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  • Electrical redundancy

    I thought i would write up a couple of things I did slightly different. I chose EFI/EI for the engine, mostly because it is what I know and understand. It does require a reliable electrical system, or it won't be reliable.

    I wanted extra battery capacity in case of alternator failure, and I wanted to be able to jump start my own aircraft, or somebody else's. So instead of a full 2 battery system, I bought a big LI-ion jump start pack. It normally resides in an easy to remove mount, plugged into the aircraft for backup-battery use only. No onboard charging allowed. Or it can be removed from its' mount for jumpstarting and charging. It is rated at 21 ah/hour. A "Gotcha" with any lithium battery is the marketing. Many are sold as PB/eq. Or lead equivalent. It will say 15 ah/hr, Pb/eq. That means it will crank like a 15 ah/hr lead battery, but doesn't have the same ah/hr capacity. Usually, it is about 1/3 of that.

    I call this "almost 2 batteries". The ships battery and Jump pack should run the engine for 2 hours.

    The other "other", is I wanted more redundancy in the alternator. VAF had a great "alternator reliability poll" post on their forum. Very long post. Most alternator failures, like >80%, are actually voltage regulator failures. So I thought instead of a second alternator, maybe just carry a 2nd VR? That morphed into I will mount it next to the 1st VR, and put a connector on both to swap them. Which morphed into putting both of them on switches, which is what I have now. Maybe sometime I will decided I want 2 alternators. If I do, its' VR is already installed.

    But for now, I have almost 2 alternators.

    VR.jpg




    The basic circuit architecture is straight out of Bob Knuckles.


    The last thing that is less common than most is I used a "fuse/relay" panel, similar to what cars use. The main advantage is similar to the VPX - it reduces mechanical connections by 2/3. I like the VPX and probably would have used one, but the EFI manufacterer sort of recommended against it. Nothing wrong with them, but they are software controlled, as is the EFI. They are unsure how the two might interact. Spruces sells several models, and those manufacterers have different models. Mine is from Eaton's "Littlefuse" brand.

    EFI/EI require more switched/fused circuits than a carb or MFI.


    fues:relay.jpg





  • #2
    svyolo I am installing an EFII by SDS and had similar concerns about electrical backup that you have. Along with the B&C 60 amp alternator, I decided to install a Monkworkz M 30 for a second source and use the battery for a third source. My friend, who is designing my electrical system, has put duel battery contacters (controlled by separate switches) in the system that will power both essential and non-essential busses. There will be a switch to take the non-essential buss out of the system to reduce load if the main alternator or VR fail.
    Last edited by rkennell; 02-09-2025, 09:36 AM.
    Roger
    QB Companion C-9
    N51RK

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    • svyolo
      svyolo commented
      Editing a comment
      I have a switch currently labeled "Avionics SW". In actuality the way I am using it is just as you describe - it shuts off everything but the engine, and simultaneously connects the backup battery in parallel with the ships battery.

      I may end up with one of those Monkworkz units. But I will start up with what I have for now.

  • #3
    I considered doing something similar but then opted to go with a Li-Fe backup battery (IBBS via ACS). I wasn't comfortable with the failure modes of Li-Ion batteries. They have much higher thermal runaway risk. If you must use Li-Ion, make sure to use a robust battery management system (BMS). Also be aware that either battery chemistry typically fails not only in excessive heat but also produces copious amounts of nasty smoke. This is important to know when enclosing it in a fire proof box. Unless venting it to the outside, the potential smoke might still find its way to the cockpit and interfere with finishing the flight.
    Last edited by noema; 02-10-2025, 05:32 PM.
    Bearhawk "XHawk" Patrol, O-360, Trailblazer 80", tubeless 26" Goodyears, Stewart Systems. See XHawk Build Log.

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    • svyolo
      svyolo commented
      Editing a comment
      Yeah that is definitely a concern. But it is not wired to charge on board. I have to remove it from its mount to charge it.
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