Austro Engine IAE50R-AA User Manual

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Page 1

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 05.Dec.2014 Page: Intro - 1

Revision No: 8

Engine Manual

Operation / Maintenance / Installation

IAE50R – AA

Doc. No.: E1.01.05 – E

Page 2

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018 Page: Coversheet - 1

Revision no: 9

Page 3

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018 Page: Coversheet - 2

Revision no: 9

Date: Wiener Neustadt, 25-Jan-2018

Author: Austro Engine GmbH Rudolf – Diesel – Straße - 11 2700 Wiener Neustadt, Austria

Document number: E1.01.05 – E

Revision: 9

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E1.01.05 – E

Issue date: 25.Jan.2018 Page: 0-1

Revision no: 9

0 TABLE OF CONTENTS

0 TABLE OF CONTENTS ..................................................................................................................... 0-1

1 INTRODUCTION .............................................................................................................................. 0-1

1.1 Record of Revisions .......................................................................................................................... 1-2

1.2 List of Revisions ................................................................................................................................ 1-3

1.3 List of Valid Pages ............................................................................................................................ 1-5

1.4 List of Incorporated Temporary Revisions .................................................................................... 1-7

2 GENERAL INFORMATION .............................................................................................................. 2-1

3 SAFETY INFORMATION ................................................................................................................. 3-1

3.1 Safety Symbols ................................................................................................................................. 3-1

3.2 Model Designation Breakdown ....................................................................................................... 3-2

3.3 Replacement parts ........................................................................................................................... 3-2

4 RESERVED ......................................................................................................................................... 4-1

5 GENERAL ENGINE DATA ................................................................................................................ 5-1

5.1 Description ........................................................................................................................................ 5-1

5.2 Technical data ................................................................................................................................... 5-1

5.2.1 Design Responsibility

5.2.2 Certification

................................................................................................................................... 5-1

5.2.3 Engine Overall Dimensions

5.2.4 Engine Particulars

5.2.5 Out – put Drive

5.2.6 Net Dry Weight

5.2.7 Cooling

........................................................................................................................................... 5-4

5.2.8 Fuel Specification

5.2.9 Fuel Consumption Curve

5.2.10 Pressure to Fuel Injector

5.2.11 Lubrication

.................................................................................................................................... 5-5

5.2.12 Oil Specification

................................................................................................................... 5-1

......................................................................................................... 5-2

........................................................................................................................ 5-3

............................................................................................................................. 5-3

......................................................................................................................... 5-4

............................................................................................................. 5-4

............................................................................................................ 5-5

............................................................................................................................ 5-5

6 OPERATING DATA / LIMITATIONS ............................................................................................ 6-1

6.1 Maximum Take – off Rating ............................................................................................................ 6-1

6.2 Maximum Continuous Rating .......................................................................................................... 6-1

6.2.1 Power Curve

6.3 Operating Limitations....................................................................................................................... 6-2

6.3.1 Engine RPM

6.3.2 Ambient Temperature Limits

6.3.3 Liquid Coolant Temperature Limits

6.3.4 Rotor Cooling Air Outlet Temperature Limits

6.3.5 Exhaust Gas Temperature (EGT)

6.3.6 Fuel Pressure

6.3.7 Altitude

6.4 Manuals .............................................................................................................................................. 6-3

7 COMPONENTS .................................................................................................................................. 7-1

7.1 Description of Components ............................................................................................................. 7-2

7.1.1 Rear Assemblies

7.1.2 Front Assemblies

7.1.3 Centre and Rotating Assembly

7.1.4 Rotor Sealing

................................................................................................................................. 6-2

................................................................................................................................... 6-2

...................................................................................................... 6-2

........................................................................................... 6-3

........................................................................... 6-3

............................................................................................... 6-3

................................................................................................................................ 6-3

.......................................................................................................................................... 6-3

........................................................................................................................... 7-2

.......................................................................................................................... 7-2

................................................................................................... 7-2

................................................................................................................................ 7-2

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8 DESCRIPTIONS OF SYSTEMS ....................................................................................................... 8-1

8.1 Fuel System ....................................................................................................................................... 8-1

8.1.1 Typical Schematic Fuel System (provided by engine installer)

8.1.2 Throttle Valve Setting

8.2 Cooling System ................................................................................................................................. 8-2

8.2.1 Liquid Cooling System

8.2.2 Water Pump

.................................................................................................................................. 8-2

8.2.3 Temperature Regulation

8.2.4 Coolant

.......................................................................................................................................... 8-3

8.2.5 System Pressure

8.2.6 Air cooling system

8.2.7 Rotor Cooling Air Parts

9 OPERATING THE ENGINE ............................................................................................................. 9-1

9.1 Starting Procedure and Warm–up ................................................................................................. 9-1

9.2 Engine Start down to approximately -10 °C ................................................................................. 9-2

9.3 Ground Tests..................................................................................................................................... 9-2

9.3.1 Full Power Check

9.3.2 Idle Check

..................................................................................................................................... 9-3

9.3.3 Stopping the Engine

9.4 Power Loss at Altitude ..................................................................................................................... 9-3

9.5 Storage .............................................................................................................................................. 9-4

9.5.1 Storage up to 90 Days

9.5.2 Storage beyond 90 Days

9.5.3 Returning to Service from Storage

.................................................................................................................. 8-1

................................................................................................................. 8-2

............................................................................................................. 8-2

........................................................................................................................... 8-3

........................................................................................................................ 8-3

................................................................................................................ 8-4

.......................................................................................................................... 9-2

.................................................................................................................... 9-3

................................................................................................................ 9-4

............................................................................................................. 9-4

............................................................................................ 9-5

............................................. 8-1

10 ENGINE EMERGENCY PROCEDURES ........................................................................................ 10-1

10.1 Fan Belt Failure ............................................................................................................................... 10-1

10.1.1 Low Oil in the Tank

10.1.2 Low Fuel Pressure

10.1.3 Rotor Cooling Air Temperature

10.1.4 Coolant Temperature

11 MAINTENANCE NOTES ................................................................................................................. 11-1

11.1 Austro Engine GmbH Available Consumables ............................................................................ 11-1

