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Where appropriate, new gaskets should be fitted between mounting faces, and new O-rings
should also be fitted on generator drive shafts.
Generator cables should be checked for signs of damage to terminations, for fraying, and for
chafing of insulation covering. The coincidence of cable ends should also be checked to ensure
that cables will not be subjected to strain particularly at points of entry to terminal boxes or other
forms of connector.
Installation Procedures
When locating generators of the splined drive shaft type, they should be turned slightly in each
direction about the drive axis to facilitate proper engagement of the splines.
After a generator has been correctly orientated on its mounting, it should be secured, paying
particular attention to any torque values specified for tightening retaining nuts or quick
attach/detach couplings as appropriate to the installation. Before finally tightening the retaining
nuts of generators having buttonhole-shaped slots in their mounting flanges, the generators
should be rotated on the mounting studs until the latter are concentric with the slotted sections.
Generators which are to be mounted horizontally should be adequately supported during

installation and not be allowed to hang on their drive shafts or on mounting studs. In some
aircraft in which constant-speed generators may be removed and installed separately from their
drive units, or which are of the integrated drive type, a special hoisting rig is provided and this
must be used in the manner specified in the relevant aircraft Maintenance Manual.
Integrated drive generator units are usually provided with an electrically-operated disconnect
mechanism which permits isolation of the generator from the engine in the event of malfunction
of either the transmission system, the constant-speed drive or the generator. The mechanism is
controlled by a switch in the flight compartment, and a solenoid which, on being energised,
disengages the constant-speed input drive clutch from the input gear thus preventing rotation of
the transmission. The constant-speed drive can normally only be re-engaged by manually
operating a reset handle located at the bottom of the integrated drive unit.
NOTE: This should only be done with the engine at rest or damage may result.
Cooling Systems
Whenever servicing is carried out on an integrated drive generator, the following information
should be carefully observed.
 An integrated drive generator which has recently been running may contain hot oil under
pressure.
 Do not overfill. Overfilling can cause overheating and oil sludging, resulting in
transmission damage.
 The minimum number of components should be in the line when flushing is carried out
This is to prevent the debris that usually accumulates in the oil cooler from contaminating
them: never flush with new components connected into the system.
Module 13.5 Electrical Power (ATA 24) 5.101

Turkish Technic Inc.
© Copyright 2016 Training Purpose Only Rev.00 – 31 March 2016
 Specific maintenance procedures for each type of generator and aircraft installation will
be found in the relevant Maintenance Manual, to which full attention should be given. The
following procedures are therefore to serve only as a general guide.
Before connecting cooling ducts to an air-cooled generator, the ducts should be inspected for
cleanliness, signs of damage and for correct orientation. Where a cooling-air duct or scoop is
fitted to a removable cowling panel, the duct or scoop should be checked for correct alignment
with the air inlet connection of the generator.
The oil supplied to integrated drive generators passes through an oil cooler mounted on the
engine. Before installation of a replacement integrated drive generator it is necessary to ensure
that the cooler inlet and outlet pipelines are free from any contamination.
Flushing should be carried out to ensure that debris from a previous failure will not contaminate
the replacement. On completion, the pipelines should be correctly orientated and their con-
nections to the generator unit tightened to the specified torque values, and wire locked. This
also applies to vent pipes and drains. On completion of the installation procedure, the oil system
must be filled and primed.
Flushing
This should be carried out with the minimum number of components in the lines to prevent the
debris that usually accumulates in the oil cooler, from contaminating them. A system should
never be flushed with new or replacement components connected into the lines. A preferred
method would, therefore, be to remove the system for flushing in the workshop. The general
procedure for flushing the aircraft system, when required, should be carried out in accordance
with the following steps:
a) Fill and prime the system but do not carry out the topping-up section of the procedure.
b) Drain the system.
c) Fill and prime the system.
Draining
a) Place a suitable container beneath the magnetic drain plug.
b) Vent the integrated drive generator by pressing in the case pressure vent valve, after first
allowing the oil to cool.
c) Clean the area around the magnetic drain plug.
d) Remove the magnetic drain plug.
e) Inspect the magnetic drain plug for contamination.
f) Fit the drain hose in place of the magnetic drain plug; oil will flow through the drain hose.
When the oil content has drained into the container, remove the drain hose.
NOTE: This oil should never be used to refill the system.

Ensure that serviceable sealing rings are fitted to the magnetic drain plug, then refit. Place a
warning placard on the integrated drive generator stating that it is drained of oil.
Fill and Prime

a) Vent the integrated drive generator case.
b) Connect the delivery hose of the replenishing gun to the re-oiling coupling.
5.102 Module 13.5 Electrical Power (ATA 24)

Rev.00 - 31 March 2016 Training Purpose Only © Copyright 2016
c) Carefully fill with oil until the oil reaches the top of the oil level mark on the sight glass.
d) Close the case pressure vent valve.
e) Disconnect the re-oiling delivery hose and assemble the quick-release cap to the re-
oiling coupling.
f) Pull the disconnect reset handle to ensure that the integrated drive generator is engaged.
g) Carry out an engine dry motoring cycle, to ensure that the system is fully primed.
h) Vent the case and allow the specified time for the oil levels to equalise. Check that the oil
level is within the oil level mark on the sight glass. If the oil level is correct, close the case
pressure vent valve by pulling it out to its fullest extent.
i) If the level is not correct, repeat steps (a) to (g) for low level or carry out the drain
procedure for high level.

