Electrical System Upgrade Ground

Training
TCTO 1C-130-1339

OPR HQ
AMC/DOTA
15 APRIL 1999
 ESU Ground Training Overview

• Why is an upgrade needed ?

• Overview of Modification
• ESU Components
• Changes to Normal Procedures
• Changes to Emergency Procedures
• Aircraft Visit
 Why is an upgrade needed?
HISTORY:
• Earlier C-130s equipped with analog electrical equipment
• Newer generation avionics equipment, requires improved power
regulation

PURPOSE:
• ESU will provide cleaner, steady-state power to aircraft electrical
components/systems.
 Overview of Modification
• Replaces Generator Control Panel with Generator Control
Units (one for each engine driven generator and APU, Not
ATM generator)

• Adds 2 New AC Buses

• Each New AC Bus Is Powered Through Their Own Bus

Switching System (BSS)

• BSS provides ‘clean’ regulated power and offers an

immediately available secondary power source for its
respective bus
 ESU Components

• 4/5 Generator Control Units, 4/5 Generator Control Switches

• 2 AC buses (ESSENTIAL Avionics & MAIN Avionics)

• 2 Bus Switching Systems (BSS)

• 2 Fail-Safe Bypass Contactors (FBC)

• 2 AC Bus Warning Lights, 3 ESU Advisory Lights

• 2 Solid State Inverters (2,500 & 250 KVA)

General Location of ESU Components
 4 or 5 Generator Control Units (GCU)

• Mounted on the electrical control and supply rack

• Takes place of the Voltage Regulator, Generator

Control Panel, and Frequency Sensitive Relay
• Controls the contactors that tie the generators to the
buses
• Provides protection from: over/under voltage,
over/under frequency, and feeder faults by
deenergizing the appropriate contactor
 4 or 5 Generator Control Units (GCU)
Test
Circular Button
Connector
• Two Major TOP VIEW Bit
Display
Panel

Features of the
GCU Truth
Table
Perforated
Surface

– BIT (Built-In Test)

– Engine Generator
Switches
FRONT VIEW
 Built In Test of the GCU
• Push button on GCU initiates test
– Can be run anytime ISOL DC is Test
Button
available and generator switches are Circular
Connector TOP VIEW
BIT
“ON” (does not have to be on-line) Display
Panel

• LED indicators light for 10 Truth

Seconds then extinguish (if good) Perforated

Support
Table

• Template decodes LED

indication (Truth Table)

• GCU does its own BIT prior to

connecting generator to a bus FRONT VIEW
 Built In Test of the GCU
Test
• If the GCU trips in flight an Circular
Connector
Button

LED code will be displayed TOP VIEW BIT

Display

on the GCU. The Truth Panel

Table shows the meaning.

• RESET = Generator fig. p. 84 Truth
Table
Perforated

OFF, Generator ON Support

(Recheck Output)
– The GCU has a ‘latching’
circuit that prevents a
serious electrical problem FRONT VIEW
from being RESET.
LED TRUTH TABLE
NO FAULTS

OVER VOLTAGE

UNDER VOLTAGE

UNDER FREQUENCY

OVER FREQUENCY

FEEDER FAULT

PREVIOUS FEEDER FAULT

CONTACTOR CURRENT LIMIT

INCORRECT GENERATOR SELECT

GENERATOR SELECT TIME OUT

INTERUPT CAPACITY EXCEEDED

PREVIOUS BIT FAILURE

DIGITAL BOARD FAILURE

POWER BOARD FAILURE

CHASIS FAILURE

BIT IN PROGRESS
 Generator Control Switches

NO. 1 ENGINE NO. 1 ENGINE

GENERATOR GENERATOR

OFF FIELD OFF

TRIP

RESET

OLD ESU
Engine Generator Switches of the GCU

• Switches appear identical, except ESU have no RESET or

FIELD TRIP positions (no need)

• Causes and Reactions of a GENERATOR OUT light:

– Disconnects generator from bus (can be RESET): If any phase

>130VAC or <95VAC (after 4 seconds of the under/over voltage)
– Temporarily disconnects generator from bus: <368HZ or >440HZ

– Permanently disconnects generator from bus: Feeder Fault

(>35amp difference between generator and contactor terminals)
ESS AC Primary Secondary Main AC Primary Secondary
AC AC AC AC
Bus Bus

BSS No. 1 BSS No. 2

FBC FBC

ESS AVI Bus Main AVI Bus

Pilots Upper CB Panel Copilots Upper CB Panel

•Radar
•C-12 Compass 1 & 2
•SKE
•Autopilot
•(other, see -1)
•INU (3 Phase)
•BICU (3 Phase)
•Radio Compass 36VAC
• (other, see -1)

Pilots Lower CB Panel Pilots Side CB Panel Copilots Upper CB Panel

•Prop Synchrophaser •TACAN 1 & 2
•HSI 1 & 2
•CP AC Instr. Stby Pwr •IFF
•(other, see -1)
(3 phase) •Flt Dir 1 & 2
•(other, see -1) •(other,see -1)
 ESS AVI - PRI
#1 #2 #3 #4 APU/
ESS AVI - SEC
GEN GEN GEN GEN GEN
MAIN AVI - PRI