11.2 General Torque Settings................................................................................................................ 11-1

11.2.1 Specific Torque Settings

11.2.2 MAP Hoses

.................................................................................................................................. 11-2

11.2.3 Checking & Setting Fan Belt Tension

11.2.4 Adjusting engine idle speed

12 SCHEDULED MAINTENANCE ...................................................................................................... 12-1

12.1 Maintenance Schedule ................................................................................................................... 12-1

12.2 Typical 50 Hours Check ................................................................................................................. 12-2

12.3 Mandatory Life Limitation.............................................................................................................. 12-3

13 COOLING SYSTEM ......................................................................................................................... 13-4

13.1 Liquid Cooling System ................................................................................................................... 13-4

13.2 Coolant leak check ......................................................................................................................... 13-4

13.3 Coolant System Filling and Bleeding ........................................................................................... 13-4

13.4 Coolant System Pressure Test ...................................................................................................... 13-5

13.5 Air Cooling System ......................................................................................................................... 13-6

13.5.1 Fan Belt

....................................................................................................................................... 13-6

13.5.2 Fan Belt Replacement

.................................................................................................................... 10-1

...................................................................................................................... 10-1

................................................................................................ 10-1

................................................................................................................. 10-1

........................................................................................................... 11-1

...................................................................................... 11-2

..................................................................................................... 11-2

............................................................................................................... 13-6

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13.5.3 Air Filters

13.5.4 Air Filter Cleaning Procedure

13.5.5 Rotor Cooling Air Fan Impeller

14 ENGINE INTERNAL INSPECTION .............................................................................................. 14-1

14.1 Spark Plug ....................................................................................................................................... 14-1

15 GROUND RUN ................................................................................................................................. 15-1

15.1 Pre–start Checks Outside Aircraft ................................................................................................ 15-1

15.2 Pre–start Checks Inside Aircraft ................................................................................................... 15-1

15.3 Ground Run ..................................................................................................................................... 15-1

15.4 Ground Run Check List (example) ............................................................................................... 15-2

16 MAINTENANCE AND OVERHAUL ............................................................................................... 16-1

17 TROUBLE SHOOTING ................................................................................................................... 17-1

17.1 General ............................................................................................................................................ 17-1

17.2 Rough Idle ....................................................................................................................................... 17-1

17.3 Engine Misfires on One Spark Plug .............................................................................................. 17-2

17.4 Engine Cannot Develop Full Power .............................................................................................. 17-2

17.5 Excessive Rotor Cooling Outlet Temperatures ........................................................................... 17-2

17.6 Liquid Coolant Overheats on Medium and High Power ............................................................ 17-2

17.7 ECU Error Warning Light Flashes ................................................................................................. 17-3

..................................................................................................................................... 13-7

.................................................................................................... 13-7

................................................................................................. 13-8

18 NOTES FOR INSTALLERS OF ENGINES .................................................................................... 18-1

18.1 General Notes ................................................................................................................................. 18-1

18.2 Notes for engine installers ............................................................................................................ 18-1

18.3 Fuel System ..................................................................................................................................... 18-2

18.3.1 Fuel Specification

18.3.2 Fuel delivery

18.3.3 Fuel filters

................................................................................................................................... 18-3

18.3.4 Pressure Regulator

18.3.5 Water in Fuel

18.3.6 Fuel Lines

18.4 Oil System ....................................................................................................................................... 18-3

18.5 Engine mounting ............................................................................................................................ 18-4

18.6 Exhaust system ............................................................................................................................... 18-4

18.7 Air Filters ......................................................................................................................................... 18-4

18.8 Drive interface ................................................................................................................................ 18-4

19 ELECTRICAL SYSTEM ................................................................................................................... 19-1

19.1 Engine Control System .................................................................................................................. 19-2

.................................................................................................................................... 18-3

19.1.1 Fuel injection

19.1.1.1 Injection Timing ................................................................................................................................ 19-2

19.1.1.2 Load Demand..................................................................................................................................... 19-2

19.1.2 Ignition System

19.1.2.1 Ignition Triggering ............................................................................................................................ 19-2

19.1.2.2 Ignition ............................................................................................................................................... 19-2

19.1.3 Mechanical installation of the ECU

19.1.4 Electrical installation of the ECU

19.1.4.1 Harness Connector for ECU ............................................................................................................. 19-5

19.1.4.2 ECU Pin Assignment .......................................................................................................................... 19-6

19.1.4.3 CAN Bus .............................................................................................................................................. 19-8

19.1.4.4 Option: Installation of ECU according D0160 section 16 CAT Z ................................................. 19-9

19.1.4.5 Error Codes ...................................................................................................................................... 19-10

19.1.4.6 Error Code Table ............................................................................................................................. 19-11

....................................................................................................................... 18-2

............................................................................................................................... 18-2

.................................................................................................................... 18-3

.............................................................................................................................. 18-3

.............................................................................................................................. 19-2

.......................................................................................................................... 19-2

.......................................................................................... 19-3

.............................................................................................. 19-4

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19.2 GND Concept IAE50R .................................................................................................................. 19-12

19.3 Sensors and actuators ................................................................................................................. 19-13

19.3.1 Air Temperature sensor

19.3.2 Rotor cooling air out temperature sensor

19.3.3 Map Sensors

19.3.4 Speed Sensors

19.3.5 Ignition Coils

19.3.5.1 H.T. Leads ........................................................................................................................................ 19-19

19.3.5.2 Spark plugs ...................................................................................................................................... 19-19

19.3.6 Injector

............................................................................................................................. 19-16

.......................................................................................................................... 19-17

............................................................................................................................. 19-18

...................................................................................................................................... 19-20

19.3.7 Coolant Temperature Sensor for instruments

19.4 Generator regulator and Generator wiring ............................................................................... 19-22

19.4.1 Mechanical installation of the Generator Regulator

19.4.2 Electrical installation of the Regulator

19.5 Starter ............................................................................................................................................ 19-24

19.5.1 Mechanical installation

19.5.2 Electrical connection of starter

19.6 Electronic Components Capability .............................................................................................. 19-25

19.6.1 Electrical tests

........................................................................................................................... 19-25

19.6.2 Environmental tests

19.6.3 Control System Reliability

19.6.3.1 Control system reliability objective. .............................................................................................. 19-27

19.6.3.2 Software Quality level ..................................................................................................................... 19-27

.......................................................................................................... 19-13

............................................................................ 19-14

...................................................................... 19-21

............................................................ 19-22

.................................................................................. 19-23

............................................................................................................ 19-24

.............................................................................................. 19-24

................................................................................................................. 19-26

....................................................................................................... 19-27

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ENGINE MANUAL

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Revision no: 9

These technical data and the information contained therein are the property of Austro

Engine GmbH and may not be reproduced either in full or in part or passed on to a third

party without written consent from Austro Engine GmbH.

