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This document and its content is the property of Airbus Defence and Space, S.A.U. and is strictly confidential.

It shall not be communicated to any third party without the written consent of Airbus Defence and Space, S.A.U.

08 July 2021
Tomasz Czuchman
CN-235 GA01
ELECTRICAL SYSTEM
Electrical System 2

DISCLAIMER
The purpose of these training notes is to provide structured technical
information to the students in order to support the apprenticeship process
of the C-295.
It is not the intention of these training notes to be used as supplement to,
or instead of, any official publication.
This document does not have official nature.
The documentation included in the official technical publications has always
priority.

8 July, 2021 ONLY FOR TRAINING


Electrical System 3

• Contents
• General
• DC Power Generation
• AC Power Generation
• External Power Sources
• Power Distribution
• Controls and Indicators
• Operation
• Limitations
• Failure Conditions

8 July, 2021 ONLY FOR TRAINING


General 4

• The Electrical System of the CN-235 aircraft is designed to provide electrical


power supply to the aircraft under all flight and ground operating conditions.
• The main electrical power supply is 28 volts direct current (DC).
• The electrical power supply is possible by means of:
• DC Power Generation: 2x Starter-Generators (main power suply),
2x Batteries (secondary power suply),
1x Back-up Battery, and
1x Transformer Rectifier (TR) in case of
emergancy, powered by AC generator.

• AC Power Generation: 3x Inverters (one as backup), and


2x AC generators

• Exterior Power Source: DC Ground Power Unit (GPU), connected to the


aircraft through exterior power sockets.

8 July, 2021 ONLY FOR TRAINING


General 5

Main architecture of electrical system

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6

DC Power Generation

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DC Generation - Introduction 7

• The DC subsystem is designed in a


dual redundant manner, with two
independent channels in normal
conditions, SUBSYSTEM 1 and
SUBSYSTEM 2.

• During failure conditions, only one


source of power is capable of feeding
the essential systems indefinitely by
connecting both systems.

• The DC electrical system consists of


three functional blocks:
• Power Sources (Generation)
• Power Distribution
• Monitoring & Control

ONLY FOR TRAINING


DC Generation - Introduction 8

Main architecture of electrical system

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DC Generation - DC Gen 9

• The primary DC power sources are two Starter-Generators located in the engine
cowlings
• The two DC Generators are controlled through two corresponding units called
Generator Control Unit (GCU), located under the main cabin floor.

ONLY FOR TRAINING


DC Generation - DC Gen 10

• Each DC generator provides 28 VDC power to two separate DC bus bars.

• Operation as a starter:
- Speed: 1.550 RPM
- Torque: 4,8 m Kg
- Current consumption: 900 A
- Voltage: 17 V DC
• Operation as a generator: DC Generators

- Speed: 7.200 – 12.000 RPM


- Power: 12 KW
• DC GEN load limits:
- 400 A (continuous)
- 500 A (3 minutes)
- 600 A (30 seconds)

ONLY FOR TRAINING


DC Generation - GCU 11

• The GCU has the following functions:

• Control:
• Voltage regulation
• Generator /Bus Bar connection control
• Current limiter
• Engine start functions (speed sensor, change of batteries configuration, overspeed
protection)

• Protection:
• Overvoltage
• Low voltage
• Overcurrent
• Ground faults.
• Reverse polarity.

GCU 1 GCU 2

ONLY FOR TRAINING


DC Generation - GCU 12

• When the engines are on, the output voltage of DC Generators can be regulated
(26 VDC to 30 VDC).
• One voltmeter and a screwdriver are necessary to perform this task.

screwdriver

ONLY FOR TRAINING


DC Generation - GCU 13

• LC1 and LC2 line contactor switches are the GCU connectors from the generator to the
main DC electrical system.

ONLY FOR TRAINING


DC Generation - Batteries 14

• As a reserve source there are 2 batteries located in the fairing of the main landing
gear.

ONLY FOR TRAINING


DC Generation - Batteries 15

• SAFT Ni-Cd batteries characteristics:


• Nominal voltage: 24 V
• Capacity: 37 Ah
• Power: 15 kW
• Cell number: 20
• The batteries are used to:
• energize the aircraft on the ground if there
is no GPU
• start the engines
• Energize the aircraft in flight in case of dual
DC GEN failure

• They are charged by the DC generators.