Intentionally Blank

Voltage Regulation
Voltage regulation is accomplished by varying the field strength of the AC generator's exciter
field in order to keep the output voltage constant under varying speed and load conditions.
There are two main methods of carrying this out:
 The exciter field is fed with DC, which is varied in strength using an Error Sensing
Bridge.
 The exciter field is fed with a stream of pulses, the amplitude of which remains constant
whilst the width of the pulses is increased to increase the overall field current and
decreased to decrease field current. This is known as Pulse Width Modulation.
Voltage regulators are used in aircraft primary power supply systems to maintain the system
voltage within the limits necessary for the correct operation of the associated electrical services.
In addition, they are, in some cases, used to control the sharing of load between generators
operating in parallel.
Depending on the size of the aircraft and design of the generating system, regulators may be of
the single unit type operating in conjunction with separate reverse current cut-out relays, voltage
differential sensing relays and paralleling relays, or integrated with these components to form
special control units or panels.
Figure 5.61: Theory of voltage regulation
The basic requirement of maintaining a substantially constant voltage in an aircraft power

supply system is achieved by the automatic control of the generator field strength, using various
types of voltage regulator. The principles of operation of some of these types are contained in
the following paragraphs.

Carbon-pile Voltage Regulator
The operation of the carbon-pile type of voltage
regulator is based on the fact that the contact
electrical resistance between faces of carbon discs
varies not only with actual area of contact, but also
with the pressure by which disc faces are held
together. If therefore, a 'pile' of carbon discs or
washers is connected in series with the shunt field
winding of a generator (Figure 5.63) the resistance
of the field circuit can be varied by adjusting the
pressure applied to the 'pile'.
Figure 5.62: A typical carbon pile regulator
Figure 5.63: Carbon pile regulator circuit

Figure 5.64: Carbon pile regulator sectioned
The necessary variation of pile compression is made through the medium of an electromagnet
which opposes the compressive effect of a plate-type control spring (Figure 5.63). Under static
conditions the compressive effect is at a maximum and carbon-pile resistance is at some
minimum value. The electromagnet is energised by a voltage coil which is connected across the
generator output terminals so that coil current and, consequently, electromagnetic force are
substantially proportional to generator output voltage. As the rotational speed of the generator
increases, the progressive increase in its voltage results in an increase of electromagnetic force
until, at a pre-set voltage level, the electromagnetic force is balanced by the plate-type control
spring. If the generator output voltage exceeds the pre-set level, the increase in electromagnetic
force overcomes the force of the plate-type control spring and reduces the pile compression,
thereby increasing the resistance of the generator shunt field circuit and thus checking the rise
in output voltage.

Construction
The construction of a typical carbon-pile voltage regulator is shown in Figure 5.64. The pile unit
is housed within a ceramic tube which, in turn, is enclosed in a solid casing or, more generally,
a finned casing for dissipating the heat generated by the carbon pile. Electrical contact at each
end of the pile is made by carbon inserts. The initial pressure on the pile is set by a
compression screw acting through the pile on the armature and spring plate which is supported
on a bi-metal washer. This washer compensates for temperature effects on voltage coil
resistance and on any expansion characteristic of the regulator, thus maintaining constant pile
compression. The electromagnet assembly comprises a cylindrical yoke in which is housed the
voltage coil, a detachable end-plate and an adjustable soft-iron core. The cables from the
voltage coil and carbon pile terminate at a connector block or plug on the end plate of the
regulator.
Figure 5.65: Carbon pile regulator circuit

Regulator Adjustments
Three separate adjustments are normally provided in carbon pile-voltage regulators: (a) voltage
coil circuit resistance, (b) magnet core airgap and (c) carbon pile compression.
Voltage Coil Circuit Resistance - Adjustment of voltage coil circuit resistance is accomplished
by a ballast resistor, pre-set by the manufacturer, to give the correct ampere turns in the voltage
coil at the nominal voltage to be controlled. In addition to the ballast resistor, a trimming resistor
is also provided for raising or lowering the regulated voltage level within certain limits, after the
regulator is installed in an aircraft.
Magnet Core Airgap - The airgap between the magnet core and the armature is pre-set by
adjusting the position of the magnet core within the end-plate of the electromagnet housing. The
adjustment provides for optimum regulation at the nominal controlled voltage.
NOTE: In some older types of regulator a screw passes through the magnet core, limiting
excessive armature movement and preventing the armature from adhering to the face of the
core. In later designs this screw is not fitted.
Carbon Pile Compression - Initial compression of the carbon pile is adjusted by the
compression screw (Figure 5.64) to give the correct setting of the plate-type control spring, so
that, over the working range of the pile, the spring and magnetic forces exactly counterbalance
at any position of the armature. The setting of the screw may be regarded as the characteristic
setting of the regulator, and determines the degree of regulation and the stability factor