This text must be included in any full or partial reproduction of this documentation.

1 INTRODUCTION

This engine may only be operated in accordance with the procedures and operating limitations

of the Engine described in this manual.

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Revision no: 9

1.1 Record of Revisions

All revisions of this manual must be recorded in chapter 1.2. Revisions of chapter

“6 OPERATING DATA / LIMITATIONS” requires approval by EASA.

All incorporated Temporary Revisions must be recorded in chapter 1.4.

The new or amended text is indicated by a vertical line at the left hand side of the revised

page, with the revision number and data appearing at the bottom of the page.

If pages are revised which contain information valid for your particular serial number

(modification level of the engine, Equipment Inventory, etc.), then this information must be

transferred to the new pages in hand–writing.

Temporary revisions, if applicable, are inserted behind the cover page of this manual.

Temporary revisions are used to provide information on systems or equipment until the next

‘permanent’ revision of the Engine Manual. When a ‘permanent’ revision covers a Mandatory

or Optional Design Change (MDC or ODC), then the corresponding temporary revision is

superseded.

It is the responsibility of the operator to ensure that this manual is maintained to a current

status.

If the address or the ownership of the engine/aircraft changes, an address card has to be sent

to Austro Engine GmbH.

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Revision no: 9

Rev. No.

Reason

Chapter

Page(s)

Date of Revision

Approval

Date of Approval

Date Inserted

Signature

Editorial changes. Part No Correction

5.2.3

5.2.4

11.1

5 6 6

15.Feb. 2006

Page numbering

all

10.March

2006

Editorial Changes

1.2

1.3

8.2.1

8.2.4

8.6.4

9.4

9.5.1

12.2

13.3

13.5.5

14.1

17.2

19.1

19.2

19.4

20.0

1-4 1-5 8-1 8-5

9-3 12-2 13-1 13-4 13-5 14-1 14-2 17-1 19-2 19-3 19-4 20-2

Maintenance Interval

12.1

12-1

New spark plug implemented

1.1

1.2

11.1

1-3

1-4 11-1

22.Nov.

2006

No. changed

MDC-E1-072

1.1

1.2

8.4

11.1

1-3

1-4

8-2 11-1

10.Nov.

2008

Editorial change MDC-E1-083

1.1

1.2

8.4

11.1

1-3,1-4

1-5

8-1 11-1

08.July

2009

All Diamond Logos changed to Austro Engine Logo. Oil specification changed MDC-E1-116

all

10.Narch

2011

MDC-E1-148

1.1

2,3,4,5

3 2

16.Oct.

2013

1.2 List of Revisions

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Revision no: 9

MDC-E1-154

All

18.Dec.

2014

MDC-E1-186

5.2.4

6.3.3

6.3.4

9.5.2

8.1

8.2.5

9.1

12.1

13.2

13.3

19.3.2

1.1 5-3 6-3 6-3 9-4 8-1 8-3 9-1

12-1 13-4 13-4

19-14

25.Jan.

2018

*) The technical content of this document is approved under the authority of DOA ref. EASA.21J.0399.

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Revision no: 9

Chapter

Page

Revision

Date

Coversheet

25.Jan.2018

0 - Index

25.Jan.2018

1.3 List of Valid Pages

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Revision no: 9

25.Jan.2018

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Revision no: 9

Temporary Revision Number

Title of Temporary Revision

E10105-EM-TR-MDC-E1-163

Rotor Cooling Air Outlet Temperature Measuring Position

1.4 List of Incorporated Temporary Revisions

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Revision no: 9

2 GENERAL INFORMATION

Every reasonable effort has been made to ensure that the information contained in this

publication is correct when going to print.

However, as Austro Engine GmbH policy is one of continuous improvement, the information

given here may be superseded over a period of time by manual revisions or temporary by

Service Bulletins.

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3 SAFETY INFORMATION

The instructions in this manual have been compiled to assist pilots and personnel responsible

for maintenance in the correct operation of the engines produced by Austro Engine GmbH.

Only correct operation and maintenance can ensure optimum availability throughout engine

life.

No recommendation in this manual absolves operators from compliance with any official

directive that may be issued by the controlling aviation authority of any country concerned, or

with any relevant Austro Engine GmbH Service Bulletins.

Austro Engine GmbH personnel are always happy to answer queries or give advice on

individual service problems. All queries to Austro Engine GmbH should be accompanied by

details of the engine model and serial number, hours operated and any other relevant

information.

3.1 Safety Symbols

The following symbols and warning signs are used in this manual to point out important instruction. They must be observed strictly to prevent personal injury and material damage, to insure operational safety of the aircraft and to avoid any damage to the aircraft as a result of incorrect handling.

Disregarding these safety rules can cause personal injury or even death.

Disregarding these special instruction and safety measures can damage the engine or other components.

The maintenance intervals must be strictly observed. When the service is not executed in accordance to this manual Austro Engine GmbH will reject any warranty claims.

Additional note or instruction for better understanding of an instruction.

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3.2 Model Designation Breakdown

3.3 Replacement parts

It is strongly recommended that only genuine, quality–

assured, replacement spare parts are used when carrying

out maintenance operations on this engine.

The use of parts not approved by Austro Engine GmbH may

significantly affect the performance, reliability and life of

the engine and may hazard the operator.

The use of parts not approved by Austro Engine GmbH may

invalidate the Engine Certification.

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4 RESERVED

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5 GENERAL ENGINE DATA

5.1 Description

Wankel type rotary, single rotor, dual spark ignition, liquid cooled rotor housing, forced air

cooled rotor, ECU, normal aspirated.

