RvAviator

Member
Hi,
I hope this description of my problems is not too confusing.

I have a Plane Power generator, factory mounted on a new engine. Aircraft first flight in 2022. I also have the VPX Pro installed.
Three years ago, with only 25 hours on the installation, my generator started to cut out during some flights and resetting randomly.

After a couple of more flights the VPX started to randomly cut different avionics out and sometimes restarted some of them. Both on ground with engine shut down and in flight, Some I manually had to reset in the VPX G3X menu. I checked all cables and switches which where all ok.
As I have IBBS backup power installed, I do not understand why it did not take over the power supply to the units connected to the IBBS so they did not have to restart.

Talked to Plane Power and they thought the voltage regulator was the problem and sent me a new 100-dollar regulator. Had to pay for it as warranty had expired, even if the hours were very low…
Everything worked ok for some flights, but the problem came back….

After a lot of communication with Astronics VPX support it was decided that I should send the VPX for troubleshooting. Did so, and they found a defective board, charged me 1100 dollars and sent it back to me.
Everything worked for a little over a year, but now the amps annunciation has reappeared on my G3X, and the VPX intermittently shuts down some avionics. The symptoms are more or less the same as before.

Downloaded data from the G3X and it seems like the voltage is slightly lower than normal (steady 14.4 previous flight). Voltage not stable, variating 13.1-14,7 Volts. Low amps message several times, looking at the panel during those events the VPX generator box get blank and filled randomly, so it seems as the VPX try to reconnect the generator. Turning back to my home airfield and the system worked ok…..

In the attached file I have cut out some data from the G3X from that flight, hope they make some sense.
I have tried to reach out to Astronics, but not got any answer.

I have no idea what can cause the problem, maybe vibrations doing harm to the VPX or generator? I have done a forum search, and it looks like another owner with same electronics as me had the same problem. But it was posted long time ago, 2015. No final solution posted as far as I could see.
So, my thoughts go to the generator or voltage regulator, but how come the VPX is doing strange things after a generator failure as both battery and IBBS power are available?
As of now I only dare to do local flights, my objective building an airplane was to get around to different more distant destinations. Not going to do that until problem is finally solved.
 

Attachments

Have you checked ALL connectors to see if they are tight, have secure crimped connections & not corroded? Did you check the D-sub connectors & confirm pins are not loose & crimps are secure?
Have you checked ALL ground connectors are tight & secure? Including engine ground strap?
Have you noted which specific instruments went black & checked or replaced the control switch for each? Switches even with 5 volts can go bad.
Have you taken the alternator to an Auto Electric Repair Shop (not an auto parts outlet!) and had it checked out?
Did you go back to the IBBS instructions & confirm wiring & what conditions it or VPX would make it kick in?
I suggest you break your issues into groups-
1- Alternator/regulator
2- Wiring/switches
3- VPX
4- IBBS
If you lump everything together, you will only go around in circles.
I suggest you tackle & confirm them in the order above.
 
Put an oscilloscope on the alternator, good chance you will see the PP is sporadically putting out spikes of very high voltage. You won't see this on the amp meter. The VPX will do what it's supposed to do, stop the spike from destroying your sensitive instruments. I have seen this now on several PP units.
 
Have you checked ALL connectors to see if they are tight, have secure crimped connections & not corroded? Did you check the D-sub connectors & confirm pins are not loose & crimps are secure?
Have you checked ALL ground connectors are tight & secure? Including engine ground strap?
Have you noted which specific instruments went black & checked or replaced the control switch for each? Switches even with 5 volts can go bad.
Have you taken the alternator to an Auto Electric Repair Shop (not an auto parts outlet!) and had it checked out?
Did you go back to the IBBS instructions & confirm wiring & what conditions it or VPX would make it kick in?
I suggest you break your issues into groups-
1- Alternator/regulator
2- Wiring/switches
3- VPX
4- IBBS
If you lump everything together, you will only go around in circles.
I suggest you tackle & confirm them in the order above.
Thanks Ralph!

Will check the generator first as you suggest, as I think that is a possible cause to the random problems.

The VPX is a little bit more demanding to isolate the problem. No special pattern except the radio and GNX 375 always turned off without restart. The two G3X are not shutting down not so frequent. System is configured in the VPX so left G3X (PFD) starts up when Master is set to on. The right G3X (MFD), Radio, GNX 375 starts up when Avionics switch is turned on (with Master on). IBBS are backing up both G3X when Master is off.

I have checked the switches (Master, Avionics and IBBS backup), they were all new in the install. But the nature of the failure makes me believe that the problem lies somewhere else. But I can of course change them anyway, no big cost.

All avionics are wired by a professional Garmin installer, but I have checked all connections.

The IBBS is wired as described in the manual, battery is ok.

Found an old tread, same problem as I have. Unfortuantely no info if the problems he had was solved.

"I am having an issue with my alternator where when watching it via the VPX screen on my G3X it shows the alternator turning off and then on again at random intervals. This is causing my battery to drain and create havoc with my systems not hooked up to my backup battery.
I have replaced the voltage regulator thinking that might be the problem, but no luck, same issue.
It is not the current, the VPX shows the alternator go to a power off state, like I turned off the switch, then it comes back on again at random intervals."
 
Put an oscilloscope on the alternator, good chance you will see the PP is sporadically putting out spikes of very high voltage. You won't see this on the amp meter. The VPX will do what it's supposed to do, stop the spike from destroying your sensitive instruments. I have seen this now on several PP units.
Thanks!
I will get a scope to check that out.