Vibrator-type Voltage Regulator
This type of voltage regulator usually consists of a voltage regulator, a current Iimiter, and a
reverse current cut-out relay housed in the one metal container.
Figure 5.66: Vibrator Type voltage regulator
Principle of Operation
The voltage coil senses the output voltage from the generator. When the voltage reaches a pre-
set level (set by the adjustment spring), an electromagnetic force created within the voltage coil
will open the contact points and reduce the flow of current to the shunt field. The output of the
generator will fall rapidly and thus the contact points will close again, allowing the
electromagnetic force within the voltage coil to build back up.
The resultant effect is that the contact points are continually vibrating open and closed..
Figure 5.67: Vibrator type voltage regulator circuit

Three-Unit Regulators
Many light aircraft employ a three unit regulator for their generator systems. This type of
regulator includes a current limiter and a reverse current cut-out in addition to a voltage
regulator.
The action of the voltage regulator unit is similar to the vibrating-type regulator described earlier.
The second of the three units is a current regulator to limit the output current of the generator.
The third unit is a reverse current cut-out that disconnects the battery from the generator. If the
battery is not disconnected, it will discharge through the generator armature when the generator
voltage falls below that of the battery, thus driving the generator as a motor. This action is called
"motoring" the generator and, unless it is prevented, it will discharge the battery in a short time.
The operation of a three unit regulator is described in the following paragraphs. (Refer to Figure
5.68.)
Figure 5.68: Three unit regulator circuit
The action of vibrating contact C1 in the voltage regulator unit causes an intermittent short
circuit between points R1 and L2. When the generator is not operating, spring S1 holds C1
closed; C2 is also closed by S2. The shunt field is connected directly across the armature.
When the generator is started, its terminal voltage will rise as the generator comes up to speed,
and the armature will supply the field with current through closed contacts C2 and C1.
As the terminal voltage rises, the current flow through L1 increases and the iron core becomes
more strongly magnetized. At a certain speed and voltage, when the magnetic attraction on the
movable arm becomes strong enough to overcome the tension of spring S1, contact points C1
are separated. The field current now flows through R1 and L2. Because resistance is added to

the field circuit, the field is momentarily weakened and the rise in terminal voltage is checked.
Also, since the L2 winding is opposed to the L1 winding, the magnetic pull of L1 against S1 is
partially neutralized, and spring S1 closes contact C1. Therefore, R1 and L2 are again shorted
out of the circuit, and the field current again increases; the output voltage increases, and C1 is
opened because of the action of L1. The cycle is rapid and occurs many times per second. The
terminal voltage of the generator varies slightly, but rapidly, above and below an average value
determined by the tension of spring S1, which may be adjusted.
The purpose of the vibrator-type current limiter is to limit the output current of the generator
automatically to its maximum rated value in order to protect the generator. As shown in Figure
5.68, L3 is in series with the main line and load. Thus, the amount of current flowing in the line
determines when C2 will be opened and R2 placed in series with the generator field. By
contrast, the voltage regulator is actuated by line voltage, whereas the current limiter is actuated
by line current. Spring S2 holds contact C2 closed until the current through the main line and L3
exceeds a certain value, as determined by the tension of spring S2, and causes C2 to be
opened. The increase in current is due to an increase in load. This action inserts R2 into the
field circuit of the generator and decreases the field current and the generated voltage. When
the generated voltage is decreased, the generator current is reduced. The core of L3 is partly
demagnetized and the spring closes the contact points. This causes the generator voltage and
current to rise until the current reaches a value sufficient to start the cycle again. A certain
minimum value of load current is necessary to cause the current limiter to vibrate.
Figure 5.69: Inside a three-unit regulator

The purpose of the reverse current cut-out relay is to automatically disconnect the battery from
the generator when the generator voltage is less than the battery voltage. If this device were not
used in the generator circuit, the battery would discharge through the generator. This would
tend to make the generator operate as a motor, but because the generator is coupled to the
engine, it could not rotate such a heavy load. Under this condition, the generator windings may
be severely damaged by excessive current.
There are two windings, L4 and L5, on the soft iron core. The current winding, L4, consisting of
a few turns of heavy wire, is in series with the line and carries the entire line current. The
voltage winding, L5, consisting of a large number of turns of fine wire, is shunted across the
generator terminals.
When the generator is not operating, the contacts, C3 are held open by the spring S3. As the
generator voltage builds up, L5 magnetizes the iron core. When the current (as a result of the
generated voltage) produces sufficient magnetism in the iron core, contact C3 is closed, as
shown. The battery then receives a charging current. The coil spring, S3, is so adjusted that the
voltage winding will not close the contact points until the voltage of the generator is in excess of
the normal voltage of the battery. The charging current passing through L4 aids the current in
L5 to hold the contacts tightly closed. Unlike C1 and C2, contact C3 does not vibrate. When the
generator slows down or, for any other cause, the generator voltage decreases to a certain
value below that of the battery, the current reverses through L4 and the ampere turns of L4
oppose those of L5. Thus, a momentary discharge current from the battery reduces the
magnetism of the core and C3 is opened, preventing the battery from discharging into the
generator and motoring it. C3 will not close again until the generator terminal voltage exceeds
that of the battery by a predetermined value
Current Limiting
At any time the current drawn by the load reaches the pre-set value, the magnetic field
produced by the heavy coil of the current Iimiter will open the limiter contacts and insert a
resistor into the generator field circuit. The increased field resistance will, therefore, lower the
output voltage and decrease the current. When the current drops, the contacts close and the
voltage again increases. As long as the demands for current exceed the pre-set value, the
current-limiter contacts will vibrate.