5.2 Technical data

5.2.1 Design Responsibility

Austro Engine GmbH

Rudolf – Diesel – Straße 11

2700 Wiener Neustadt

Austria

5.2.2 Certification

Refer to Engine Type Certificate Data Sheet No EASA.E.085.

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5.2.3 Engine Overall Dimensions

Fig. 1: Engine overall dimensions

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5.2.4 Engine Particulars

Design Single rotor Wankel–type rotary engine

Eccentricity 11.6 mm

Width of Housing 68.2 mm

Generating Radius 69.0 mm

Compression Ratio 9 : 1

Swept Volume 294 ccm

Rotor billet steel internally cooled by a belt driven

centrifugal fan.

Main and End Housing Aluminum alloy castings, cooled with a pump

circulated pressurized water–glycol mixture and

supporting an optional oil separator assembly

(supplied by the installer mounted directly onto the

outlet casting).

Eccentric Shaft Hardened and ground alloy steel. The complete

rotating assembly is in full dynamic balance to

minimise vibration, achieved by counter weighting

each end of the assembly. Both the main and rotor

bearings are rolling element types.

Flywheel billet steel fitted with an induction–hardened steel

starter ring gear.

5.2.5 Out – put Drive

Take from the eccentric shaft via a woodruff key.

Rotation Direction The eccentric shaft rotate in a clockwise direction

when viewed from the driving side of the engine.

5.2.6 Net Dry Weight

Approximately 59.5 lbs. (27 kg)

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5.2.7 Cooling

Approximately 90% of surplus heat is rejected into

the liquid cooling system; the balance is rejected via

rotor cooling air.

Coolant 50 : 50 Distilled Water – Ethylene Glycol mix

Silkolene PRO–COOL (or equivalent)

5.2.8 Fuel Specification

AVGAS 100LL

EUROSUPER, ROZ 95, in accordance with EN228

or equivalents.

5.2.9 Fuel Consumption Curve

Fig. 2: Fuel consumption curve

Note that these values are taken from JAR 22 calibration test results and are not indicative of

actual consumption rates.

Typical in–flight fuel flows, particularly at part–throttle conditions, may be expected to be

significantly lower.

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5.2.10 Pressure to Fuel Injector

Nominal 3 bar, operation range 2.8 bar to 3.2 bar

Controlled by a pressure regulator.

5.2.11 Lubrication

Lubrication of all bearings and rubbing surfaces is

achieved via two lines from the oil metering unit

driven off the water pump. The flow rate of the

metering unit is calibrated and must not be adjusted.

Use only approved engines oils.

Oil Separator An optional oil separator is recommended. The

separator is to be supplied by the engine installer.

5.2.12 Oil Specification

SILKOLENE Comp 2 Premix

SILKOLENE Classic 2T Premix

CASTROL XR77 (EMPA specification 417478/01)

CASTROL Power 1 Racing 2T (API TC+, JASO FD, ISO EGD)

AEROSHELL Oil Sport Plus2 (API TC)

The use of SILKOLENE Comp 2 Injector is NOT allowed.

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6 OPERATING DATA / LIMITATIONS

Static sea level ratings under the following conditions:

- International Standard Atmospheric conditions at sea level

- Generator functioning

- Liquid coolant outlet temperature 65 °C (± 5 °C)

- Standard induction pipe fitted with filter

- Power measured at eccentric shaft output

- Approved fuels

- Test bed exhaust used

6.1 Maximum Take – off Rating

Max. T/O – Power (minimum) 37.3. kW (50 BHP)

(Value quoted includes losses associated

with intake exhaust conditions specified.)

Max. T/O – RPM 7 750 RPM

Fuel consumption (max) 24 liters / hr

Exhaust back pressure 0.21 bar ± 0.04 bar (3 psi ± 0.5 psi)

at 7750 RPM with test bed system

6.2 Maximum Continuous Rating

Max. Cont. Power 35.8 kW (48 BHP)

Max. Cont. rpm 7 100 RPM

Fuel consumption (max) 18 liters / hr

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6.2.1 Power Curve

Fig. 3: Typical power curve

6.3 Operating Limitations

6.3.1 Engine RPM

Maximum for take–off ( for 3 mins) 7 750 RPM

Maximum Continuous 7 100 RPM

Maximum Overspeed (20 sec. limit) 8 000 RPM

Idle Minimum 2 500 RPM

6.3.2 Ambient Temperature Limits

Minimum Starting Ambient (without priming) -10 °C

Maximum Ambient +55 °C

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6.3.3 Liquid Coolant Temperature Limits

Maximum for Take–off 100 °C

Minimum for Take–off 60 °C

Maximum continuous 90°C

6.3.4 Rotor Cooling Air Outlet Temperature Limits

Maximum for Take–off (3 minutes) 120 °C

Maximum Continuous 110 °C

The specified Rotor Cooling Air Outlet (RCAO) Temperature Limits for the given engine ratings are valid for the measuring position defined by Austro Engine GmbH. For detailed information refer to chapter 19.3.2.

For an installation of a RCAO temperature sensor different from the sensor position defined by Austro Engine, contact Austro Engine GmbH for specification of applicable limits (e.g. by means of a reference test).

6.3.5 Exhaust Gas Temperature (EGT)

Maximum Exhaust Gas Temperature 970 °C

6.3.6 Fuel Pressure

Nominal Fuel Pressure 3 bar (43.5 psi)

Fuel Pressure Tolerance ± 0,2 bar (± 2.9 psi)

6.3.7 Altitude

The engine has been tested for use up to 14.000 ft pressure altitude

6.4 Manuals

Operation / Maintenance / Installation Doc. No. E1.01.05–E

Overhaul Manual MWE (D) 085

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7 COMPONENTS

Fig. 4: Location of components

Fig. 5: Location of components

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Revision no: 9

7.1 Description of Components

7.1.1 Rear Assemblies

These assemblies comprise of a back plate, with integral mounting lugs, water pump,

alternator, speed sensors, rotor cooling air fan assembly, oil pump and starter motor.

7.1.2 Front Assemblies

The front assemblies comprise of a water cooled end plate, temperature transmitter.

