Dynon pulling a whopping 1 amp, and my SL30 sending
a VOR signal to the Dynon HSI, I can handle most stormy night
situations. That may mean diversion, but you already have a problem, so
you're diverting anyway, right? If you fly all the way home with a major
problem at night, we'll you're just accepting lots of risk. All of these
designs are based on getting you to safety, not transcontinental flight
after major power loss.
Early system planning is fantastic, but I find most folks over do it.
What is your mission? Are you flying the mail every night? Based on the
traffic I see at most airports at night, I'm glad I don't depend on them
for food. I'd be starving.
Have a good handheld WAAS GPS on board and keep the batteries fresh. I
use the True Flight job which does approaches nearly as well as the
Garmin (in a pinch of course). Turn all the unnecessary crap off. That's
most of it.
Recently I bought one of those head mounted lamps. They are fantastic
for that situation. Get the best one you can buy. The one I bought has
the red night light included. I find I use it all the time now.
Include some good cabin LED lights in your plan. Most cockpits are
poorly lighted for night operations. Get some good lighting that don't
draw much juice.
Most importantly have fun and good holiday.
Glenn
--
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nuckolls.bob(at)aeroelect Guest
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Posted: Tue Nov 23, 2010 9:42 am Post subject: Z13/8 Rev Q comments |
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<snip>
Quote: | Include some good cabin LED lights in your plan. Most cockpits are
poorly lighted for night operations. Get some good lighting that don't
draw much juice.
|
Most importantly have fun and good holiday.
Well considered posting sir. Thank you. I'll remind the
ol' timers and alert the newbies of the ideas
and deliberations offered in the systems reliability
chapter of the 'Connection.
I've never owned and airplane with an electrical
system in it . . . the one airplane I did own for
a time wasn't a cross country machine (J-3).
When I fly, it's always in a rented airplane selected
from a fleet of perhaps a dozen options. I don't KNOW
the history of the airplane's electrical system in
detail. I PLAN to be able to complete a leg of my trip
in the "J-3 mode". I.e., panel dark, master switch off.
http://aeroelectric.com/Pictures/Misc/Vacination_for_Dark_Panel_Syndrom.pdf
So if your mission profiles call for system capabilities
that cannot be COMFORTABLY conducted in a minimalist
approach to backup, then as Glen suggests, think all
this stuff through very carefully.
It's not a task that should be scarry, just informative
so that good judgement can prevail for any situation
you're faced with. The vast majority of unhappy days
in the cockpit or unplanned arrivals with the earth
had nothing to do with an alternator failure or system
configuration/maintenance. Poor judgement and/or over-
stretched skills account for most of aviation's sad stories.
Airplanes are never SAFE. Like cars, handguns,
and skateboards, they are but tools that offer an
opportunity for great utility, fun and personal
satisfaction. Deliberations on the AeroElectric-
List are not about safety. They're about risk
reduction for how YOUR machine will be configured
for how YOU plan to use it combined with YOUR
skills to cope. This isn't something you get by
reading the emergency procedures section of the
POH.
Bob . . .
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Tundra10
Joined: 14 Jun 2010 Posts: 102 Location: Scarborough, Ontario
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Posted: Wed Nov 24, 2010 7:14 am Post subject: Z13/8 Rev Q comments |
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> My battery will be on the front of the firewall. I planned the
> connections between busses, contactors and relays all to be less than
> 6", so I originally omitted fuses. I am minimizing my inventory by
> purchasing only 14, 18 and 22 gauge wire, since the numbers worked out
> that I would rarely need 16 and 20 gauge wire. So the 16 awg feeders
> changed to 14 awg.
>
> I can send you a chunk of any other size . . . but
> it would be better to go down as opposed to up
> in size for the un-fused, short wires. 20AWG would
> be fine. Use REAL PIDG terminals on these wires.
>
> Since my busses will be fuse blocks, it is quite easy to use one of
> the fuse positions to feed the bus. However, I would prefer fewer
> connections if you think the additional fuses are not needed.
>
> Okay, 20AWG and no fuses it is.
So assuming all these wires are 6" or less, should I use 20awg and no
fuses on both the diode and the relay path to the Endurance bus ?
> My "Endurance" bus grew. I will be flying IFR. My Plan B for a main
> alternator failure is to have a sufficient secondary alternator to
> continue to power one Dynon Skyview screen, a Garmin 430W, audio panel
> and instrument lights and some indicators. This could be 10A, peaking
> to 16A during transmissions. Rather than a load meter, the low
> voltage indicator will confirm that the secondary alternator is
> carrying the load. The dark and stormy night equipment is my Plan C.
>
> Okay, does your SD-8 drive pad give you 4000 rpm
> at engine red-line? Even then, you won't keep a low
> voltage warning light OFF during endurance operations.
> The SD-8 may be too small for your plan-b loads in
> an un-limited endurance mode. You may have to up-size
> the alternator or plan for using significant battery
> energy to support the e-bus. This is STILL much better
> than a battery-only scenario but might call for a
> comfortable plan-b endurance of 1 hour or so. You'll
> want to measure your REAL plan-b loads as soon as
> all the goodies can be fired up.
For a while, I was planning on a larger secondary alternator, but the
plan was getting out of control for an unlikely situation. Glenn's
comments make sense. I think I am better off minimizing the
electrical usage. Some of the items, like the Skyview will probably
take less in actual use than the rated maximum.