Figure 5.70: Current limiter circuit

Reverse Current Cut-out Relay
When the generator voltage rises above that of the battery, the magnetic field of the voltage coil
in the reverse current cut-out relay will close the contacts and place the generator on line. Load
current then flows through the current coil and produces a magnetic field, which aids that
produced by the voltage coil and holds the contacts tightly closed. When engine speed
decreases and the generator output drops below that of the battery, current will flow from the
battery into the generator armature. Current flowing through the current coil of the cut-out relay
produces a magnetic field which opposes the field of the voltage coil, and a spring will now open
the contacts, taking the generator off line.
Figure 5.71: Reverse current cut-out circuit

Error Sensing Bridge Method
Operation with a single generator running is as follows: The output of the AC generator is fed
via a full-wave rectifier bridge, complete with choke/capacitor smoothing, to an Error Sensing
Bridge (Figure 5.72 phases A, B, and C). A trimmer is used to set the circuit so that, when the
AC output is correct (200V), 170Vdc is applied to the bridge. The two constant voltage tubes in
the bridge each maintain a voltage of 85V across itself throughout its working range.
Under correct output conditions the points A' and 'B' are at the same potential and no current
flows in the control winding of the magnetic amplifier.
If there is an increase in line voltage (caused by increased speed or reduction in load) then this
will cause an increased DC voltage to be applied to the error sensing bridge. Due to the action
of the constant voltage tubes, point A now becomes positive with respect to point B and current
flows through the control winding (in the voltage regulator) from A to B.
Figure 5.72: Error sensing voltage regulation

This has the effect of reducing the current in the exciter field and so reducing the generator
output voltage back to normal.
With a decreased line voltage (caused by decreased speed or increase in load) this causes an
action that is opposite to that of the previous paragraph, with point B becoming positive with
respect to point A. This causes current to flow in the opposite direction through the control
winding, resulting in an increase in field current and an increase in generator output.
Figure 5.73: Current transformer (CH47D Chinook)

Solid-state Voltage Regulators
These generally fall into two categories: transistorised voltage regulators, which use a transistor
to actually control the flow of field current but an electromagnetic coil is used to sense the
voltage, and transistorised voltage regulators, which are fully solid-state and sense the voltage
by a zener diode.
Transistorised Voltage Regulator

This effectively causes a switch in the form of a transistor to pulse a DC signal to the generator
exciter - the longer the pulse the greater the increase in the voltage.
With reference to Figure 5.74 the output from the PMG is fed to the star connected primary of
the transformer in the GCU. The star connected secondary of the transformer feeds a combined
voltage regulator and Transformer Rectifier Unit (TRU) to ensure the voltage to the field circuit a
constant DC voltage.
The circuit continues through a contact of the Generator Control Relay (GCR), through to the
main exciter field windings, back into the GCU to a transistor in the output stage of the voltage
regulator to earth.
Figure 5.74: Transistorised voltage regulation
This is the field circuit - note the GCR contact, this is important because under fault conditions
the GCR is tripped and the field circuit will be broken.

The generator output is fed via the rectifiers to a sensor in the voltage regulator. It is compared
to a reference value and the difference signal will signal the amplifier to switch the transistor ON
and OFF. This ON/OFF pulse is varied according to whether voltage is required to be increased
or decreased, i.e. effective current to the field is increased or decreased (Figure 5.75).
Figure 5.75: Pulse width modulation
If the generator loading increases, the terminal voltage of the generator will decrease (due to
internal voltage drop). This would be sensed by the regulator which would signal the switching
transistor to increase the width of the pulse, i.e. stay on for a longer period of time. The pulsing
is fast so the field senses an effective average current, which will increase in this case to
increase the output of the generator.
When a heavy load is taken off the generator, the terminal voltage will rise. The regulator this
time would signal the switching transistor to switch on for a shorter period of time, lowering the
effective current, which will decrease the current to the field, lowering the output of the
generator.
The voltage amplitude of the pulses remains the same, it is just the width of the pulses that is
varied, and hence the name given to this type of regulation system which is PULSE WIDTH
MODULATION.
When the generator is under a high load, its output voltage tends to drop. The voltage regulator
will increase the ‘mark-to-space’ ratio of the field supply pulses thus restoring the generator
output voltage to normal.
When the generator is under a low load, its output voltage tends to rise. The voltage regulator
will decrease the ‘mark-to-space’ ratio of the field supply pulses thus restoring the generator
output voltage to normal.

