Rotax 24-30-00 Manual de funcionamiento original

08 February 2019 Current valid documentation see: 24-30-00

Initial Issue www.flyrotax.com Page 1 of 21

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SI-PAC-001

SERVICE INSTRUCTION - PAC

External alternator for ROTAX®Engine Type 915 i (Series)

ATA System: 24-30-00 External alternator

1) Planning information

“PAC” Service Instruction Documents provide detailed information on non-certified ROTAX®

Aircraft Engine Parts and Accessories. Referenced parts and accessories are provided without

EASA certification or ASTM compliance. Certification / Compliance of referenced Parts and

Accessories must be completed by the aircraft OEM.

To obtain satisfactory results, procedures specified in this publication must be accomplished with

accepted methods in accordance with prevailing legal regulations.

BRP-Rotax GmbH & Co KG cannot accept any responsibility for the quality of work performed in

accomplishing the requirements of this publication.

1.1) Applicability

Refer to the latest issue of the relevant Illustrated Parts Catalog.

1.2) Concurrent ASB/SB/SI and SL

None.

1.3) Reason

An external alternator is not included in the scope of delivery for 915 i Series aircraft engines. An

external alternator set part no. 887259 is available which includes brackets for 915 i Series gear-

box mounting.

1.4) Subject

External alternator for ROTAX®Engine Type 915 i (Series).

1.5) Compliance

NONE - For Information Only.

1.6) Approval

None.

1.7) Labor time and credit

Estimated labor hours:

Engine installed in the aircraft - - - labor time will depend on airframe installation and therefore no

estimate is available from the engine manufacturer.

1.8) Mass data

Change of weight - - - see section 3.1).

Moment of inertia - - - to be calculated by aircraft manufacturer.

1.9) Electrical load data

See Chapter 3.

mWARNUNG

NOTICE

The external alternator is not a part of the Engine Type Design. The exter-

nal alternator has been tested and released by BRP-Rotax, but it is not

certified.

The correct function in conjunction with the entire system and the certifica-

tion of the external alternator is the responsibility of the aircraft manufactu-

rer and must be carried out jointly with the aircraft.

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SI-PAC-001

SERVICE INSTRUCTION - PAC

1.10) Software modifications

No change.

1.11) References

In addition to this technical information refer to current issue of

- Illustrated Parts Catalog (IPC)

- Maintenance Manual Line (MML)

- Maintenance Manual Heavy (MMH)

NOTE: The status of the Manuals can be determined by checking the table of amendments.

The 1st column of this table shows the revision status. Compare this number to that

listed on the ROTAX website:

www.FLYROTAX.com. Updates and current revisions can be downloaded for free.

1.12) Other Publications affected

None.

1.13) Interchangeability of parts

- Not affected

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SERVICE INSTRUCTION - PAC

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Initial Issue Page 3 of 21

2) Material Information

2.1) Material- cost and availability

Price and availability will be provided on request by ROTAX®Authorized Distributors or their inde-

pendent Service Centers.

2.2) Company support information

- Any possible support by BRP-Rotax will be provided on request by ROTAX®Authorized Dis-

tributors or their independent Service Centers.

2.3) Material requirement and credit per engine

parts requirement:

NOTE: Refer to the latest issue of the relevant Illustrated Parts Catalog.

2.4) Material requirement and credit per spare part

None.

2.5) Rework of parts

None.

2.6) Special tooling/lubricants- /adhesives- /sealing compounds

None.

Fig.no. part no. Qty/

engine Description Application

1 887259 1 Alternator set 915 i Series

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SI-PAC-001

SERVICE INSTRUCTION - PAC

3) Accomplishment/Instructions

-ROTAX

®reserves the right to make any amendments to existing documents, which might

become necessary due to this standardization, at the time of next revision or issue.

NOTE: Before maintenance, review the entire documentation to make sure you have a com-

plete understanding of the procedure and requirements.

