Vertical Power VP-X Pro User Manual

Electronic Circuit Breaker System
VP-X Pro — VP-X Sport
Installation and Operating Manual
August 5, 2020
Rev. D
Current as of software version 1.6
VP-X Installation and Operating Manual Rev. D Copyright © 2020 Astronics

Vertical Power VP-X Pro Specifications

General

Brand	Vertical Power
Model	VP-X Pro
Category	Circuit breakers
Language	English

Summary

Important Notice

Limited Warranty

Information regarding the terms and conditions of the product's warranty.

Copyright Notice

Statement detailing the copyright ownership and usage permissions for the manual.

Trademarks

List of registered trademarks associated with Vertical Power and its products.

1. Introduction

1.1 Welcome to Vertical Power!

Overview of the VP-X system, its benefits, and its place in aircraft electrical systems.

1.2 Vertical Power Terms

Definitions of key terminology used throughout the VP-X installation and operating manual.

1.3 Other Reference Documents

List of supplementary documents recommended for planning a safe electrical system.

2. VP-X Overview

2.1 Installation Overview

A summary of the five main steps involved in installing the VP-X system.

2.2 System Overview

Description of the VP-X's capabilities and its integration with EFIS units.

2.3 Supported Bus Architecture

Details on the aircraft electrical bus architectures compatible with the VP-X.

3. Electrical System Basics

3.1 Free Advice on Designing your Electrical System

High-level guidance on planning an aircraft's electrical system, emphasizing mission clarity.

3.2 Introduction

Breakdown of an aircraft electrical system into primary, secondary, and user components.

3.3 Alternator Operation

Explanation of alternator function, voltage regulation, and dual alternator considerations.

3.4 Wire Sizes and Circuit Protection

Guidelines for selecting appropriate wire sizes and circuit protection devices.

3.5 Grounding

Methods and considerations for establishing proper grounding in the aircraft electrical system.

3.6 Switch Nomenclature

Explanation of common switch types, their symbols, and operational mechanisms.

3.7 Alternator Current Sensing (Shunt)

Discussion on the necessity and function of alternator current sensing.

3.8 Bench Testing the VP-X

Procedure for performing initial tests on the VP-X unit before aircraft installation.

4. Planning

4.1 EFIS

Recommendations for EFIS selection and integration with the VP-X system.

4.2 How Switches Are Wired

Explanation of the VP-X's unique switch input wiring method, differing from traditional systems.

4.3 Wiring Harness

Information regarding the availability and purpose of a dedicated VP-X wiring harness kit.

4.4 Dual Bank Technology (VP-X Pro)

Description of the VP-X Pro's dual power bank redundancy for enhanced safety and reliability.

4.5 Tools and Other Stuff

A generic list of tools, supplies, and items needed for planning and installation.

4.6 VP-X Connectors

Identification and description of the various connectors used on the VP-X unit.

4.7 Installing and Removing Power Connector Terminals

Step-by-step instructions for safely installing and removing terminals in VP-X power connectors.

4.8 Alternator and Voltage Regulator Considerations

Factors to consider when selecting alternators and voltage regulators for the aircraft.

4.8a Over-voltage Planning

Planning considerations for preventing and managing over-voltage conditions in the system.

4.8b Low-voltage Planning

Planning considerations for managing and responding to low-voltage conditions.

4.9 Landing Light Wig-Wag (Pulsing) Considerations

Configuration options for implementing wig-wag functionality for landing lights.

4.10 HID Light Considerations

Specific considerations for wiring and operating High-Intensity Discharge (HID) lights.

4.11 Electronic Ignition Considerations

Guidance on wiring various electronic ignition systems with the VP-X.

4.12 Electric Motor Considerations

Advice on using the VP-X for powering electric motors like trim and flap motors.

4.13 VP-X Planner

Instructions and benefits of using the online VP-X Planner tool for system design.

4.13a What if I run out of power pins?

Strategies for managing insufficient power pins for multiple devices.

4.13b What if I run out of switch inputs?

Methods to overcome limitations when requiring more switch inputs than available.

5. Installation

5.1 Pre-Installation Tasks

Essential safety and preparatory steps to perform before commencing VP-X installation.

5.2 VP-X Installation

Guidelines and considerations for selecting an optimal mounting location for the VP-X.