The Zener Diode
The principle of operation of a zener diode is that it will allow a free flow of electrons in one
direction, but will block the flow in the reverse direction until the voltage has risen to its
breakdown, or zener, voltage. This breakdown action does not damage the properties of a
zener diode in any way.
Figure 5.76: Zener diode principle
Principle of Operation
A complete basic circuit of a typical transistor voltage regulator is shown in Figure 5.77. The
output of the generator is connected across the voltage divider network of resistors R1, R2 and
R3. The zener diode D, senses the volts drop across R1 and a portion of R2. When the voltage
across D1 is low, there is no current flow through the base of driver transistor T1; with no base
current there will be no emitter-collector current to produce a volts drop across Rs. Base current
can flow through the output transistor T2 and will conduct, giving a current flow to the generator
field. With the field receiving its full field excitation current, the output voltage will rise, and at the
regulation level the voltage across the zener diode will cause it to breakdown. With this break-
down, base current will now flow in T1s which causes an emitter-collector current to flow
through R5. The voltage build-up across R5 brings the base of T2 to the same potential as its
emitter and shuts it off, so no field current can flow through T2, causing the generator terminal
voltage to fall. Diode D2 provides a constant voltage drop, so the emitter of T2 will be
sufficiently below the level of the line voltage, permitting the current through Rs to bring the
base voltage of T2 up to that of its emitter so that T2 is shut off. Diode D3 protects the
transistors against voltage surges when field current is suddenly cut off. The rapid collapse of
the field would induce a voltage high enough to damage the transistors but is prevented from
doing so by D3 conducting the voltage to earth. Diode D4 is a transient suppression diode that
protects the transistors from any externally-generated voltage surges, while capacitors C1 and
C2 smooth out pulsations and cause the regulator to operate smoothly.

Figure 5.77: Zener diode circuit

Magnetic Amplifier Voltage Regulator
This voltage regulator is essentially a two-stage magnetic amplifier which derives its AC power
from the generator output and supplies rectified power to the generator exciter field. The
reactive load division circuitry provides balanced kVAR loading during parallel operation. In
case of either a three-phase symmetrical line-to-line or line-to-earth fault, the regulator can
usually supply sufficient excitation to enable the generator to supply current to operate
protective devices. During an unbalanced fault condition, negative sequence sensing circuitry
limits the highest phase voltage to specified limits. The regulator performs all of its functions
with the AC generator and integral exciter as its only power supply.
Operation
Figure 5.78 is a block diagram of the regulator/generator circuitry. The regulator can be
considered as four basic parts: the voltage error detector and reactive load division section, the
pre-amplifier, the DC bias supply and negative sequence sensing unit, and the power amplifier.
When full load is applied to the generator, line voltage will start to decrease and an error signal
is introduced to the pre-amplifier. An amplified error signal is then fed into the signal winding of
the power amplifier, resulting in additional core saturation, thus allowing more current to flow
through the load winding and to the exciter field. The increased exciter field current results in
increasing generator output voltage towards the desired level.
Figure 5.78: Regulator/Generator circuitry

Voltage Error Detector
The voltage error detector monitors or 'senses' the average three-phase output of the generator
and provides an error signal proportional to the variation of that voltage above or below a
nominal pre-set or reference value.
Reactive Load Division

During parallel operations a current transformer and reactor package provide a corrective signal
to the error detector to maintain proper reactive load division between generators. In parallel
operation all generator output voltages are common regardless of differences in excitation
applied to the various generators. However, since those generators with more excitation are
producing more kVAR than those with less excitation, reactive current will flow from those with
more excitation to those with less. One of the functions of the regulator is to sense the
difference in reactive load division, by means of the direction and magnitude of reactive current
flow, and to balance the system by increasing the excitation on each generator as required. In
single generator operation, output voltage varies with the excitation applied.
Negative Sequence Sensing Unit

Under balanced three-phase voltage conditions, only a positive sequence vector rotation is
present, i.e. vector rotation is ABC, assuming generator output rotation to be ABC. However,
during an unbalanced three-phase condition, both positive sequence (ABC) and negative
sequence (CBA) vector rotation will exist (Figure 5.79).
Figure 5.79: Positive and negative sequence rotation
The negative sequence sensing filter (Figure 5.80) is designed to allow only the CBA rotation to
be sensed. Thus, unbalanced three-phase voltages can be detected.
Positive Sequence Power Supply

A positive sequence sensing filter is used to obtain a power supply for the pre-amplifier load
winding as it will not deviate greatly under unbalanced line conditions. The positive sequence
voltage magnitude changes little in comparison with the change between line voltages under a
wide range of unbalanced fault conditions.

Figure 5.80: Negative sequence sensing filter
The positive sequence sensing filter (Figure 5.81) is identical with the negative sequence
sensing filter (Figure 5.80) except that the input connections have been reversed. This, in
essence, takes the ABC rotation of the generator output and reverses it to CBA, thus the
positive sequence voltage of the generator has been reversed to negative sequence voltage by
reversing the leads, and fed into the filter to obtain an output signal.
Figure 5.81: Positive sequence sensing filter
DC Bias Supply
The DC bias supply obtains power from a three-phase transformer, which is connected to the
generator terminals and fed into a three-phase, full-wave silicon rectifier bridge. The DC bias
supply provides power to the bias windings of the pre-amplifier and the power amplifier.