7.1.3 Centre and Rotating Assembly

The centre assembly comprises a rotor housing with passageways for liquid cooling. Externally

is the throttle body with fuel injector, spark plugs, and exhaust flange and, internally, the

eccentric shaft and rotor assembly.

7.1.4 Rotor Sealing

Rotor sealing is provided by the tip seals, side seals and corner seals with each seal being

spring loaded outwards. The corner seals placed at the junction of the side and tip seals

provide sealing at these critical locations.

Fig. 6: Rotor sealing

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Provided by AE as part of the engine

8 DESCRIPTIONS OF SYSTEMS

8.1 Fuel System

The fuel injector requires clean fuel at 3 bar ± 0.2 bar with a minimum return flow of 80 liters

per hour.

Continuous circulation of fuel trough the rail removes heat from the injector and reduces the

risk of vapor locking.

8.1.1 Typical Schematic Fuel System (provided by engine installer)

Fig. 7: Typical schematic of fuel system

8.1.2 Throttle Valve Setting

As a flight safety measure, the throttle valve is set to return to wide–open throttle position by

the return spring in the event of disconnection from the throttle cable.

A spring–loaded adjuster screw on the throttle body controls idle speed setting.

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8.2 Cooling System

8.2.1 Liquid Cooling System

Fig. 8: Coolant circuit items

8.2.2 Water Pump

A water pump impeller, driven from the eccentric shaft via a tufnol drive coupling (a shear

point) is mounted at the rear of the engine and circulates coolant through the engine casting

and radiator.

8.2.3 Temperature Regulation

No thermostat is fitted. A minimum coolant temperature of 60 °C must be maintained and a

normal operating temperature of 70 °C is desirable.

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8.2.4 Coolant

Coolant is a 50 / 50 water – ethylene glycol mix. For details refer to Chapter 5.2.7

The use of a pre–mix solution such as Silkolene Pro–Cool is

strongly recommended so that there is no variation in the

strength or the heat transfer properties of the coolant.

8.2.5 System Pressure

The cooling system is a closed loop system, designed for a working pressure of 0.9 bar

(13 psi) overpressure.

8.2.6 Air cooling system

Lubrication of the eccentric shaft rear bearings is achieved by direct injection of oil from the

metering oil unit and results in an oil mist being entrained into the rotor cooling air system.

The oil mist, in turn, lubricates the rotor bearing, front main bearing and cools the inside of

the rotor.

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8.2.7 Rotor Cooling Air Parts

Fig. 9: Rotor cooling air parts

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9 OPERATING THE ENGINE

9.1 Starting Procedure and Warm–up

Starting

The settings, start and warm–up procedures for the first start of a newly installed engine are

obviously to be treated with the greatest care. However, all engines supplied by Austro Engine

GmbH will have been fully run–in and performance–tested prior to shipping.

If the engine fails to start after three attempts (normal

maximum starter engagement per attempt of five seconds)

there is something incorrect!

(Fuel, ignition, or outside air temperature).

Starting between -5 °C and below may require assistance

for the aircraft battery!

1) Check coolant level

2) Check engine oil tank level is sufficient for flight / test

3) Check fuel level, fuel condition (no water contained); set fuel master “ON”

4) Set throttle slightly off the idle stop.

5) Switch on battery and alternator.

6) Switch on ignition – verify that all gauges / alarms are correct.

7) Switch on both fuel pumps – verify that all gauges / alarms are correct.

8) Switch on one ECU supply – verify error light on continuously (switch off).

9) Switch on second ECU supply and verify error light on continuously (switch off).

10) Switch on both ECU supplies and verify error light on continuously.

Ensure all personnel are clear of propeller and aware that

the engine is to be started.

9) Crank the engine for 5 seconds (or less if the engine starts).

10) If the engine fails to start, recheck switch positions and alarms.

11) If cold start – repeat (9) at 15 second intervals.

12) (See NOTES above for starting limitations).

13) Allow engine to warm up at approximately 3 000 RPM to 50 °C.

14) Check that the rpm rise is smooth and trouble free.

15) A sudden liquid coolant temperature rise indicates air trapped in the coolant system.

In this case the bleed procedure should be carried out (see 13.3)

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During cold starts not more than 5 x 5 second start attempts

in any 3 minute period.

9.2 Engine Start down to approximately -10 °C

The engine will start equally well with either permitted fuels.

9.3 Ground Tests

See chapter 15.

9.3.1 Full Power Check

Set WOT and note RPM achieved in relation to the minimum acceptable value as defined in

the aircraft operating manual. Check that all instrumentation is functioning and that all

parameters are within limits. Check that single ignition drops are less than 300 RPM at 6 200

RPM.

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9.3.2 Idle Check

Fully close the throttle and note rpm; it should be 2,500 RPM ± 100 RPM. Adjustment, if

required, is by the throttle stop screw on the throttle body. For method, and precautions, see

the aircraft manufacturer’s manual.

9.3.3 Stopping the Engine

It is usual to idle the engine for 2 to 3 minutes before stopping (to dissipate internal heat prior

to shut down) [see aircraft manufacturers operating manual].

Switching off either the ECU power, or ignition switches, or the fuel pumps will stop the

engine. The latter gives a short run down and dissipates pressure in the fuel lines.

9.4 Power Loss at Altitude

Performance at altitude is degraded due to a reduction in air density. The approximate power

available (at given RPM / throttle setting) is given in 6.2.1 for Sea Level.

Fig. 10: Power loss at altitude

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9.5 Storage

General (installed engine).

Proper steps must be taken, on engines used infrequently, to lessen the possibility of

corrosion. This is especially true if the aircraft is based near the sea coast or in areas of high

humidity.

In all geographical areas the best method of preventing corrosion of internal parts of the

engine is to fly the aircraft at least once a week. Alternatively the engine should be run long

enough to reach normal operating temperatures.

9.5.1 Storage up to 90 Days

No special treatment is required for storage periods of up to 90 days.

The aircraft should be protected from the weather and excessively damp conditions.

9.5.2 Storage beyond 90 Days

The following procedures may require that the engine is

removed from the aircraft – see aircraft manufacturer’s

instructions.