• The two Ni-Cd batteries feed their respective


Battery Buses: BAT BUS 1 and BAT BUS 2.

• Battery load limit: 500 A (continuous)


Batteries

ONLY FOR TRAINING


DC Generation - Batteries 16

• The temperature sensors are mounted inside of the batteries to measure their
temperature to be displayed on the indicators installed in the cockpit and initiate warnings
in case of the overheating conditions.

ONLY FOR TRAINING


DC Generation - Batteries 17

• The WARM light comes on when the temperature of any battery reaches 120ºF (49ºC).
When the temperature of the affected battery drops below 115ºF, WARM light goes off.

• The HOT light and BAT HOT light in the Warning Panel come on at 150ºF (65ºC). When
the temperature of the affected battery is less than 145 ºF, corresponding HOT light and
BAT HOT light in the Warning Panel go off.

ONLY FOR TRAINING


DC Generation – Batteries – BAT TEMP Test 18

• When the BAT TEMP switch, located on the SYSTEM TESTS panel, is set and hold the
Batteries Temp. Indicating System is tested.

ONLY FOR TRAINING


DC Generation – Batteries – BAT TEMP Test 19

• At the batteries temperature indicator, the indexes


increse and the WARM and HOT lights come on at
their corresponding values. The BAT HOT caption on
the warning panel comes on as well.

• Amber light: 120ºF


• Red light: 150ºF

ONLY FOR TRAINING


DC Generation - EFIS B/U Battery 20

• The EFIS Back-Up battery circuit gives a 24V DC


power supply to the pilot's displays of the EFIS during
engines start-up, to avoid memory losses due to
voltage drop.

• This battery is different from the aircraft batteries.

• Once the engines are running, and the engine MODE


SEL selector is back in OFF, the back-up battery ends
to supply power and starts to be charged from the
BAT BUS 1.

ONLY FOR TRAINING


DC Generation - EFIS B/U Battery 21

ONLY FOR TRAINING


DC Generation - EFIS B/U Battery 22

• Each battery has 12 cells in series to supply 24VDC and


is charged witch 28VDC input voltage.

• Each battery has a heater to keep the inner temperature


from 0°C to 20°C when the ambient temperature ranges
from -15°C to -55°C.

• Each front panel includes:


- Cell indicators – Each of 12 cells has a switch and LED
to monitor the cell condition.
- Output Voltage Indicator – Four LED´s with and
adjacent indication of +27, +25, +24 and +20 VDC,
to monitor the battery voltage.
- TEST switch, used to do a test of the cells and the
output voltage
- The green LED, comes on when the heater operates
- The red LED, comes on when there is a temp. of more
then 55°C.

ONLY FOR TRAINING


DC Generation - EFIS B/U Battery 23

• BACK UP BAT TEST is located on the Central Instrument Panel

ONLY FOR TRAINING


DC Generation - Transformer-Rectifier (TR) 24

• Transformer-Rectifier (TR) transforms and rectifies 115 V AC into 28 V DC


• Manufacturer: Eldec
• TR load limit: 300 A (continuous)
• Overload rating: 450 A for 5 min, 750 A for 1 min
• In case of dual DC generator failure, 28VDC can be obtained from the TR.

• TR is supplied by Alternator 1 or Alternator 2.

ONLY FOR TRAINING


DC Generation - TR 25

• Transformer-Rectifier (TR) is located beneath the cargo cabin floor

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26

AC Power Generation

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AC Generation 27

8 July, 2021 ONLY FOR TRAINING


AC Generation 28

• The main components of AC Power Generation are:


• Inverters: three inverters, the third one as a standby, energized from
BAT BUSs, provide constant frequency AC power to avionics equipments.

Each inverter delivers two output voltages: 115 V AC at 400 Hz (const. fr.)
26 V AC at 400 Hz (const. fr.)

• Alternators: two alternators, driven by the related propeller reduction


gearbox. When Np>77% the related alternator provides wild frequency AC
power to the engine air inlet de-icing system, wing and tail distributor valves
(heater blankets) and Transformer Rectifier (TR)

Each alternator delivers three-phase voltage: 115 V AC (wild freq.)