5.3 Wiring Harness Construction

Instructions for constructing custom wiring harnesses according to planned diagrams.

5.4 Backbone Wiring

Explanation of the major components and wiring of the primary electrical system.

5.5 Master Contactor Wiring

Detailed steps for correctly wiring the master contactor for power distribution.

5.6 Starter Switch and Contactor Wiring

Procedure for wiring the starter switch and its associated contactor.

5.7 Starter Annunciator Wiring

How to wire the starter annunciator input to report starter engagement to the EFIS.

5.8 Other Contactor Wiring

General guidance on wiring other contactors, such as those for hydraulic pumps or AC.

5.9 Alternator Wiring

Wiring procedures for various types of alternators, including primary and backup systems.

5.9a Primary Alternator (B&C External Regulator)

Specific wiring instructions for B&C external regulator primary alternators.

5.9b Primary Alternator (Plane Power)

Wiring guidelines for Plane Power alternators, which feature built-in voltage regulation.

5.9c Backup Alternator (B&C 20 Amp)

Instructions for wiring the B&C 20 Amp backup alternator with LR-3C or LS-1A regulator.

5.9d Backup Alternator (B&C 8 Amp)

Wiring procedures for the B&C SD-8 8 Amp backup alternator using a relay.

5.9e Backup Alternator (Plane Power 30 Amp)

Wiring guidelines for the Plane Power 30 Amp backup alternator with built-in voltage regulation.

5.9f Alternator – Rotax, Jabiru, or UL Power engines

Wiring for alternators integrated into Rotax, Jabiru, and UL Power engines.

5.10 Primary EFIS Wiring – Power and Data Connections

Connecting the primary EFIS for power, data, and fault reporting.

5.11 Advanced Flight Systems EFIS Wiring

Wiring specific to Advanced Flight Systems EFIS units for data communication.

5.12 GRT EFIS Wiring

Wiring specific to GRT EFIS units, covering Horizon and Sport models.

5.13 MGL EFIS Wiring

Wiring specific to MGL EFIS units for data communication.

5.14 Garmin G3X EFIS

Wiring instructions for Garmin G3X EFIS systems, including dual screen setups.

5.15 Dynon SkyView Wiring

Wiring specific to Dynon SkyView EFIS units, covering dual display configurations.

5.16 Items you don't have to wire to the EFIS

Features now integrated into VP-X, eliminating the need for direct EFIS wiring.

5.17 Ground Wiring

Guidelines and options for establishing proper ground connections for all system components.

5.18 General Power Wiring

General principles and chart for sizing wires for power distribution to devices.

5.19 Trim System Wiring

Instructions for wiring trim motors and position sensors, and configuring trim operation.

5.19a Pitch Trim Wiring

Specific wiring details for pitch trim servos, including motor and position feedback connections.

5.19b Roll Trim Wiring

Specific wiring details for roll trim servos, including motor and position feedback connections.

5.19c TruTrak Auto Trim Module

Wiring instructions for integrating the TruTrak auto trim module with the VP-X.

5.19d Co-Pilot Disconnect Switch

Implementing a switch to disconnect the common ground wire for the co-pilot's trim stick.

5.19e Wiring a third trim motor

Instructions for wiring an additional, third trim motor to the VP-X system.

5.19f PH Aviation Trim

Information regarding the use of PH Aviation Trim systems with the VP-X.

5.19g Garmin GSA 28 With Auto-Trim

Wiring the Garmin GSA 28 autopilot servos, which include auto-trim functionality.

5.19h Trio Auto Trim Module

Wiring instructions for integrating the Trio auto trim module with the VP-X system.

5.20 Flap System Wiring

Wiring the flap system, including motor control and optional position sensor.

5.20a Flaps System With Limit Switches

Alternative wiring for flap systems that utilize limit switches.

5.21 Panel Switches Wiring

General guidelines for wiring panel switches to VP-X discrete inputs.

5.21a Standard switches

Instructions for wiring standard, non-lighted switches to VP-X inputs.

5.21b Wiring lighted switches

Considerations and methods for wiring lighted switches compatible with the VP-X.

5.21c Alternator switch

Wiring switches for controlling single or dual alternators, including safety interlocks.

5.21d Boost pump switch

Wiring instructions for single or dual-speed boost pump switches.