Pre-amplifier
Load and Bias Winding - Basically the pre-amplifier consists of a push-pull, parallel, self-
saturating, load-winding circuit and four matching sets of control windings, all wound on four
common cores. Each control winding functions is described below:
Error Winding - The error, stability, and negative feedback control windings are wound uni-
directionally, whereas the load and bias windings are wound push-pull or opposing. Therefore, a
current flow in the uni-directional windings will tend to add to the net flux, and hence increase
the load current, in one half of the load circuit while decreasing the net flux and the current flow
in the other half. The opposing voltage, dropped across resistors, will differ and a resultant
voltage will appear across the amplifier output. The polarity and proportional magnitude of the
output voltage will vary with that of the input or control signal, thus high gain voltage
amplification is obtained. A DC input signal of a few milliamperes at very low voltage applied to
the error winding, controls a substantial output signal voltage.
Negative Feedback Winding - Like any high gain amplifier, the magnetic pre-amplifier is
subject to drift or slight change in output with respect to fixed input, due to temperature and
other variables. In order to minimise such drift and to provide a convenient gain control, a
negative feedback circuit is provided.
As indicated by Figure 5.78, a portion of the pre-amplifier output is taken from the load circuit
and fed into the negative feedback windings. These windings create a control flux opposing that
created by the error signal winding. The effects of this action should be noted:
 In the case of amplifier drift, the output tends to vary with no change in the error signal. In
this case a portion of the output is fed back in opposition to the direction of change and
automatic correction takes place.
 Since a portion of the output signal is fed back in opposition to the error signal, a large
error signal is required to obtain the same output. Since a variable resistor controls the
amount of feedback, it therefore controls the required input for a given output and hence
the gain of the amplifier. This resistor may be used to control the overall gain of the
regulator to provide the required degree of generator output voltage control.

Stability Winding - The purpose of a stability circuit is to oppose sudden changes in error
signal and thereby to minimise or damp out generator voltage overshoot and prevent system
oscillation. As Figure 5.78 indicates, it obtains its signal from the exciter field and from the pre-
amplifier output. Usually a special stabilising or damping winding is provided in the exciter field
of AC brushless generators.
By transformer action, this winding picks up a rate-of-change signal from the current supplied to
the exciter field. Whereas a steady state of slowly changing exciter field current will have little
effect on the winding, a sudden increase or decrease will immediately create a signal in the
stabilising winding, which, when applied to the stability winding of the pre-amplifier, will oppose
the direction of the change and hence tend to damp it out.
Negative Sequence Winding - The negative sequence winding is wound in such a fashion that
a signal from the negative sequence unit will produce a flux in the pre-amplifier in such a
direction as to reduce the voltage regulator output. In this way, the highest phase voltage can
be limited to a safe value during unbalanced faults.
A negative sequence voltage is produced only during an unbalanced line-to- line or unbalanced
line-to-earth fault. Although a negative sequence voltage is produced during an unbalanced
fault, a diode is usually put in series with the negative sequence winding to prevent the winding
from being energised unless approximately a one-third balance of one phase, in comparison
with the average phase voltage, exists.
Power Amplifier - The power amplifier comprises a three-phase, full-wave bridge magnetic
amplifier, supplied from the combination of a three-phase power transformer and three current
transformers, the latter being a part of a current transformer package. The power amplifier
supplies current to the exciter field of the generator. Silicon rectifiers are used in the self-
saturated circuits of the amplifier, to maintain minimum size and weight, and to reduce reverse
currents to a very low level; because of the high-gain, square loop core materials are used in
the amplifier. Utilisation of current transformers as an integral part of the regulator electrical
design causes the power output capabilities of the regulator to increase in accordance with the
load on the AC generator, and hence the excitation demands of its rotating exciter. When the
AC generator is subjected to a three- phase fault, all power for the exciter field is supplied via
the current transformers and the power amplifier in the regulator. This method of supplying field
power improves voltage recovery time after load switching, or removal of fault.
Load Winding - Power obtained from the transformer package and the boost current
transformers is fed directly through the six load windings and to the exciter field.
Bias Winding - Power is obtained from the same DC bias supply that feeds the pre-amplifier
bias winding. The load circuit would be self-saturating in the absence of other control and
maximum current would flow at all times. To prevent this and to provide a range of control, DC
bias is applied through the bias winding such that the induced flux opposes the load flux and the
output is reduced by approximately one-half. Adjustment is normally provided for initial setting
up.