8 July, 2021 ONLY FOR TRAINING


AC Generation - Constant Frequency 29

• Inverter 1 is fed by the Bat Bus 1 (22 to 32 VDC)


• Inverter 2 is fed by the Bat Bus 2
• Standby inverter by the Gen Bus 1
• Each inverter delivers two outputs of 600 VA with two voltages: 115 V AC at 400 Hz
26 V AC at 400 Hz
• Overload of 900 VA is allowed up to 5 minutes

• The inverter detects any type of failure


and disconnects for the following reasons:
• Overvoltage and under voltage,
• Overfrequency (420Hz) and low frequency (380Hz)
• Overload
• Overheating (100ºC)
• Input voltage above 32 VDC.

8 July, 2021 ONLY FOR TRAINING


AC Generation - Constant Frequency 30

• Elements powered by 115 V AC: VG, GPS, VM, ICE DET, WXR
• Elements powered by 26 V AC: ADF, VOR, DG, VG, Yaw Rate Sensor (YRS), GPS

8 July, 2021 ONLY FOR TRAINING


AC Generation - Constant Frequency 31

• The Inverters are controlled and managed by AC INVERTERS Control Panel located
on the cockpit overhead panel.
• The Inverters are located beneath the cargo compartment floor.

ONLY FOR TRAINING


AC Generation - Constant Frequency 32

• AC Generation - Constant Frequency Architecture

8 July, 2021 ONLY FOR TRAINING


AC Generation - Wild Frequency 33

• AC Generation Wild Frequency provides power to:


• Air inlet deicing system
• Heater blankets of wing and tail distributor valves
• Main electrical buses, when both DC generators are not available.
• The AC Generation Wild Frequency system consists of:
• Alternator (AC Generator) - 2x
• Alternator Control Unit (ACU) - 2x
• Current Transformer - 2x
• Contactor Box - 2x
• Test Switch - 2x
• Transformer Rectifier (TR) - 2x

ONLY FOR TRAINING


AC Generation - Wild Frequency - Alternators 34

• Alternator (AC Generator) is installed on the propeller gear box

•Engine Air Inlet.


•T/R

ONLY FOR TRAINING


AC Generation - Wild Frequency - Alternators 35

• The Alternator (AC Generator) is manufactured by Lucas Aerospace


• It produces three-phase alternating current at 115/200 V AC

• The main characteristics of the alternators are:


• Refrigeration: Self-cooling and by ram air cooling.
• Weight: 12.700kg (28.00Lb).
• Speed range: 9.250 to12.000 r.p.m.
• Variable frequency: 463Hz at 9.250 r.p.m, 600HZ at 12.000 r.p.m.
• Wave form: Three phases
• Output Power: 26 kVA .
• Overload capacity: 29,25kVA for 5 minutes, 35 kVA for 5 sec.

PMG - Permanent Magnet Generator

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AC Generation - Wild Frequency - Alternators 36

• Alternators are controlled from the panel AIR INLET ANTI-ICE installed on the upper side
of the overhead panel.

PMG - Permanent Magnet Generator

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AC Generation - Wild Frequency - Alternators 37

AIR INLET ANTI-ICE Control Panel

ONLY FOR TRAINING


AC Generation – Wild Frequency - ACUs 38

• Alternator Control Units (ACUs), installed in the leading edge of the center wing,
controls the output voltage of the alternator and makes certain that the output is 115 V
AC three-phase, even though speed and load requirements may change.

• The unit measures the output voltage of the alternator and load requirements. It
automatically adjusts the exciter field current to keep a regulated output voltage.

• Protection circuits make sure that the alternator is automatically disconnected from the
loads if an over voltage or ground fault condition occurs.

ONLY FOR TRAINING


AC Generation - Wild Frequency – Contactor Boxes 39

• Contactor Boxes are located in the centralwings.

ONLY FOR TRAINING


AC Generation – Wild Frequency – Test Switches 40

• Two test switches, that can do a test of the Alternator Control Units (ACUs),
are installed in the left (right) electrical rack,.

Alternator Control Unit (ACU)


ONLY FOR TRAINING
AC Generation – Wild Frequency – Block Diagram 41

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AC Generation – Wild Frequency – Cautions 42

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43

External Power

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External Power Sources - GPU connector 44

• The external DC power connector is located close to the nose of the aircraft

• The connector is composed of three pins (one shorter to avoid electric arcs) and
a circuit breaker.