5.21e Dual-Function Switch

Wiring switches designed to control multiple devices or functions from a single switch.

5.21f Dimmer wiring

Instructions for wiring dimmer controls for variable lighting output.

5.21g Mag switch wiring

Wiring the magneto or electronic ignition switch, separate from VP-X.

5.22 P-Mag wiring

Wiring guidance for P-Mag electronic ignition systems.

5.23 Lightspeed Ignition wiring

Wiring instructions for Lightspeed ignition systems, including dual LSE setups.

5.24 Planning and Wiring Backup Circuits

Comprehensive guide to planning and implementing backup power circuits for critical avionics.

5.24a Backup Circuit Considerations

Factors to consider when determining the number and type of backup circuits needed.

5.24b Backup Method B

Detailed instructions for implementing Method B backup circuits.

5.24c Backup Method C

Detailed instructions for implementing Method C backup circuits for EFIS.

5.24d Do not wire backups this way

Illustrates incorrect methods for wiring backup power directly to devices.

5.24e Aft-mounted battery considerations

Specific wiring and routing considerations for aircraft with aft-mounted batteries.

5.25 TCW Integrated Back-Up Battery System

Introduction to the TCW Integrated Back-Up Battery System (IBBS) and its use with VP-X.

5.25a TCW IBBS 2/4ah Wiring

Wiring instructions for TCW IBBS 2/4ah models, covering single and dual power inputs.

5.25b TCW IBBS 3/6ah Wiring

Wiring instructions for TCW IBBS 3/6ah models, covering single and dual power inputs.

5.26 Dual Battery/Single Bus Wiring

Considerations and wiring for aircraft utilizing a dual battery architecture.

5.27 Aux Battery Wiring and Voltage Measurement

Wiring and measuring auxiliary battery voltage, applicable to VP-X Pro.

5.28 AeroLEDs Wiring

Wiring tips and recommendations for installing AeroLEDs wingtip lights.

5.29 Strobe Light (non-LED) Wiring

Wiring instructions for non-LED strobe lights, including power supply connections.

5.30 Retractable Gear Wiring

Instructions for wiring retractable landing gear systems using VP-X power.

5.31 Testing Individual Circuits

Detailed steps for verifying correct installation of all wired circuits.

6. Configure the System Settings

6.1 Configuring the AFS EFIS

Steps for configuring the VP-X system through an Advanced Flight Systems EFIS.

6.2 Configuring the GRT EFIS

Steps for configuring the VP-X system through a GRT EFIS.

6.3 Configuring the MGL EFIS

Steps for configuring the VP-X system through an MGL EFIS.

6.4 Configuring the Garmin G3X EFIS

Steps for configuring the VP-X system through a Garmin G3X EFIS.

6.5 Configuring the Dynon SkyView

Steps for configuring the VP-X system through a Dynon SkyView EFIS.

6.6 Installing and using the VP-X Configurator

Guide to downloading, installing, and using the VP-X Configurator software.

6.7 Switch Input Verification

Procedure for verifying switch input functionality using the VP-X Configurator.

6.8 Device Configuration (Starter, Avionics, Lights, etc.)

Configuring individual electrical devices (e.g., starter, avionics) within the VP-X system.

6.9 Current Fault Detection

Setting up and understanding the current fault detection feature for circuits.

6.10 System Configuration (Over-voltage and Backup Alternator)

Configuring over-voltage trip levels and backup alternator settings.

6.11 Wig-Wag Configuration

Configuring the wig-wag functionality for aircraft lighting systems.

6.12 Trim Configuration

Steps for configuring pitch and roll trim operation, including limits and polarity.

6.13 Flaps Configuration

Configuring flap operation modes (momentary/position) and setting limits.

6.14 Export Settings

Instructions for saving VP-X configuration settings to a computer.

6.15 Import Settings

Instructions for restoring previously saved VP-X configuration settings.

7. Ground Test

7.1 Testing without engine running

Procedures for ground testing the VP-X system without the engine operating.

7.2 Testing while engine running

Procedures for ground testing the VP-X system with the engine running.

8. Flight Test

8.1 Notes about first flight

Recommendations and considerations for conducting the initial flight test of the aircraft.

8.2 VP-X system checkout

In-flight checks to verify the proper operation of the VP-X system.

