A PA27 crew, while conducting a test flight, experienced multiple failures while on approach to cae.

Attributes
ACN	541841
Time
Date	200203
Day	Wed
Local Time Of Day	1201 To 1800
Place
Locale Reference	navaid : cae.vortac
State Reference	SC
Altitude	msl bound lower : 1500 msl bound upper : 2000
Environment
Flight Conditions	IMC
Light	Daylight
Aircraft 1
Controlling Facilities	tracon : cae.tracon
Operator	general aviation : personal
Make Model Name	PA-23-250 Aztec
Operating Under FAR Part	Part 91
Navigation In Use	other other vortac
Flight Phase	descent : approach
Route In Use	approach : instrument non precision
Flight Plan	IFR
Person 1
Affiliation	other
Function	flight crew : captain oversight : pic
Qualification	pilot : atp pilot : cfi
Experience	flight time last 90 days : 159 flight time total : 12000
ASRS Report	541841
Person 2
Affiliation	other
Function	flight crew : first officer
Events
Anomaly	aircraft equipment problem : critical altitude deviation : undershoot non adherence : published procedure non adherence : clearance non adherence : far other anomaly other other spatial deviation
Independent Detector	atc equipment other atc equipment : radar other controllera other flight crewa
Resolutory Action	controller : issued alert none taken : detected after the fact
Consequence	faa : reviewed incident with flight crew other
Factors
Maintenance	performance deficiency : testing performance deficiency : repair
Supplementary
Problem Areas	Flight Crew Human Performance Maintenance Human Performance Aircraft
Primary Problem	Aircraft
Air Traffic Incident	Pilot Deviation

Narrative:

On mar/wed/02, XA15-XB15 I was test flying a PA23-250 aztec. This aircraft was test flown 10 hours in VFR before flying in the actual IFR. While holding at 4000 ft the HSI began to turn 30 degrees off heading. We were cleared for a VOR-a approach at cae. We descended to 2000 ft. At this point we had an electrical surge caused by 1 alternator. The HSI showed 'to' (navigation #1), navigation #2 showed 'from,' the GPS showed 4.4 to map. This with the navigation #2 'from' should have put us west of the VOR. We should have been going to MDA 820-1. Approach control called us to let us know we were at 1500 ft MSL and still east of the VOR. After landing the left and right alternators and HSI had to be replaced. The autoplt would disengage but would not turn off without pulling the breaker. We were not unsafe at any point nor was there any damage to any aircraft or persons. Safety recommendations: more test flying in VFR conditions when this extensive replacement of equipment before actual IFR or night flying.

Original NASA ASRS Text

Title: A PA27 CREW, WHILE CONDUCTING A TEST FLT, EXPERIENCED MULTIPLE FAILURES WHILE ON APCH TO CAE.

Narrative: ON MAR/WED/02, XA15-XB15 I WAS TEST FLYING A PA23-250 AZTEC. THIS ACFT WAS TEST FLOWN 10 HRS IN VFR BEFORE FLYING IN THE ACTUAL IFR. WHILE HOLDING AT 4000 FT THE HSI BEGAN TO TURN 30 DEGS OFF HEADING. WE WERE CLRED FOR A VOR-A APCH AT CAE. WE DSNDED TO 2000 FT. AT THIS POINT WE HAD AN ELECTRICAL SURGE CAUSED BY 1 ALTERNATOR. THE HSI SHOWED 'TO' (NAV #1), NAV #2 SHOWED 'FROM,' THE GPS SHOWED 4.4 TO MAP. THIS WITH THE NAV #2 'FROM' SHOULD HAVE PUT US W OF THE VOR. WE SHOULD HAVE BEEN GOING TO MDA 820-1. APCH CTL CALLED US TO LET US KNOW WE WERE AT 1500 FT MSL AND STILL E OF THE VOR. AFTER LNDG THE L AND R ALTERNATORS AND HSI HAD TO BE REPLACED. THE AUTOPLT WOULD DISENGAGE BUT WOULD NOT TURN OFF WITHOUT PULLING THE BREAKER. WE WERE NOT UNSAFE AT ANY POINT NOR WAS THERE ANY DAMAGE TO ANY ACFT OR PERSONS. SAFETY RECOMMENDATIONS: MORE TEST FLYING IN VFR CONDITIONS WHEN THIS EXTENSIVE REPLACEMENT OF EQUIP BEFORE ACTUAL IFR OR NIGHT FLYING.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.