ONLY FOR TRAINING


External Power Sources 45

• The illuminated amber light (GPU) indicates that a GPU is connected to the aircraft.

• Pushing the “ON” pushbutton illuminates it, indicating that all the distribution bus bars
are being fed from the DC external source. The batteries automatically disconnect as
well as the generators if they were connected.

ONLY FOR TRAINING


External Power Sources 46

• The DC GPU, when plugged, is connected to both BAT BUS 1 and BAT BUS 2.

External DC GPU Connection

• If the engine start is to be performed with external power source, the DC GPU must be
capable of producing 28 V DC at loads up to 2.000 Amps with negligible voltage drops

• NOTE: The GPU doesn't charge batteries

ONLY FOR TRAINING


External Power Sources 47

2.000 Amp.

34V more
than 2 sec.

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48

Power Distribution

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Distribution 49

• The power distribution is carried out through:


• One BDU (Battery Distribution Unit) (Beta box)
• Two BPUs (Bus-Bar Protection Units) (Alpha box)
• Protection fuses
• Circuit breakers

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Distribution - BDU 50

• The Battery Distribution Unit (BDU) receives and distributes Direct Current only.

ONLY FOR TRAINING


Distribution - BPUs 51

• The two Bus-Bar Protection Units (BPUs) receive and supply DC power only.

ONLY FOR TRAINING


Distribution - BDU and BPUs 52

• All power buses, relays etc. are located


inside of the (Battery Distribution Unit) BDU
and (Bus-Bar Protection Units) BPUs.

• BB1 - BAT1 contactor (connects BAT 1 to Bat Bus 1)


• BB2 - BAT2 contactor
• PSC - Parallel Serial contactor
• GPC - Ground Power Contactor (disconnects the
battery when a GPU is connected)
• BBC1 - connects BAT1 to Start Bus
• BBC2 - connects BAT2 to Start Bus

• LC1 - Line Contactor (DC Gen 1 to Gen Bus 1)


• GB1 - connects Gen Bus 1 and Bat Bus 1
• BT1 - BUS TIE contactor
• GG1 - GEN TIE contactor
• ST1 - START Bus Bar contactor

ONLY FOR TRAINING


Distribution - DC Power Electrical Circuit 53

ONLY FOR TRAINING


DC Distribution. Fuses Panels 54

• There are two Fuse Panels for the different systems located in the cockpit behind the
pilot and co-pilot seats

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DC Distribution. Circuit Breakers Panels 55

• The circuit breakers panels that protect and provide power to the user circuits
are located in the cockpit .

Circuit Breakers Location

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DC Distribution. Circuit Breakers Panels 56

• AVIONICS 1
• BATTERY BUS 1
• MISCELLANOUS
• BATTERY BUS 2
• AVIONICS 2

U1 U2 U3 U4 U5

ONLY FOR TRAINING


DC Distribution. Circuit Breakers Panels 57

• R MISCELLANOUS
• L MISCELLANOUS

ONLY FOR TRAINING


DC Distribution. Circuit Braker Identification 58

U2-Panel
A6-Circuit Braker

U2-Panel
A5-Circuit Braker

ONLY FOR TRAINING


59

Controls and Indicators

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Controls & Indicators 60

• The indication and control panels for the DC Subsystem:

ONLY FOR TRAINING


Controls & Indicators 61

• Master Electric Panel

GEN Master Switch - allows each generator to be connected to


BAT Master Switch - allows each battery to be connected to its bus
its bus bar with the related GEN switch on the Power Generation
bar with the related BAT switch on the Power Generation panel.
panel.

Hot Bus is always energized by the batteries

ONLY FOR TRAINING


Controls & Indicators 62

• DC POWER GENERATION Panel

• Battery 1 and 2 switches connect the A/C BAT 120ºF (50ºC) 150ºF (65ºC
batteries to their associated bus bar. Switch

• Magnetic Indicators display connection or + suplied


- charging
disconnection of the batteries to their
corresponding bus bars. Magnetic
Indicator

• Ammeters indicating consumption or


provision of the batteries, to the bus bars,
and if a GPU is connected to the aircraft, it
displays the power provided to the bus
bars.
• Lighted pushbutton for connecting the
external DC provided by the G.P.U. (4).

