PIPER AIRCRAFT, INC.
PA-28-161, WARRIOR III
MAINTENANCE MANUAL
2E10
24-30-00
PAGE 18
Nov 30/06
E. Overvoltage Test
The BC203-2D contains internal over-voltage protection. Grounding for both regulation and
overvoltage protection is achieved through terminal 7 of the regulator, through the case mounting
bolts and through the grounding stud provided under the terminal strip. Overvoltage protection may
be tested for correct operation using either of the following two tests:
(1) Test 1
(a) Disconnect the aircraft wiring harness from terminal 6 of the regulator.
(b) Connect a current limited power supply with an output voltage adjustable between zero
and 35 volts to terminals 6 and 7 with the positive lead on terminal 6.
(c) Connect a 10 ohm, 10 watt resistor from terminal 6 to terminal 5.
CAUTION: THE POWER SHOULD BE REMOVED FROM TERMINAL 6 WITHIN FIVE
(5) SECONDS OF ACHIEVING THE SHORTED CONDITION.
(d) Limiting the output current to 5 amps or less, gradually raise the power supply voltage
until the regulator shorts the output of the power supply. Remove power from terminal 6
as soon as the short occurs.
(e) The short should occur between 32.0 and 33.0 volts. No short indicates the failure of the
overvoltage protection circuitry of the regulator and necessity for repair or replacement of
the regulator.
(f) If the test is satisfactory, switch power OFF, disconnect the power supply, remove the 10
ohm resister, and reconnect terminal 6 to the aircraft wiring harness.
(2) Test 2
(a) Disconnect the aircraft wiring harness from terminal 6 of the regulator.
(b) Connect a 5 amp in-line fuse from the aircraft bus to the negative terminal of a 12 volt
lantern battery.
(c) Connect a 10 ohm, 10 watt resistor from terminal 6 to terminal 5.
(d) Energize the aircraft Bus and momentarily connect the positive terminal of the lantern
battery to terminal 6 of the regulator.
(e) The fuse should blow immediately. If the fuse does not blow, the over-voltage protection
circuit has failed and the regulator must be replaced or repaired.
(f) If the test is satisfactory, switch power off, reconnect terminal 6 to the aircraft wiring
harness, and remove the 10 ohm resistor.
F. Repair
Failure due to broken wires or damaged connectors may be corrected in the field using repair
procedures complying with the latest revision of AC43.13-1. All other repairs are by replacement
only.
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