Never rotate the engine with the oil can nozzle still in the

spark plug or exhaust / inlet ports!

1) To protect the internal of the engine it is recommended that additional engine oil be

introduced. This can, for example, be via the spark plug holes, the throttle body or

the exhaust and is determined by the aircraft manufacturer.

2) Where appropriate, ensure all electrical circuits are off, and then manually rotate the

propeller shaft and engine.

3) Inject 5cc of the prescribed engine lubrication oil through either spark plug hole in the

rotor housing. (See CAUTION! above)

4) Rotate the engine through 1 revolution of the flywheel (by turning the propeller or

propeller shaft and hence the eccentric shaft, by hand).

5) Repeat (3 & 4) five times.

6) Rotate the engine through 6 revolutions of the flywheel then refit the spark plugs.

7) Seal all inlets and exhaust openings to prevent moisture ingress.

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8) To protect the bearings and associated parts, engine oil should be introduced into the

area. The aircraft manufacturer describes the method by which this is achieved and

the instructions must be followed carefully.

9) Blank off all open holes.

10) To protect the outside of the engine, anti corrosion oils of well–known oil companies

are recommended, such as:

Anticorit 5 of Messrs FUCHS, D – 6600 Mannheim, Germany

Lubrication Oil MTL – L – 644 B of MOBIL–OIL

Shell ENSIS Fluid 2360 of SHELL

RUST BAN 395 of ESSO

It is also ESSENTIAL that the fuel system be drained.

Items (1) to (3) should be carried out every 90 days.

9.5.3 Returning to Service from Storage

1) Restore the engine to operation according to the Aircraft Manufacturers instructions.

2) If the aircraft been laid–up for more than 6 months, please carry out 9.5.2 ((1) to

(6)).

3) Rotate the engine by hand several times to ensure that all excess oil is drained via the

spark plug holes.

4) Clean and refit, or replace, the spark plugs.

5) Check the engine for external damage or deterioration suffered during storage, and

rectify as necessary.

6) Clean engine to remove inhibitor and remove all storage blanks.

7) Refit engine in accordance with the aircraft manufacturer’s instructions.

Stale fuel must NOT be reused!

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10 ENGINE EMERGENCY PROCEDURES

10.1 Fan Belt Failure

In the unlikely event of a fan belt failure, the indication will be a sudden rise in Rotor Cooling

Air temperature. The engine load / rpm should be reduced as much as is practical to prevent

further heat build-up. If the rotor cooling outlet air temperature reaches 130 °C the engine

should, if possible, be switched off. Continued running of the engine under these conditions

will cause damage.

10.2 Low Oil in the Tank

In the unlikely event of low oil alarm the engine RPM should be reduced as much as is

practical. Flying time should be limited to a total of 10 minutes at this reduced power. Flying

under such conditions may cause damage to the engine.

10.3 Low Fuel Pressure

If low fuel pressure is indicated, the engine may stop or operate at reduced power and may

also indicated an excessively high exhaust temperature. Throttle setting should be adjusted, if

practical, to minimise excess temperature.

Continued operation at excess exhaust temperature will cause damage to the engine.

10.4 Rotor Cooling Air Temperature

If the rotor cooling air temperature rises above the specified limit, the engine should be shut

down as soon as possible. Continued operation at excess temperature is likely to cause

damage to the engine.

10.5 Coolant Temperature

If the coolant temperature rises above the specified limit, the engine should be shut down as

soon as possible. Continued operation at excess temperature is likely to cause damage to the

engine.

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4 mm

2.0 Newton-meters (Nm)

5 mm

4.5 Nm

6 mm

8.5 Nm

8 mm

21.5 Nm

10 mm

30.0 Nm

Spark Plug

10.0 Newton-meters (Nm)

Coolant Temperature Sender

4.5 Nm

Starter Motor Terminal

8.0 Nm

Oil Pump Inlet Fitting

2.5 Nm (caution)

Oil Pump Outlet Banjo

2.5 Nm (caution)

Oil Pipe Nut & Olive

3.0 Nm (caution)

11 MAINTENANCE NOTES

11.1 Austro Engine GmbH Available Consumables

R1A-06-000-803 Rotor Cooling Air Filter

R1A-06-000-805 Induction Air Filter

Engine Oil see Chapter 5.2.12

Glysantin Aluprotect Premium Engine Coolant (One Litre Container)

Copper ease Copper ease

Loctite 243 Screw Locking

Loctite 595 Sealing silicone

R1A-09-000-801 Spark Plug (NGK)

K&N Filter Oil Air Filter Oil

R1A-30-000-801 Injector

For further part replacement contact Austro Engine GmbH.

11.2 General Torque Settings

Bolts / Socket Head Cap Screw

Nuts and Stiff Nuts – as above.

11.2.1 Specific Torque Settings

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11.2.2 MAP Hoses

Remove all MAP hoses and clips and clean out any oil. Make sure that they are dry before

placing them back onto the engine.

11.2.3 Checking & Setting Fan Belt Tension

Fig. 11: Belt tension

The silicon rubber tube and the tie wraps are left in place

during the test.

1) Slacken the three attachments numbered 1, 2 and 3 above.

2) Attach a loop of suitable material around the fan outlet duct.

3) Using a suitable spring balance, apply a force to the loop of 6 – 7 Kilograms.

4) With this force still applied, tighten the 3 housing attachments (with 8 lbft/11 Nm).

5) Confirm the attachments are not at the end of their adjustment slots.

6) If a new belt is required, see Section 13.5.2

11.2.4 Adjusting engine idle speed

For adjusting procedure, and precautions, see the aircraft manufacturer’s instructions.