POWER GENERATION Panel

ONLY FOR TRAINING


Controls & Indicators 63

• DC POWER GENERATION Panel

Ammeters on the DC generation panel indicate positive current


when the battery is providing power or negative current when
the batteries are recharging.

GPU ON

The batteries and the generators are automatically


disconnected, the battery bus tie is turned on, and the
GPU supplies the busses.

The current supplied by the GPU is shown on the


battery ammeters and the voltmeters show the 28VDC
supplied by the GPU.

POWER GENERATION Panel

ONLY FOR TRAINING


Controls & Indicators 64

• DC POWER GENERATION Panel

Magnetic Indicator Normal situation: both systems


separates.

Bat Bus Tie Switch:


Aut: Normally disconnected, if Gen fails or Gen Bus isoltate,
Automatically connected.
Off: Bat Bus disconnecte, independent circuit.
On : Bat Bus connected, the loads are equally divided between
Two generators if battery and generator bus bars are connected

RESET: re-establish the connections between the related


battery and generator bus bars.

BAT-GEN to isolate both


Buses due to overload or overvoltage
POWER GENERATION Panel

ONLY FOR TRAINING


Controls & Indicators 65

• DC POWER GENERATION Panel


GEN BUS TIE: ties the two generator bus bars if the BAT BUS TIE
selector is at the OFF position. The ON light and the line turn on,
indicating a connection.

AMMETER: shows the current supplied by the generator (also the


TRU/Alternator) to its related bus bar.

TR Selector. connects the LH alternator through the TR to the generator


bus bar 1 or connects the RH alternator through the TR to the generator
bus bar 2.

By setting switch TR, alternating current will arrive at the transformer-


rectifier which will produce a direct current of 28V, with a maximum
intensity of 300A

POWER GENERATION Panel

ONLY FOR TRAINING


Controls & Indicators 66

• DC POWER GENERATION Panel

TEST Switch - OVV simulates over voltage in the GCU. The generator
GEN/RESET Switch - ON connects the generator to its
disconnects from its bus bar and the DC GEN warning appears on the
related bus bar. RESET re-establishes the conditions for
IEDS. GF simulates a ground failure in the GCU. The generator is
the operation of the GCU. It is necessary to pass through
disconnected and its DC GEN light warning appears on the IEDS.
this position in order to put it at ON.

POWER GENERATION Panel

ONLY FOR TRAINING


Controls & Indicators 67

• DC POWER GENERATION Panel

ONLY FOR TRAINING


Controls & Indicators - EFIS Back-Up Battery 68

The BAT lighted captions should appear if the battery voltage is equal to or more than 24VDC.

The ADVISORY EFIS panel contains the BAT B/U lighted switch and lets you do a test of the battery
output voltages.
When the switch is pushed a 28VDC signal is applied to the TEST inputs of the EFIS back-up batteries.
If the output voltages are equal to or more than 24VDC a signal through the battery TEST LAMP output
will occur, and the BACK UP BAT TEST lighted switch will turn on.

ONLY FOR TRAINING


Controls & Indicators – Cautions and Warnings 69

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70

Operation

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Operation - DC Generators 71

• The first step is to turn ON the switch labeled GEN on


the MASTER Electric Panel (1).

• Connect the No. 1 Generator to its corresponding bus


bar by using the three position GEN 1 switch (2).

• The magnetic indicators are in line (3) and the ammeter


shows the generator output (4). (5)

(4)

• The guarded GEN BUS TIE pushbutton, when pressed,


connects the No. 1 and No. 2 generator bus bars but (3)

only if the BAT BUS TIE switch (5) is OFF.


(2)

(1)

Generators Operation

ONLY FOR TRAINING


Operation - DC Generators 72

• When the pushbutton is pressed, the ON light


illuminates and a bar illuminates to confirm that the
connection is effective.

• The “Reset position” in Generators switches re-


establishes operating conditions in the Generator
Control Unit after a generator disconnection (1).