Signal Winding -The output signal from the pre-amplifier varies from zero for nominal generator
output voltage to positive for below nominal, and to negative for above nominal. For a below-
nominal generator voltage, the signal applied to the signal winding causes an increase in flux in
the six cores, thus approaching saturation and increasing the field current to the generator
exciter. For an above-nominal signal, the signal is negative; the core flux and the excitation
current are reduced.
Current Transformer Boost Current

The three current transformers mounted on the generator feeders are connected in series with
the low potential ends of the power transformer secondary windings. One of the regulator
requirements, generally, is that it shall furnish excitation to the generator during a three-phase
system fault or line-to-earth fault. During such a fault, generator voltage drops to near zero, but
a very high current flow occurs through the generator feeders and, by means of the current
transformer boost circuit, power is taken from the current in the generator feeders and fed into
the power amplifier power supply. In the absence of bias and signal voltage, the power amplifier
load windings tend to self-saturate the cores and full load current flows to the exciter field,
proportional to the fault current.
The current transformer boost circuit also performs two other functions. During normal operation
a small but significant amount of voltage is added to the power supply and, since the amount
added is proportional to the load current, this aids the power amplifier and hence the regulator
in compensating for load instabilities.
The current transformers are also sensitive to the phase relation of the generator output current
to voltage; the function is much the same as that of the reactive load division circuit and tends to
increase or reduce the excitation as required to provide reactive load equalisation in parallel
operation.
Temperature-Compensation
As the power amplifier is single-ended, whereas the pre-amplifier is push-pull or self-balancing,
some temperature compensation is required. This is usually provided by positive temperature
coefficient resistors (TCR) built into the saturable reactor cases and connected in series with the
DC bias winding. This temperature compensation takes care of core shift and control winding
resistance changes due to temperature variation.
Commutating Rectifier
The output of a magnetic amplifier normally contains a sawtooth AC ripple component in
addition to the DC component. Since the output current is uni-directional by virtue of the silicon
rectifiers, and since the exciter shunt field is inductive, the field winding will tend to store energy.
If there were no way to discharge this energy the apparent resistance would increase,
increasing the voltage and decreasing the current to the field to the point where failure of one or
more of the silicon rectifiers may occur due to high inverse voltage. To prevent this, another
silicon rectifier is usually connected across the output, opposed in direction to the DC amplifier
output. This rectifier, called the commutating rectifier, provides a convenient path for discharge
of stored energy in the field winding and permits the exciter field load to appear resistive rather
than inductive to the magnetic amplifier.

Intentionally Blank

Constant Speed Drive Unit (CSDU) and Integrated Drive Generator
(IDG)
Principle of the CSDU/IDG

It is essential that the alternator output has a nominal frequency of 400 hertz with a tolerance
usually from 380 to 420 hertz (±5%). This is accomplished throughout the engine operating
speed range by using a hydraulically operated constant-speed drive unit between the engine
and the alternator.
A CSDU consists of a variable hydraulic pump and motor, connected together so that
regardless of the engine speed, the CSDU output will be constant. This constant speed is
required for the alternator to have an output of 400 hertz. Many modern aircraft employ an
Integrated Drive Generator (lDG) which contains both the alternator and CSDU in one compact
unit. If there is a generator or CSDU failure, the pilot may disconnect the input shaft from the
drive to prevent any damage.
Figure 5.82: CSDU controlling the Generator Speed

Figure 5.83: Typical CSDU and generator locations on the engine

Generator Configuration Types
 First type, the CSDU is located between the engine driven gearbox and the generator.
The generator has to be removed for replacing the CSDU.
 Second type, The CSDU is located on opposite side of the gearbox. CSDU input/output
occurs via coaxially arranged shafts. Each component can be replaced separately.
 Third type, the IDG (Integrated Drive Generator) is reduced to a single component.
Figure 5.84: Evolution of Generator Drive
For many aircraft the generator is connected to a unit called a Constant Speed Drive Unit
(CSDU), this in turn is driven by the engine via the auxiliary gearbox. The CSDUs job is to
ensure the generator runs at a constant speed and hence constant frequency, irrespective of
the speed of the engine.

The speed of the generator can be 12,000 RPM, 6,000 RPM or 8,000 RPM depending on type.
On some aircraft the generator is part of an Integrated Drive Generator (IDG). This effectively
combines a generator with a constant speed drive system all in one unit - an IDG.
In general there are two types of AC power distribution systems:

 Non paralleled (non-load sharing)
 Paralleled (load sharing)
In a non paralleled system each generator supplies its own bus and all the services attached
thereto. So, in general, if there are four generators then there are four buses each supplying
their own services. The buses are interconnected by relays so if one generator output fails then
another generator can be switched in to supply some power to that bus. This is sometimes
called a Non-Load Sharing system.
With a paralleled or Load Sharing system all generators share the load to the busses. In general
terms all the generators are connected to the one bus and each generator is taking exactly the
same load as each of the others.
For all constant frequency systems the generators must be run at a constant RPM and for
paralleled systems the frequencies of all the generators must also be in-phase. This means that
the main difference between a CSDU for a non-paralleled system and that for a paralleled
system is the fitting of a speed trimming device (more later).
CSDU in a Non-Paralleled System

These are generally all similar in that they use a hydraulic pump and hydraulic motor assembly
to vary the output speed of the unit depending on a governor unit - while the input speed can
vary depending on engine throttle settings.
We shall take as an example a unit fitted to the JT8D engine, which is a twin-spool axial flow
turbo fan engine. At the front of the N2 compressor is a vertical shaft called the Tower Shaft,
which is driven by the N2 compressor/turbine assembly. The tower shaft drives the accessory
gearbox and all the mechanical accessories such as the oil pump, fuel pump, hydraulic pump
and the CSDU (sometimes called a CSD).

