e-Flaps FLAP CONTROLLER
Contents
1. Gear Alert if installed Ore E S r light dimmer output z lt 2 Z is 5v to 14v the Flap S 8 e Controller switch lights N will go to dim setting F x e ni aa Red 12v 20 AWG minimum Violet Black GND 20 AWG minimum Temporary bare wire splice to verify position sensor wiring Orange sens r voltage Yellow signal Green gnd nD with fixed internal limit switches The actuator must be rated for no greater than 5 amps RAC POS 12 __ S oO z z o NS g ol 2 g 2 Q D 3 g Flap x 3S ego l 8 a 6 Position Use a linear actuator a Sensor lt Temporary bare wire splice to verify actuator motion Drawing not to scale 13 04 09 Flap Actuator Page 5 of 8 Flap Controller Verifying Actuator Motion a Insure that the Flap Controller is OFF Place the Flap Controller in Manual Mode by holding the UP switch light depressed while applying power until the UP switch light flashes In Manual Mode pressing the UP switch light should now move the flaps UP and pressing the 1 switch light should move the flaps DOWN If pressing the UP and 1 switch lights move the flaps in the wrong direction reverse the WHITE BLACK and WHITE wire connections to the flap actuator When the Flap Controller moves the flaps in the correct direction permanently connect and insul2. Kohm to 10 Kohm d Tefzel wire sized and protected according to AC43 13 1B Page 3 of 8 Flap Controller V COMPONENT INSTALLATION AND WIRING Basic Installation NOTE Do not have a battery charger hooked up while this unit is powered up as it may damage some of the electronics Unit should be run off battery power only a The Flap Controller can be mounted vertically or horizontally in the instrument panel or any convenient consol that is within easy reach and sight of the pilot The mounting position must have sufficient space to allow for the depth of the Flap Controller module b This manual assumes that the aircraft has a linear flap actuator with fixed internal limit switches and rated to a maximum of 5 amps under load If actuator is rated more than 5 amps 2 relays will have to be installed to control the actuator power one for each line The flap actuator should be installed so that the internal limit switches will stop the flaps at the zero flap and full flap positions If actuator does not have internal limit switches it is recommended to install them c This manual assumes that the actuator has internal position sensor leads or the aircraft has a RAC POS 12 Position Sensor or similar installed so that the sliding arm moves in conjunction with the flaps and reaches full extension or is fully retracted with the flaps at the actuator internal limit switch positions d Connect the RED wire to 12 volt DC aircraft power
3. ate the WHITE BLACK and WHITE wires Verifying Position Sensor Wiring Insure that the Flap Controller is in Manual Mode Push the UP or 1 switch lights to move the flaps to a mid position Use a Digital Volt Ohm Meter DVOM to measure the voltage at each of the sensor temporary splice positions The voltage at the Flap Controller YELLOW wire connection should read approximately 2 4 volts The voltage at the other two temporary splices should read zero ground and slightly less than 5 volts With the flaps in a mid position the Flap Controller YELLOW wire must read a voltage greater than the GREEN wire splice and less than the ORANGE wire splice Reconnect the wires until the test voltages are correct Move the flaps towards the UP position and measure the voltage at the Flap Controller YELLOW wire connection The voltage should have increased from the previous 2 4 volt reading If the voltage is lower swap the wires connected to the Flap Controller ORANGE and GREEN wires Permanently connect and insulate the YELLOW ORANGE and GREEN wires Now move the flaps in the up direction until the internal limit switch shuts the actuator off Measure and record the voltage on the YELLOW wire Move the flaps in the down direction until the internal limit switch stops the actuator Again measure and record the voltage on the YELLOW wire Page 6 of 8 Flap Controller VI SYSTEM CALIBRATION Note For the system to function c
4. e Flaps FLAP CONTROLLER INSTALLATION MANUAL P N 2071 SPECIFICATION IP 2071 REV 2 Dec 9 2011 JDG Approved Aircraft Components Inc 6539 Orchid Lake Rd New Port Richey FL 34653 For Experimental Category Aircraft Only Not FAA Approved Flap Controller I INTRODUCTION Welcome to the world of e Flaps the electronic Flap Controller This manual provides information for installing and operating the Flap Controller on an experimental aircraft using a linear actuator to position the flaps All installation work should be performed in accordance with this manual and the applicable sections of AC 43 13 1B Il SYSTEM DESCRIPTION The Flap Controller is an electronic device that automatically positions the Electric Flaps in four selectable positions Up 1 2 and 3 Each position can be calibrated to stop the flaps at a user determined flap angle Flap positions are selected by pressing four push type green LED illuminating switches switch lights located on a 4 x 1 2 flap controller module that can be mounted vertically or horizontally in any convenient instrument panel or console location Flap position is indicated by the steady illumination of one of the module switch lights This removes the requirement for a separate flap position indicator but a RAC POS 12 or similar position sensor must be installed or the actuator must include this sensor internally The Flap Controller incor
5. e flaps arrive at the new position If desired flaps can be moved several positions at once For example if the flaps are UP and position 3 is desired briefly pressing switch light 3 will cause the flaps to transition directly from UP to position 3 If the position sensing functions fails in flight it is possible to use the Flap Controller to manually position the flaps a First remove all power to the Flap Controller b Now hold the UP switch light depressed while reapplying power to the Flap Controller This will place the Flap Controller in Manual Mode c While in Manual Mode holding the UP switch light will move the flaps UP and holding 1 switch light will move the flaps DOWN In Manual Mode the Flap Controller does not indicate flap position The flap actuator should stop the flaps motion when the internal limit switches are reached if installed Intermediate positions will have to be estimated by watching the flap movement IV APPLICABILITY This system is not FAA approved It is intended for installation on Experimental category aircraft only The aircraft must meet the following minimum requirements for an installation a 12 volt DC power b Linear actuator rated no more than 5 amps and with fixed internal limit switches c Linear actuator with internal position sensors or an external RAC POS 12 Position Sensor or similar The position sensor must have a resistance of 5