MAIN AVI - SEC

CONDITIONED PWR K53B K53C K53D

K53A
“DIRTY” PWR

TAP-OFF POINT
K53F K53G

K53K
K53E
EXT
AC

K55A

ESS BUS MAIN BUS

K55H K53J

LH BUS RH BUS

ESSENTIAL AVIONICS MAIN AVIONICS

BUS SWITCHING BUS SWITCHING
ESSENTIAL SYSTEM (BSS 1) SYSTEM (BSS 2) MAIN
AVIONICS AVIONICS
ACBUS AC BUS

TO ISOLATED
DC BUS
FBC TO ISOLATED
DC BUS
 AC Bus Power Sources (Airplanes Modified by TO 1C-130-1339)

AC GENERATOR POWER AC BUS POWER

ENGINE DRIVEN GENERATOR SOURCE SOURCE
ESSENTIAL MAIN
LH ESS MAIN RH
AVIONICS AVIONICS
AC AC AC AC
NO.1 NO.2 NO.3 NO.4 BUS BUS
BUS BUS BUS BUS
PRI SEC PRI SEC

1 2 3 4 2 4 3 1
2 2 3 4 2 4 3 2
1 1 3 4 1 4 3 1
1 2 4 4 2 4 4 1
1 2 3 3 2 3 3 1
4 3 3 4 3 4 3 4
1 1 4 4 1 4 4 1
1 2 2 1 2 1 2 1
2 2 3 3 2 3 3 2
2 2 4 4 2 4 4 2
1 1 3 3 1 3 3 1
4 4 4 NONE 4 NONE

3 3 3 NONE 3 NONE

2 2 2 NONE 2 NONE

1 1 1 NONE 1 NONE

APU APU APU APU

NONE NONE
GEN GEN GEN GEN
EXT EXT EXT EXT EXT EXT EXT EXT

= GENERATOR OUT = GENERATOR ON

 Bus Switching System (BSS)
Components
Rectifier 10 KVA
- Mounting Base Control
Unit (RCU)
Inverter Fans

Assembly

- Rectifier Control
Unit (RCU)

- 10 KVA Inverter

Signal Output Chassis Input Input

BSS (FRONT VIEW) Bit Balls Base Interface Power Ground Secon. Prim.
(Black - OK Assembly Stud Power Power
White - FAILURE
BSS (rear view)
 Mounting Base Assembly - BSS
• Houses a Capacitive Discharge Bank
– “Surge Protector” for the 10 KVA Inverter (provides a
minimum of 60 milliseconds of DC power, longer than
normal switchover time)
• Serves as the power interface for the GCU

WARNING
Due to residual capacitance charge , it is necessary to
allow 6 minutes after BSS shutdown prior to
removing any part of the unit or its cannon plugs.
 Rectifier Control Unit (RCU)
• Provides 340 VDC (primary power source) or 270 VDC
(secondary power source) to the 10 KVA Inverter

• How?
– 340 VDC (primary power): Developed through AC to DC
converter, then DC to DC booster to increase to 340 VDC
– 270 VDC (secondary power): Developed through AC to DC
converter

• Why two sources?

– Any power spike/drop, or switch over anomalies that temporarily
kick the primary power off line allows the secondary power to
provide uninterrupted DC current flow
340VDC 340VDC

270VDC 270VDC
 10 KVA Inverter
• Inverts 340VDC (or 270 VDC) into Regulated
115V, 400Hz AC pwr for the ESS and MAIN AVI
buses

• Safety Features:
– Input Power of < 200 VDC causes the Inverter to:
• Drop the output voltage to “0” to prevent equipment damage
• Shutdown and reset the Rectifier Control Unit circuits
• Remove the ground for the Fail-Safe Bypass Contactor
• An Input Power increase to >220 VDC will restart the inverter
 Fail-Safe Bypass Contactor (FBC)

• A ‘Fail-Safe’ backup for a BSS failure

• BSS failure causes the FBC to redirect power for:

– ESS AVI Bus off the ESS AC Bus for a BSS 1 failure
– MAIN AVI Bus off the MAIN AC Bus for BSS 2
failure

NOTE: Time between power application to the BSS and the FBC
energizing to allow BSS output connection to AVI is 2.5 - 5 seconds.
 2 Additional AC Bus Warning Lights,

BUS OUT INDICATORS

•ESS AVI (or MAIN AVI)
Indicator Lights Anytime ISO DC ESS MAIN
ON DC DC
BATT OFF OFF
•Average bus voltage < 95VAC
LH MAIN RH
AC AC
•Single phase voltage < 90VAC AC
OFF OFF OFF

•EFFECT: NO POWER is ESU BIT ESS

AC
ESS AVI

available to that bus, FOLLOW ESS MAIN OFF MAIN AVI

Bus Isolation Procedures

 3 ESU Advisory Lights
•ESU BIT Indicator
•Lights anytime a fault occurs within
the BSS 1 or BSS 2
BUS OUT INDICATORS
•EFFECT: Affected BSS may be on
Primary only or Secondary Power --
NO ABORT, Record in 781 ISO DC ESS MAIN
ON DC DC
•ESS Indicator (MAIN Indicator) BATT OFF OFF