(1)

GEN BUS TIE Operation

ONLY FOR TRAINING


Operation - DC Generators 73

• There are two generator ground test


switches with two possible positions: (1)

• OVV: simulates an over-voltage and the


generator disconnects from the bus bars
(1).
• GF: simulates a ground fault and also
disconnects the generator from the bus
bars (2). (2)

• The diverse generator failures are indicated by


the corresponding annunciations on the IEDS
accompanied by an acoustic warning:
OVV and GF Operation

• 1 and 2 DC GEN: generators failure


• 1 and 2 GEN HOT: generators overheat
(165ºF).
• BUS UNTIE: some abnormal bus bar
disconnection.

ONLY FOR TRAINING


Operation - Batteries 74

• Batteries Operation

• The batteries are used:


• As a secondary source of direct current energy for ground operations of
limited time.
• Starting the engines on the ground or in the air because of generation failure.

Battery

Batteries Location

ONLY FOR TRAINING


Operation - Batteries 75

• The first step is to turn ON the switch labeled BAT on


the MASTER Electric Panel (1). (2) (2)


(3) (3)
Switch the BAT 1 and BAT 2 switches to the “ON”
position. This places the batteries into service supplying
their respective bus bars (2).

• The magnetic indicators change position to display the


batteries inline and the meters should register current
(4)
and voltage (3).

• The voltmeters should read 24 VDC and the ammeters


register in the positive (+) area depending on how much
current the battery is supplying. The ammeter reads in
the negative (-) area when the battery is charging or
consuming current from the generator busses.

• Place the BATTERY BUS TIE switch to AUTO position. (1)


This switch is used to join the battery bus bars if
necessary (4).

ONLY FOR TRAINING


Operation - Batteries 76

• The System Tests Panel includes a switch for


testing the battery temperature circuits. BAT
BUS 2 supplies DC to the temperature
indicator so it must be ON when testing the
battery temperature. When the switch is
pushed up and held in the BAT TEMP position:

• Both WARM and HOT lights in the battery


temperature indicator will turn on.

• The red BAT HOT warning is generated

System Test Panel

ONLY FOR TRAINING


Operation - EFIS Back-Up Battery 77

• The EFIS (Electronic Flight Instruments System) back-up battery automatically supplies DC power to the
cockpit display of the EFIS during engine start. This power supply operates independently from the DC
generation system.
• This ensures that the voltage drop in the DC generation system during engine start does not have an
unwanted effect on the EFIS.

• The ADVISORY EFIS panel contains BACK UP BAT TEST lighted switch and lets you do a test of the
battery output voltages.
• When the switch is pushed a 28VDC signal is applied to the TEST inputs of the EFIS back-up batteries.
• If the output voltages are equal to or more than 24,24 V DC a signal through the battery TEST LAMP output
will occur, and the BACK UP BAT TEST lighted switch will turn on.

ONLY FOR TRAINING


Operation - Engine start 78

ONLY FOR TRAINING


Operation - ENGINE START panel. 79

ONLY FOR TRAINING


Operation - Start with batteries 80

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Operation - Start with GPU 81

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Operation - Cross Start 82

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Limitations 83

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84

Failure Conditions

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Failure Conditions 85

• Failure of a distribution bar (BUS UNTIE)

• Failure of the DC Generator (DC GEN)

• DC Generator Failure and BUS UNTIE (DC GEN


& BUS UNTIE)

• Failure of both DC Generators (DUAL DC GEN


FAILURE)

• Inverter Failure (INVERTER FAILURE)

• AC Generator Failure (AC GEN)

POWER GENERATION Panel

ONLY FOR TRAINING


Failure Conditions - List of electrical loads 86

ONLY FOR TRAINING


Failure Conditions - DC GEN Failure 87

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Failure Conditions - DC GEN Failure and Bat Bus Tie. 88

ONLY FOR TRAINING


Failure Conditions – DC GEN HOT. 89

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24.-ELECTRICAL POWER. DC Gen Failure. 90

GEN-BUS UNTIE

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Failure Conditions - AC Generation Failure. 91

1 AC GEN

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Failure Conditions - Inverter Failure 92

115-26 VAC/400Hz Single phases

Instruments and Avionics Power supplies

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24.-ELECTRICAL POWER. Inverter Failure. 93

ONLY FOR TRAINING


94

8 July, 2021 ONLY FOR TRAINING

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