SECTION System Overview 4.0 Pre-setup inspection 1.0.1 Remove the top of crate by taking out all the screws on the top panel. 1.0.2 Open the wooden crate from all four sides. Remove all packing materials. 1.0.3 Lock the caster wheels and, using 4 people, lift trainer off pallet and stand up onto caster wheels. 1.0.4 Inspect for any visible damages. If yes, take pictures and immediately inform AeroTrain Corp. at +1-810-230-8096 or email pictures with a brief description of the damage to sales@[Link]. 1.0.5 Ensure that all components are securely attached to the instruments panel and @ control panels. 1.0.6 Check electrical wiring, all connectors and components for loose connections or disconnection. 1.0.7 Identify the power cord (AC mains) and check power cables for any signs of abrasion or cuts. In case of damage to the power cord, seek services of a certified electrician and have the cord repaired or replaced. Operation and Training Manual 7 AS-51-DG1.2 Setup & Operating Instructions 1.2.1 Place the trainer on a level surface. 1.2.2 Check that the Battery Enable key switen is OFF. (where applicable) 1.2.3. Check that the Master Power Switch is OFF. 1.2.4 Turn OFF all other switches on the control panel 1.2.5. Pullall circuit breakers on the circuit breaker pane! 1.2.6 Connect the cable marked +e to battery's positive terminal, and cable marked -ve to battery negative. 1.2.7 At the back of the trainer, locate the ‘ELECTRIC POWER PANEL’. Open the panel door using a flat tip screw driver and confirm that the switch type circuit breaker marked MASTER AC POWER BREAKER’ is OFF 1.2.8 Again at the back of the trainer, locate the ‘Fault Switch Panel’, open the panel using a flat tip screw driver and confirm that all the fault switches are OFF, that is the switch lever is up. 4.2.9 Plug 110V (in North America)/220V (outside North America) AC power plug to the wall socket. nH1.3. Overview and General Description The Electrical System Trainer Model AS-51-DG is a dual generator system, configured to depict DC electrical power generation, distribution, and loading as in an actual aircraft. Most of the components installed on the trainer are FAA-approved genuine aircraft parts All wiring harnesses show the standerd practices in aircraft wiring and are made up of aircraft wires. 1.3.1. Power Generation Power generation circuit consists of two Delco-Remy 28V Aircraft DC Generators, each driven by a single phase 1.0 HP AC motor. The DC output of each generator is controlled and regulated by a solid state GCU (Generator Control Unit). The GCU also provides reverse current protection. A line contactor controller (LCC) is included to DC power circuit for providing over-voltage and under-voltage protection. The LCC is also used for adding an extra feature in the trainer, ie. the power distribution can be switched between split bus system and parallel bus system simply by flicking a switch on the conirel panel. 1.3.1 Power Distribut [Link] DC Power DC Power distribution is done from an arrangement of multiple DC bus bars. Each generator has its own main bus bar and an auxiliary bus bar. In split bus mode, the two generators operate independently and provide power to the loads connected to their respective main and auxiliary buses. In parallel bus mode, both generators share the load and their separate bus bars combine to become one single bus bar. [Link] 400 Hz AC Power The trainer also includes dual solid state inverters, providing 115 VAC and 26 VAC at 400 Hz. The two inverters are wired independently, getting their input DC power from each generator. The power cistribution area has two sets of three bus bars associated with each inverter, viz-a-viz Neutral, 115 VAC, and 26 VAC bus bars. 4.3.3 System Loads The electrical output from the two generators is connected to a wide variety of loads comprising instruments, fuel quantity measurement system, aircraft cabin & cockpit lighting, navigation lights, strobes, avionics fan, cabin air-conditioning blower fan, and landing gear motor. All loads are connected through terminal strips, enabling the students to measure and monitor electrical parameters for each load ‘Operaiion and Training Manual 3 AS-51DG1.3.4 Battery An aircraft battery is included in the system. The battery provides power to two starters, and each starter is operated independently. Battery is charged by DC generator in the same manner as would be done in an aircraft. In case of generator failure, essential loads can be powered by battery. A battery charger is provided which charges the battery when the trainer is not in use. For the battery charge to work the trainer should be connected to the mains power supply. 1.3.5 Battery Enable Switch (where applicable) The Battery Enable Switch is a key switch which is installed for safety in the electrical system trainer, The trainer can only be powered up if this switch is tumed on. This feature prevents unauthorized and unsupervised operation of the trainer, which may lead to excessive depletion of the battery or may result in an injury. 1.3.6 Sound- Proofing Two sets of Motor-Generator are housed in a sound-proof cabinet which results in a quiet operation even when both motor and generators are on 1.3.7 Circuit Protection The components on the bench are protected by circuit breakers that isolate each load, in addition to master switch and main circuit breakers. 1.3.8 Stall Warning System Model AS-51-DG includes a Stall warning System (SWS), designed for general aviation aircraft. It is device that has a surface mounted sensor on the leading edge of the wing. The sensor causes the audio warning alarm whenever aircraft lift comes close to stalling point. The parts mounted on the bench are actual aircraft parts. 1.3.9 Fuel Quantity Measurement System A float-type ratio-metric fuel level sender has been used to simulate the fuel level measurement, and a fuel indicator on the instrument panel displays the simulated fuel quantity. 1.3.10 Fault Insertion The trainer bench has an Instructor's Panel located on the rear panel, whereby the instructor can introduce fault in the system for training students on troubleshooting training Fault switches have been labeled only with a number to avoid the fault description being visible to students. Only instructor's copy of the manual has fault switch description ASST DS 4 "Operation and Training Manual1.4 Operating Procedures 1.44 Switch Mains Power ON [Link] On the back of the trainer locate the access panel marked ELECTRIC POWER PANEL’. Open this panel with a flat tio screw driver and check that the switch type circuit breaker marked 'MASTER AC POWER BREAKER’ and both switch type circuit breakers marked ‘MOTOR 1' and ‘MOTOR 2’ are in the Off position [Link] Ensure that all switches on the control panel of the trainer bench are Off, and all circuit breakers are pulled [Link] Open both front lower panel by unlocking the letches, and inspect that all wires are secure and properly connected. There should not be anything that loose and unsecured that could hinder the operation of motor generator set [Link] Ensure that the belt between the motor and generator has sufficient tension on both motor generator sets 4.41.5 Remove the cover of the battery box and check that the battery cables are connected with correct polarity, and that the cable-ends are securely tightened to the battery terminals. 4.44.6 Open the instructor panel located at the back of the trainer and check if all the switches are in the ‘OFF’ position. The switches are OFF when the switch lever in the up position. (Instructor's Panel switches are meant for instructor's use only, and the details of these switches are provided in the instructor's manual). [Link] Connect the mains power plug to110V or 220V AC power outlet (as applicable) 1.41.8 inthe ELECTRICAL POWER PANEL’, turn On the switch type circuit breaker marked ‘MASTER AC POWER BREAKER’ and both switch type circuit breakers marked ‘MOTOR 1’ and ‘MOTOR 2’. This provides AC power to the AC motor, through power relays. [Link] Close the access door. Notes: nd Traning Manual —=