Accomplish-

ment

All measures must be implemented and confirmed by at least one of the following persons or

organizations:

-ROTAX

®- Airworthiness representatives

-ROTAX

®- Authorized Distributors or their independent Service Centers

- Persons approved by the respective Aviation Authority

- Persons with approved qualifications for the corresponding engine types. Only authorized per-

sons (iRMT, Level Heavy Maintenance) are entitled to carry out this work

NOTE: All work has to be performed in accordance with the relevant Maintenance Manual.

Safety notice

NOTE: Indicates supplementary information which may be needed to fully complete or under-

stand an instruction.

mWARNUNG

mWARNING

Identifies an instruction which, if not followed, may cause serious in-

jury or even fatal injury.

mWARNUNG

mCAUTION

Identifies an instruction which, if not followed, may cause minor or

moderate injury.

mWARNUNG

NOTICE

Identifies an instruction which, if not followed, may severely damage

the engine or could void any warranty.

ENVIRONMENTAL NOTE

Environmental notes give you tips on environmental protection.

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3.1) Installation - related information

Optional

extras

- External alternator (as option if the output of the integrated generator is inadequate).

3.1.1) Technical data

General note NOTE: The voltage regulator is integrated in the alternator.

Output Max. 550 W/DC at 6000 r.p.m. (complies ~ 4800 r.p.m. crankshaft speed).

Output voltage 14.2 V - 14.8 V.

Ambient temp. Ambient temperature range:

Weight Weight: 3.0 kg (6.61 lbs).

3.1.2) Connections

See Fig. 1.

Power supply

wires

Power supply wires to external alternator (1) have to be installed depending on the mounting posi-

tion and according to the regulations of the aircraft manufacturer.

Positive termi-

nal

Positive terminal (2):

M6 screw connection suitable for cable terminal according to DIN 46225 (tightening torque 4 Nm

(35 in. lb)).

Ground Via engine block.

Control wiring Control wiring (3): Via supplied standard plug (Sumitomo 6111-2568) and 6.3x0.8 Faston connec-

tors (female).

Fig. 1.

Min. Max.

-30 °C (-22 °F) +90 °C (194 °F)

Cyl. 1

Cyl. 3

Cyl. 2

Cyl. 4

1 External alternator

2 Positive terminal

3 Control wiring

03199

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SERVICE INSTRUCTION - PAC

3.1.3) Requirements for correct operation of the integrated rectifier regulator

Fuse The rectifier regulator must be protected by a slow blowing fuse or circuit breaker. Fuse or circuit

breaker rating must be determined by load, wire size and length.

Load distrubu-

tion

Due to slightly different output voltages of the regulators (alternator and regulator A/B of fuse box)

the power is drawn by the generator with the higher output voltage at low load.

Amperage See Fig. 2.

- Ambient temperature: 20 °C (68 °F)

- Voltage: constant 13.5 V

- Tolerance: max. ± 5 %

NOTE: The speed of the external alternator is 1.18 times the crankshaft speed or 3 times the

propeller speed.

Fig. 2

mWARNUNG

NOTICE

The current over engine speed graph was determined and is only effective

under the following conditions.

1/min. /

rpm.

2000 3000 4000 5000 6000 7000 8000 n Generator

rpm. alternator

(A)

1000 1500 2000 2500 n Propeller

rpm. propeller

00547

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Wiring dia-

gram

Fig. 3. External alternator .

Fuse Box

Regulator board A Regulator board B ECU

123

Battery

Master switch Circuit breaker

(30 A)

AWG 12

Backup battery switch

(guarded switch) 24

Start power switch

(momentary)

AWG 12

AWG 04

AWG 12

Start Relais

E-Starter

AWG 12

912 iS wiring harness

Airframe Ground

EMS ground

AWG 04 (21,1 mm²)

AWG 12 (3,3 mm²)

AWG 16 (1,50 mm²)

AWG 18 (1,00 mm²)

AWG 20 (0,75 mm²)

Optional (not required)

Circuit breaker

(30 A)

AWG 06

AWG 08

AWG 12

External

alternator

Circuit breaker has to

be provided by the

aircraft manufacturer

AWG 12

Indicator

lamp

Circuit

breaker (5 A)

Circuit breaker (Max.