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ITEM

Check A

(every flight)

Check B

(every flying day)

Every 50 hrs

or annually

Every 150 hrs

or 3 years

Section

Reference

Engine oil level / coolant level check

X X X

Aircraft Manual

Coolant leak check

X X

13.4

Insp. / clean / replace air filters

13.5.4

Insp. engine, mountings and all external fasteners

Aircraft Manual

Check fan belt condition & tension

13.5.1

Check cooling system condition and security,

Inspect / clean / replace spark plugs

14.1

Full engine ground run

Coolant pressure test

13.4

Renew coolant

13.3

End plates – examine seals & seal faces

Inspect fan impeller (300 hours)

13.5.5

Replace fan belt (earlier of 300 hrs or 10 yearly)

13.5.2

Replace in line fuel filter

Aircraft Manual

Clean & inspect MAP hoses and clips

11.2.2

Replace fuel injector (150 hrs or 10 yearly)

Aircraft Manual

Continuity of ECU earth straps outer case (2)

Aircraft Manual

Continuity of ECU loom ground connections (2)

Aircraft Manual

12 SCHEDULED MAINTENANCE

12.1 Maintenance Schedule

ALL HOURS QUOTED ARE ENGINE HOURS

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Starter Ring – rotate engine via prop

Chipped or missing teeth

Generator Cables

Signs of contact and chafing/cracking

Lower Timing Sensor and cables

Signs of contact and chafing/cracking

Water Pump Housing

Vent hole

Upper Timing Sensor and cables

Signs of contact and chafing/cracking

Fan Housing

Cracks

Fan Belt

Check tension and condition

Fan Filter – remove and check

View Fan Impeller – Debris – Cracks

Engine Mounts – port side

Nuts, bolts

Fuel Rail, Injector, Pressure Regulator

Leaks – Cracks – Cable Connection

Linkage, Throttle Stops

Ram pipe

Check temperature sensor connection

Induction Air Filter

Cleanliness and damage

Rotor Housing drain screw

Security – Leaks

Exhaust System - complete

Overheat adjacent parts – Security

ECU and cables

Signs of deterioration

Voltage Regulator and cables

Signs of deterioration

REF

ITEM

CHECKS / COMMENTS

Water Outlet Cover

Leakage

Water Hoses

Security of all clips – Leaks

Oil Separator

Leakage and temperature sensor connection

Oil Pump – Lines and Terminations

Leakage

Spark Plug Coils and Plug Caps

Cables and terminations

Spark Plug Condition

Connection & gap area

Engine Mounts – Starboard Side

Nuts, bolts secure

Starter Motor Mounts and Cable

Bolts and cable connections

Starter Pinion – Condition and

Laxity

Teeth, free movement, play

Generator (Stator / Rotor)

Note any debris in the area

12.2 Typical 50 Hours Check

Visual checks only unless stated! All checks to include fastenings, cracking,

leaks, discoloration and wire locking!

Ensure that all switches are OFF before rotating the engine.

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ECU Sensors and Cables

Signs of Deterioration

Engine Alarms, Transducers and Cables

Signs of Deterioration

Oil Tank and Vent

Security – Leaks – Level - Connections

Radiator and Overflow Tank

Security – Damage – Leaks – Debris –

Level

Oil Separator Hoses

Leakage

Rotate Propeller by Hand

Check 6 x compression on prop

Carry out engine ground run according to check list!

12.3 Mandatory Life Limitation

There is no life limit of the engine, engine operation is on condition.

Reliable operation of this engine is dependent upon injector

replacement in accordance with maintenance

recommendations.

Lightning strikes may damage the ECU. Following any

lightning strike the ECU should be returned to Austro Engine

GmbH for checking.

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13 COOLING SYSTEM

13.1 Liquid Cooling System

Coolant Level Check: Refer to Aircraft Manufacturer’s instructions.

In a fault free system, the coolant level will not alter significantly. Any unusual drop in the

coolant level in the tank indicates a fault in the system that must be rectified before further

flights.

13.2 Coolant leak check

Check all hoses for cracks, wear, security and leaks. (a white or light pink crust around a joint

is an indication of a leak!). Refer also to engine installer’s handbook. If a leak is found, replace

hose and hose clips, tighten hose–clips etc. as necessary and check / bleed / pressure test the

system as detailed below.

Check all bleeding points and, if visible without engine removal, all engine housings and

mating surfaces for leaks. Check water pump bleeding hole and engine bay for any coolant

residue. If any residue is found check engine until leak is found and contact Austro Engine

GmbH.

13.3 Coolant System Filling and Bleeding

This test should be done if leaks are suspected and after any

part of the coolant system has been disturbed and replaced.

This is a guide, any variations in the aircraft manual should

be followed!

1) Slowly fill the system with the coolant mix

2) Undo bleed plugs until fluid escapes, then tighten.

3) Top up radiator header tank with coolant mix.

4) Check for coolant leaks at all connections / interfaces.

In doubt fit a coolant pressure tester.

5) If required fit a coolant system pressure tester (Blue Point No STV 262 or similar) to

6) Recheck bleed points for air after the first engine run.

7) Repeat (6) until no further air is emitted from the bleed point(s) When running the

the header tank and pressure test.

engine ensure that coolant temperature rise is slow and consistent with warm up and

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no sudden temperature jumps occur. If the coolant temperature suddenly rises then

there will still be entrained air in existence and the cycle must be repeated.

8) Top up header tank with coolant mix. Refit the filler cap and wire lock if appropriate.

9) Fill the overflow tank with coolant mixture within the MINIMUM and MAXIMUM levels.

10) Carry out full engine ground run

If coolant temperature rises rapidly shut down the engine

and bleed the system again!

Risk of scalding – do not remove the pressure cap from the

radiator until the engine and radiator have cooled.

13.4 Coolant System Pressure Test

1) Remove header tank pressure cap and fit a Coolant System Tester (Blue Point No.

SVT262 or equivalent) in its place.

2) Apply pressure of 17 p.s.i (1.2 bar) to the system.

3) This pressure is to be held for 5 minutes during which time it must not drop by more

than 0.5 p.s.i (0.03 bar)

4) Whilst under pressure the coolant system should be checked visually for any leaks for

weeps at all connections (carry out coolant leak check acc. to 13.2).

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13.5 Air Cooling System

13.5.1 Fan Belt

Check fan belt condition. Examine belt for fraying, cracks or broken strands. If in doubt

replace it. Check belt tension as in 11.2.3. Adjust as necessary.

Need for significant or regular adjustment indicates need for

belt replacement! When changing a fan belt, see 11.2 for

torque settings!

13.5.2 Fan Belt Replacement

1) Drain off the coolant & remove connections to the water pump.