6. orrectly the actuator must be installed so that the flaps are stopped by the Flap Controller and not by the internal actuator limit switches a With the Flap Controller in Manual Mode move the flaps to the position that you want for full UP Measure the voltage on the YELLOW wire It must be at least 0 05v less than the full up internal limit switch shut off position voltage recorded in f above If it is not it will be necessary to adjust the flap position linkage to guarantee that the limit switch activation point is beyond the desired full up position b While holding the 3 switch light depressed press and hold the UP switch light until the UP switch light flashes once c With the Flap Controller in Manual Mode move the flaps to the first desired flap position d While holding the 3 switch light depressed press and hold the 1 switch light until the 1 switch light flashes once e With the Flap Controller in Manual Mode move the flaps to the second desired flap position f While holding the 3 switch light depressed press and hold the 2 switch light until the 2 switch light flashes once g With the Flap Controller in Manual Mode move the flaps to the final desired flap position Measure the voltage on the YELLOW wire It must be at least 0 05v greater than the full down internal limit switch shut off position voltage recorded while verifying position sensor wiring If necessar
7. porates an interconnect to the optional P N 2070 Gear Alert system used on amphibian aircraft thereby eliminating the need to install a separate flap position cam and micro switch Weighing only 3 oz easy to read and fully automatic the Flap Controller removes the guesswork and distraction of manually positioning flaps during the busy approach and departure phases of flight Page 2 of 8 Flap Controller Il SYSTEM OPERATION When power is applied to a properly installed Flap Controller the system does a self test each of the four switch lights illuminating briefly in sequence If the self test is successful one switch light will remain ON indicating the current flap position In the unlikely event that the flaps are in an intermediate position no switch light will illuminate Pressing any switch light will cause the Flap Controller to move the flaps to the selected position If the self test fails switch light 2 and 3 will alternate ON and OFF indicating that the system has a broken wire or has not been calibrated Warning Do not use the Flap Controller until the system is calibrated Failure to calibrate the system could cause damage to actuators that do not have internal limit switches To select a flap position briefly press the desired switch light The current flap position switch light will extinguish The selected switch light flashes while the flaps are in motion and remains ON STEADY once th
8. using Tefzel wire sized and protected according to AC43 13 1B e Connect the BLACK wire to a convenient ground using appropriate Tefzel wire f Connect the VIOLET wire to the 2070 Gear Alert landing position sensor wire as installed This connection will provide a ground whenever flaps are in position 2 or greater g Using a bare wire splice temporarily connect the WHITE BLACK wire to one of the flap actuator power inputs with appropriately sized Tefzel wire h Using a bare wire splice temporarily connect the WHITE wire to the other flap actuator power input with appropriately sized Tefzel wire i Using a bare wire splice temporarily connect the 22 AWG ORANGE sensor voltage wire to the ORANGE WHITE wire on the RAC POS 12 Position Sensor The j Using a bare wire splice temporarily connect the 22 AWG YELLOW signal wire to the GREEN WHITE wire on the RAC POS 12 Position Sensor k Using a bare wire splice temporarily connect the 22 AWG GREEN sensor ground wire to the BLUE WHITE wire on the RAC POS 12 Position Sensor Page 4 of 8 Flap Controller Flap Controller H2V Wiring Schematic A eer aie Sie ie ae ser cee z ree Power Buss Gear Alert optional optional O Se ee Size breaker ang Elio If installed use ACI 2075 wire according to Power Buss AC43 13 1B E 5 eouerhes one Flap Controller sends Maximum breaker amp O j landing flap signal to size 5 amps Es ACI 2070
9. y select a higher position for full down or modify the actuator installation h While holding the 2 switch light depressed press and hold the 3 switch light until the 3 switch light flashes once i Remove and reapply power to the Flap Controller to place the system in Normal Mode The system will complete a self test indicated by each of the four switch lights illuminating briefly in sequence If the self test is successful switch light 3 will remain ON indicating the current flap position as calibrated in h above Test each of the switch lights in turn to confirm the desired automatic flap movement and calibration of the Flap Controller Verifying Gear Alert Wiring a Refer to the Gear Alert Manual and check that the Select Landing interrogation occurs at flap positions 2 3 and while moving between these positions Page 7 of 8 Flap Controller VII FREQUENTLY ASKED QUESTIONS Not allocated VHI DOCUMENTATION a The installer is responsible for making all logbook entries revising weight and balance and other documentation as required b System weight is 3 oz IX MATERIALS The following materials are included in the Flap Controller kit Check all parts before beginning the installation 1 x Flap Controller module P N 2071 1 1 x installation manual P N IP 2071 Page 8 of 8
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