Operation
The CSDU is capable of adding or subtracting from the speed received from the engine gearbox
(4,300 to 8,600 RPM) to maintain the generator speed at 6,000 RPM and the frequency at
400Hz with small allowable tolerances.
Figure 5.85: CSDU drive chain and disconnect
The CSDU is a hydro-mechanical device with electrical connections to external circuits for
control and indication purposes. It is driven by the engine and drives the AC generator.
Drive is via a differential gear arrangement and a variable displacement hydraulic unit (drive
from engine to 1 to 2 to 3 to 4 to 5 to 6 to 7 to 8 to the generator [Figure 5.85]). The hydraulic
unit comprises a wobbler plate controlled pump and a hydraulic motor. Both are rotated by the
engine. The angle of the pump wobbler plate is controlled by a piston which receives its fluid
from a governor. Moving the angle of the wobbler plate changes the hydraulic output from the
pump and hence the hydraulic input to the hydraulic motor.
With the pump wobbler plate at the 'straight drive' angle, the pistons do not pump and there is
no fluid supply to the fixed angle motor wobbler plate pistons. Consequently, they are held in a

Figure 5.87: CSDU schematic

Figure 5.88: Principle of CSDU differential drive
This means the RPM of the motor is now added to the RPM of the whole unit to bring its output
speed to that of the constant RPM required. This is called Overdrive.
When the engine is running faster than the Straight Drive speed the control piston moves the
wobbler plate in the other direction causing the output from the pump to be the reverse from the
overdrive condition.
This will cause the motor to rotate in the opposite direction from the hydraulic unit, deducting its
RPM from the hydraulic unit's RPM and causing the output RPM to remain constant at the
required speed. This condition is called Under-drive.
The drive input and the output to/from the hydraulic unit goes through an axial differential gear
box which houses a set of cyclic summing gears that sums the output from the hydraulic unit to
the output shaft to the generator.


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Where appropriate, new gaskets should be fitted between mounting faces, and new O-rings

should also be fitted on generator drive shafts.

Generators which are to be mounted horizontally should be adequately supported during

Module 13.5 Electrical Power (ATA 24) 5.101

NOTE: This oil should never be used to refill the system.

Fill and Prime

5.102 Module 13.5 Electrical Power (ATA 24)

Module 13.5 Electrical Power (ATA 24) 5.103

5.104 Module 13.5 Electrical Power (ATA 24)

There are two main methods of carrying this out:

Figure 5.61: Theory of voltage regulation

The basic requirement of maintaining a substantially constant voltage in an aircraft power

Module 13.5 Electrical Power (ATA 24) 5.105

Figure 5.62: A typical carbon pile regulator

Figure 5.63: Carbon pile regulator circuit

5.106 Module 13.5 Electrical Power (ATA 24)

Module 13.5 Electrical Power (ATA 24) 5.107

Figure 5.65: Carbon pile regulator circuit

5.108 Module 13.5 Electrical Power (ATA 24)

Module 13.5 Electrical Power (ATA 24) 5.109

Figure 5.66: Vibrator Type voltage regulator

Figure 5.67: Vibrator type voltage regulator circuit

5.110 Module 13.5 Electrical Power (ATA 24)

Figure 5.68: Three unit regulator circuit

Module 13.5 Electrical Power (ATA 24) 5.111

Figure 5.69: Inside a three-unit regulator

5.112 Module 13.5 Electrical Power (ATA 24)

Module 13.5 Electrical Power (ATA 24) 5.113

5.114 Module 13.5 Electrical Power (ATA 24)

Figure 5.71: Reverse current cut-out circuit

Module 13.5 Electrical Power (ATA 24) 5.115

Figure 5.72: Error sensing voltage regulation

5.116 Module 13.5 Electrical Power (ATA 24)

Figure 5.73: Current transformer (CH47D Chinook)

Module 13.5 Electrical Power (ATA 24) 5.117

Transistorised Voltage Regulator

Figure 5.74: Transistorised voltage regulation

5.118 Module 13.5 Electrical Power (ATA 24)

Figure 5.75: Pulse width modulation

Module 13.5 Electrical Power (ATA 24) 5.119

Figure 5.76: Zener diode principle

5.120 Module 13.5 Electrical Power (ATA 24)

Module 13.5 Electrical Power (ATA 24) 5.121

Figure 5.78: Regulator/Generator circuitry

5.122 Module 13.5 Electrical Power (ATA 24)

Reactive Load Division

Negative Sequence Sensing Unit

Figure 5.79: Positive and negative sequence rotation

Positive Sequence Power Supply

Module 13.5 Electrical Power (ATA 24) 5.123

Figure 5.81: Positive sequence sensing filter

5.124 Module 13.5 Electrical Power (ATA 24)

Module 13.5 Electrical Power (ATA 24) 5.125

5.126 Module 13.5 Electrical Power (ATA 24)

Current Transformer Boost Current

Module 13.5 Electrical Power (ATA 24) 5.127

5.128 Module 13.5 Electrical Power (ATA 24)

Principle of the CSDU/IDG

Figure 5.82: CSDU controlling the Generator Speed