9. Troubleshooting

9.1 Flap Configuration

Troubleshooting steps for issues related to flap configuration and operation.

9.2 Electrical Configuration

Troubleshooting common electrical configuration problems and nuisance trips.

9.3 Trim faults

Troubleshooting steps for trim-related faults, including power-on and switch issues.

9.4 "Cannot Connect” error when using VP-X Configurator

Guidance for resolving 'Cannot Connect' errors when using the VP-X Configurator software.

10. VP-X System Operation

10.1 Power On and Off

Procedures for powering the VP-X system on and off using the aircraft master switch.

10.2 EFIS Electrical System Page

Description of the electrical system page displayed on supported EFIS units.

10.3 Other VP-X functions

Additional VP-X data like trim, flap position, and wig-wag indicators shown on the EFIS.

10.4 Turning electrical devices on and off

Methods for controlling electrical devices using switches, backup switches, or EFIS soft keys.

10.5 Trim and flap operation

How to operate the trim and flap systems using switches or EFIS soft keys.

10.5a Trim switch fault detection on startup

Troubleshooting trim switch faults that occur during system startup.

10.5b Runaway trim and flaps

Identification and handling procedures for runaway trim or flap conditions.

10.5c Trim and flap operation with a faulty position sensor

Operating trim and flaps using EFIS soft keys when a position sensor is faulty.

10.5d Max Flap Speed Functions

Configuration of flap speed limits, alarms, and disable functions based on indicated airspeed.

10.5e RV-10/RV-14 Flap Reflex Operation

Specific flap operation features for RV-10 and RV-14 aircraft, including reflex settings.

10.5f Continuous Flaps

Enabling the 'continuous flaps' feature for commanding flap movements past intermediate stops.

10.6 Landing Light Wig-Wag

Configuration of wig-wag (pulsing) functionality for landing and taxi lights.

10.7 Circuit Faults

Understanding the causes and identification of circuit faults within the VP-X system.

10.8 Starter Disable

Explanation of how the starter circuit is automatically disabled based on engine RPM.

10.9 Low-Voltage Alarm

How the VP-X detects and reports low voltage conditions to the EFIS.

10.10 Over-Voltage Alarm

Detection and response to over-voltage conditions, including alternator shutdown.

10.11 Battery Contactor Failure

Impact of a battery contactor failure on the main bus and VP-X operation.

10.12 Backup Circuits

Explanation of how backup circuits provide independent power to devices.

10.13 Data Comm Loss

Consequences of losing data communication between the VP-X and the EFIS.

10.14 Firmware Updates

Procedures for performing firmware updates on the VP-X using the Configurator application.

Appendix A – Pinout Diagram

Appendix A1 – J8, J10, J12 Connector Wiring

Detailed pinout diagrams for the J8, J10, and J12 power connectors on the VP-X.

Appendix A2 – J1 Connector Wiring

Detailed pinout diagram for the J1 D-sub connector, used for serial data and trim/flap inputs.

Appendix A3 – J2 Connector Wiring

Detailed pinout diagram for the J2 D-sub connector, used for switch inputs and auxiliary functions.

Appendix B – Wiring Harness Contents

The following wire types and lengths are included in the VP-X Pro wiring harness kit (VP-X Sport does not have components for the J8 connector):

List of wires, their gauges, lengths, colors, and terminal types in the VP-X Pro wiring harness kit.

The following items are also included:

List of additional components included in the wiring harness kit, such as connectors and tools.

Appendix C – VP-X System Annunciators

The following VP-X annunciators are displayed on the EFIS:

List and descriptions of the VP-X system alarms and annunciators displayed on the EFIS.

Appendix D – VP-X Dimensions and Weight

Weight:

Physical weight specifications for the VP-X Pro and VP-X Sport models.

Appendix E – AeroLED Wiring Tips

Here is some information that should be helpful to builders installing AeroLEDs wingtip lights:

Wiring recommendations for AeroLEDs wingtip lights to prevent audio noise and RFI.

Appendix F – Ray Allen Stick Grip Wiring

Excerpt from Ray Allen G205 and G207 stick grips wiring instructions, modified to show VP-X integration.

Wiring instructions for Ray Allen stick grips, adapted for integration with the VP-X system.