I can use a low voltage warning for the SD-8 with a lower voltage trip
point, so I know when the battery is actually carrying part of the load.
At 2700 rpm, the SD-8 will be turning 3500 rpm, with higher fuel
consumption. I can make that tradeoff in flight, depending on the
distance of the destination.
Jeff Page
Dream Aircraft Tundra #10
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nuckolls.bob(at)aeroelect Guest
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Posted: Wed Nov 24, 2010 9:27 am Post subject: Z13/8 Rev Q comments |
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At 09:03 AM 11/24/2010, you wrote:
For a while, I was planning on a larger secondary alternator, but the
plan was getting out of control for an unlikely situation. Glenn's
comments make sense. I think I am better off minimizing the
electrical usage. Some of the items, like the Skyview will probably
take less in actual use than the rated maximum.
Exactly! I can't tell you how many exercises in load
analysis ended with considerable error in the final
totals. Not so much from a variance in the published
values for any one accessory . . . but when you have
dozens of accessories . . .
You know the ol' saw: "A million here, a billion there
and pretty soon, we're talking about real money!"
The neat thing about the e-bus architecture is the
ease with which an experimental direct measurement
of endurance loads can be accomplished. I've oft
pondered the notion of adding a shunt in series
with the e-bus alternate feed path. Silly of course,
this is a one-time exercise that does not justify
permanent installation of instrumentation.
I can use a low voltage warning for the SD-8 with a lower voltage trip
point, so I know when the battery is actually carrying part of the load.
At 2700 rpm, the SD-8 will be turning 3500 rpm, with higher fuel
consumption. I can make that tradeoff in flight, depending on the
distance of the destination.
Now you're THINKING about it. Today's bright stars
for plan-b may differ from what you ultimately
fly with. But every modification will go toward
establishing and meeting design goals for NEVER
experiencing an electrical emergency.
Bob . . .
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Tundra10
Joined: 14 Jun 2010 Posts: 102 Location: Scarborough, Ontario
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Posted: Thu Nov 25, 2010 9:17 pm Post subject: Z13/8 Rev Q comments |
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Quote: | Okay, 20AWG and no fuses it is.
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So assuming all these wires are 6" or less, should I use 20awg and no
fuses on both the diode and the relay path to the Endurance bus ?
Jeff Page
Dream Aircraft Tundra #10
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nuckolls.bob(at)aeroelect Guest
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Posted: Fri Nov 26, 2010 6:52 am Post subject: Z13/8 Rev Q comments |
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At 11:07 PM 11/25/2010, you wrote:
Quote: |
> Okay, 20AWG and no fuses it is.
So assuming all these wires are 6" or less, should I use 20awg and no
fuses on both the diode and the relay path to the Endurance bus ?
|
I WAS speaking of just the normal feed path through
the diode . . . and it occurs to me that the "6-inch
rule" would be speaking to TOTAL current pathway at
risk . . . so strict observance of the rule would call
for very short 20AWG conductors totalling 6" or less
to wire the diode up between the main and e-bus.
But then, that "rule" was never codified in any regulatory
document I recall . . . but that doesn't mean it didn't
show up on some FAA offices "green sheets". My citation
of that practices goes back a long way. I think I first
recall discussing it at Cessna when somebody was contemplating
the permanent wiring of a fat zener (50W stud mounted)
to the main bus as a transient suppressor. This was
before the zener market gave birth to the Transorb.
Is the sum total of wire from battery bus to e-bus
through the relay must surely be longer. Further, it's
primary reason for existence is to power a bus from
a battery not being charged by an alternator so we'll
not want to squander energy in voltage drops. But it
seems that the pathway would benefit from the conventional
protection methods at BOTH ends since that wire can be
SOURCED either from the main bus or the battery bus.
Bob . . .
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Tundra10
Joined: 14 Jun 2010 Posts: 102 Location: Scarborough, Ontario
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Posted: Sat Nov 27, 2010 7:04 am Post subject: Z13/8 Rev Q comments |
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Quote: | >> Okay, 20AWG and no fuses it is.
>
> So assuming all these wires are 6" or less, should I use 20awg and no
> fuses on both the diode and the relay path to the Endurance bus ?
I WAS speaking of just the normal feed path through
the diode . . . and it occurs to me that the "6-inch
rule" would be speaking to TOTAL current pathway at
risk . . . so strict observance of the rule would call
for very short 20AWG conductors totalling 6" or less
to wire the diode up between the main and e-bus.
But then, that "rule" was never codified in any regulatory
document I recall . . . but that doesn't mean it didn't
show up on some FAA offices "green sheets". My citation
of that practices goes back a long way. I think I first
recall discussing it at Cessna when somebody was contemplating
the permanent wiring of a fat zener (50W stud mounted)
to the main bus as a transient suppressor. This was
before the zener market gave birth to the Transorb.
Is the sum total of wire from battery bus to e-bus
through the relay must surely be longer. Further, it's
primary reason for existence is to power a bus from
a battery not being charged by an alternator so we'll
not want to squander energy in voltage drops. But it
seems that the pathway would benefit from the conventional
protection methods at BOTH ends since that wire can be
SOURCED either from the main bus or the battery bus.
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OK. It is easy to use fuses, since I can just use one of the
positions of the fuse block on each end.
Jeff Page
Dream Aircraft Tundra #10
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