850 W when using an

external alternator)

Circuit breaker

(50 A)

!lternatorFIELD

switch

08255

Bus bar (Airframe)

08255

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SERVICE INSTRUCTION - PAC

3.2) Operation - related information

General The external alternator is a state-of-the-art, electromechanical three-phase generator (compact

generator) with small outer dimensions. It has the task of supplying the electric consumers with

energy and charging the starter battery with the least possible fuel consumption and low noise lev-

els during operation of the aircraft.

Drive Drive is provided by the engine by means of a V-belt.

External alter-

nator

Switch and warning lamp requirements

Switch The representation of components (such as switches, protection devices etc.) that are not

included in the scope of engine delivery is purely symbolic. It does not constitute a specification of

the version and shall therefore only be seen functionally.

The actual interpretation / selection of the corresponding regulations is the task of the aircraft

manufacturer.

Warning

lamps

Mechanical power consumption of the external alternator

Max. 1200 W

EXTERNAL ALTERNATOR

SWITCH Requirement Connector/slot

Switch type Single Pole, Single Throw (SPST) switch

Nominal voltage 28 VDC

Nominal current 5 A

Number of poles 1-pole

Designation on wiring harness Not connected to the wiring harness.

EXTERNAL ALTERNATOR

INDICATOR LAMP Requirement Connector/slot

Lamp colour In accordance with the regulations

Nominal voltage 12 V

Nominal current Maximum 300 mA

Designation on wiring harness Not connected to the wiring harness.

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Initial Issue Page 9 of 21

3.3) Maintenance (Line) - related information

3.3.1) Checking the V-belt tension

General note In the case of configurations with additional external alternator, inspect attachment and V-belt ten-

sion.

Checking the

V-belt tension

Inspect V-belt tension as per drawing below.

Fig. 4.

3.3.2) Adjust the V-belt tension

Belt tension To adjust the belt tension:

Fig. 5. .

Step Procedure

1 Loosen the hex. screw M10 (1) and the 2 Allen screw M8 (2 and (3).

2 Press the alternator upwards and tighten Allen screw (3).

3 Then tighten Hex. screw M10 (1) with tightening torque 40 NM (30 ft.lb) and Allen

screw M8 (2) with tightening torque 22 Nm (195 in.lb).

mWARNUNG

NOTICE

Deflection of the V-belt must not exceed 6 mm (1/4”) with al load of 50 N

(11 lb) at center.

1 Hex. screw M10

2 Allen screw M8

3 Allen screw M8

00353

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SERVICE INSTRUCTION - PAC

3.4) Maintenance (Heavy) - related information

Safety

information

3.4.1) Preparation

- Loosen pulley tension

- Remove the propeller. See “Documentation of aircraft manufacturer”.

3.4.2) V-Belt pulley -removal

See Fig. 6.

Fig. 6.

3.4.3) Alternator - removal

See Fig. 7 to Fig. 10.

mWARNUNG

mWARNING

Danger of damage to engine!

There is a risk of short circuits and cable fires during work on the electric

system. All installation work on the electric system should be carried out

with the engine switched “OFF” and the battery (negative terminal) dis-

connected.

Ignition, main and Lane selector switches must be “OFF”.

Step Procedure

1 Loosen 8 Allen screws M5x16 with lock washers.

2 Remove pulley carries, V-belt pulley and V-belt.

1 Allen screw M5x16

2 Lock washer A5

3 Pulley carries

4 V-belt pulley

5 V-belt

Step Procedure

1 Loosen 2 hex. screws M8x20 along with lock washers and washers.

2 Remove the tension bar underneath the external alternator.

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