•Lights anytime a fault within BSS 1 LH MAIN RH

(BSS 2) causes the Fail-Safe Bypass AC
OFF
AC
OFF
AC
OFF
Contactor to deenergize
•EFFECT: Affected Bus is on ESU BIT ESS AVI
ESS
“dirty” power, no more clean power AC
ESS MAIN OFF MAIN AVI
from BSS
 250 VA and 2500 VA Solid State
Inverters
• Replaces the old rotary 250VA and 2500VA
Inverters (for the Secondary AC Power Supply,
CoPilot’s AC Instrument and AC Instrument &
Engine Fuel Control Bus)

• Provides a cleaner, better regulated power source

for these buses

• NO Change in operations or restrictions

 Changes to Normal Procedures

• Before Exterior Inspection (Cargo Compartment)

– BSS Circuit Breaker Panel (FS-245) - Checked
(Ensure power is off before resetting circuit breakers)
• Power On Inspection
– Generator Switches - Set, as required
(ON for ESU Aircraft, OFF for non-ESU Aircraft)
• Cockpit Checklist
– Electrical Panel (ESU Aircraft) - Set
• Engine Generator Switches - ON
 Changes to Normal Procedures

• Starting Engines Checklist

– (Procedures modified to include ESU Aircraft) Check for voltage
output on all 3 Phases After engine is on speed.

• Taxi Checklist
– Generators and Loads - Checked (ESU Aircraft should have
normal indications if the generator is not “OUT”)

• Engine Shutdown Checklist

– Leave Generator Switches ON, for ESU Aircraft
 Changes to Emergency Procedures
• 4 Engine Power Loss
– Step 5. (Turning off the generator supplying Essential AC Bus) Not
applicable for ESU Aircraft

• Electrical System Failure

– A malfunction to the LH, RH, or Main AC bus (or Main AVI Bus
for ESU Aircraft) or its equipment may require turning off all 4
Engine Generators to isolate problem

• Generator Out Light on ESU Aircraft (New GCU)

– Frequency and Voltage Normal, No Load - Leave Generator On and
Monitor
– No Frequency, Voltage, or Load - Place Generator Switch Off, then
On, Recheck Indications, If Still Bad -- Generator Disconnect
 Changes to Emergency Procedures
• AC Bus Off Light
– ESU: follow procedures for “Airplanes with ESU”
• If Affected Gen Out Light is ON, turn Gen OFF and Disconnect
• If Affected Gen Out Light is NOT On, Check Voltage,
Frequency, and Load -- if all good, Continue Ops & Monitor
• If Affected Gen Out Light is NOT On, but Equipment is
Malfunctioning -- follow Bus Isolation Procedures.
• Loss of ESS AC Bus (on ESU Aircraft)
– Will NOT Affect ESS AVI or Main AVI Buses (Normally)
– ESS AVI affected if FBC is de-energized (“Dirty Power”)
 Changes to Emergency Procedures
Illumination of an AVI Bus Off Light (ESU AIRCRAFT)

No, Continue Ops

Equip. Malfunctioning ?
and Monitor
If Yes

Check CB’s, reduce load and reset CB’s

Is power restored with reduced load?
If No Yes, Continue Ops
and Monitor
Isolate If the problem occurred on the
AVI bus ESS AVI Bus - “Regardless of apparent
success, Land As Soon As Possible”
 Changes to Emergency Procedures
Electrical Isolation Procedures for ESU Aircraft
Transitioning from BSS regulated power to
Power Directly from the ESS/Main AC bus
ESS AVI/Main AVI: Pull ISOL DC BUS
AVIONICS ESS/MAIN “FBC CONTROL” Circuit
Breaker (located on Pilots Side CB Panel)
Isolating/Removing the BSS 1 (BSS 2)
• Pull the 2 sets of 3 “ganged” Circuit Breakers on the
aft side of Flight Station 245
• ESS / MAIN AVI SECONDARY POWER
• ESS / MAIN AVI PRIMARY POWER
 Changes to Emergency Procedures
• Electrical Isolation Procedures for ESU Aircraft
Isolating/Removing Power from an AVI Bus

ESS AVI: Pull the 3 ESS AVI AC BUS POWER Circuit

Breakers (Pilots Upper CB Panel)
• WARNING: Prior to pulling ESS AVI power, ensure
P/CP FDMS panel vertical reference switch is in “VG”
position
• CAUTION: Prior to pulling ESS AVI power, place CP’s
Secondary AC Inverter Switch to DC position
Main AVI: Pull the 3 MAIN AVI AC BUS POWER Circuit
Breakers (Copilots Upper CB Panel)
 ESU Ground Training Review

• Why is an upgrade needed ?

• Overview of Modification
• ESU Components
• Changes to Normal Procedures
• Changes to Emergency Procedures
• Aircraft Visit
QUESTIONS?