2) Disconnect alternator leads and oil pipes.

3) Remove the fan assembly and check bearings for play / roughness.

4) Remove the Water Pump Housing along with the Alternator Stator Assembly and

check the water pump bearings for play.

Care should be taken in withdrawing the assemblies due to

the loose internal tufnol drive coupling!

5) Fit the new Fan Belt (using Austro Engine GmbH “Fan Belt Kit”).

6) Reassemble using the reverse procedure for items (2) to (5) inclusive, above, and

tension the belt as in 11.2.3.

Replace tufnol drive coupling from the fan belt kit and

assemble with the reduced diameter towards the water

pump!

Fit the new O–Rings in the water pump housing with those

from the fan belt kit using compatible grease to hold in

place!

Use Loctite 242 on all fixings!

7) Connect services, as appropriate and fill with coolant.

8) Ensure that the coolant lines and oil lines are bled.

9) If necessary, pressure test the coolant system as per aircraft manual or chapter

IF IN DOUBT PLEASE CONTACT Austro Engine GmbH!

above, and check for leaks.

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10) Test run the engine to verify satisfactory operation before flight.

13.5.3 Air Filters

The two air filters, induction and rotor cooling air, should be visually inspected at the specified

intervals for contamination, large pieces of debris and cracks. Both filters may be cleaned and

re–used, although great care must be taken to correctly follow the manufacturer’s

instructions. Damaged filters should be replaced.

13.5.4 Air Filter Cleaning Procedure

1) Tap filter gently, and then brush outside of filter with a soft bristle brush, to remove

loose dirt.

2) Wash the outside of the filter with mild liquid soap and warm (maximum 40 °C)

water, by agitating the filter in the solution.

3) Ensure that the contaminated solution does not come in contact with the inside

surfaced of the filter.

4) Rinse off the filter, from the inside, with clean low pressure water – from a tap or a

similar supply. Rinse thoroughly to ensure all soap is removed.

5) Examine filter and if necessary repeat stages 2 and 3.

6) Shake off all surplus water and allow filter to dry naturally.

7) Re–oil element: Aerosol – Spray one pass per pleat into each pleat, from the

outside

Liquid – One bead of oil every 6 mm down each pleat.

8) Check that no white patches remain after 10 minutes.

9) Re–oil where necessary. A red dye in the oil clearly shows those areas that have been

correctly oiled.

10) Reinstall air filter and tighten all clips and fittings.

Do not use harsh detergents, caustic solutions, solvents,

fuel, steam, or pressure washers!

Excess heat (over 40 °C), or compressed air will damage the

filter:

Do not use without re–oiling!

Only use filter oil from Austro Engine GmbH or K & N!

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Once the filters have been removed, the associated duct and

fan impeller should be inspected for dust or debris of any

type. If found, it indicates inadequate filter care or a

damaged filter and could have serious consequences. Advice

should be sought from Austro Engine GmbH on the

significance of this material and the effect it may have on

the engine. Either or both filters should be replaced if their

condition is suspect.

13.5.5 Rotor Cooling Air Fan Impeller

1) At the intervals stated in 12.1 the fan impeller should be inspected. The complete fan

should be removed from the engine and the bearing housing assembly removed from

the fan housing.

2) Carefully examine the impeller for cracks with a X 10 magnifying glass, particularly on

the fan blade – back plate, root radius. No cracks are allowed.

If in doubt change the impeller / bearing housing assembly!

The impeller cannot be removed from spindle!

3) Refit and check the fan belt tension (see Section 11.2.3).

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14 ENGINE INTERNAL INSPECTION

Remove all dirt from the exterior of the engine and inspect for evidence of overheating or

other unsatisfactory conditions.

Inspect rotor tip seals and internal side plate faces.

1) It will be necessary to remove the throttle body and the exhaust pip to carry out this

inspection. The use of a ‘Boroscope’ or fibre optic probe facilitates viewing.

Care must be taken to ensure the probe is withdrawn before

the engine is rotated!

2) Once the openings are exposed, rotate the eccentric shaft by hand to view the rotor

tip seals. Each seal should not be stuck in the groove and free to spring. The side

plate seal faces inside the engine should not exhibit significant distress. Minor scoring

and scuffing is acceptable. It is important to obtain a good view of the side faces

above the centre line of the engine, where the cooling medium is air. This can only be

achieved through the inlet port.

3) If there is any doubt about the acceptability of the faces or the seals, then access

should be gained to the air outlet of the front plate by removal of the oil separator. If

there are any hard carbon deposits on the internal walls of the duct in the front plate

then the side seals may have allowed combustion gas to blow by. Austro Engine

GmbH should be consulted if this condition is found.

14.1 Spark Plug

The spark plug is of the surface discharge type with a long life platinum centre electrode.

See 11.1 for the replacement Part Number.

The spark plugs must be removed for inspection at the intervals required in the maintenance

schedule.

1) Check the electrical connections for corrosion and lightly smear with silicone grease.

2) Clean the electrode area of the plugs with gasoline if required.

3) If possible check plug function under pressure.

4) Replace spark plug in engine, (torque to value as in 11.2.1)

5) Anti–seize grease must be used on the threads. See 11.1 for Part Number.

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Fitting other types of spark plug may cause damage to the

engine!

Do not sand blast, or clean with steel or brass wire brush, or

use abrasive materials!

If due to local conditions, the plug connections become corroded then the corrosion may be

removed from the plug nipple with a wire brush and the inside of the plug cap cleaned with a

dry cloth or paper wiper. When complete, re–smear the connections with fresh silicone

grease. Torque to the value given in 11.2.1. If the plug are unserviceable they should be

replaced with new ones.

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15 GROUND RUN

15.1 Pre–start Checks Outside Aircraft

1) Position aircraft into wind

2) Brakes fully on and wheels chocked

3) Check fuel drains, (no water)

4) Check coolant level at overflow tank

5) Check oil tank level

6) Check fuel level

15.2 Pre–start Checks Inside Aircraft

1) Close and lock canopy if appropriate

2) Record outside air temperature (Minimum limit -10 °C for normal starts)

3) Battery master ON

4) Check / note all indicators and alarms, as indicated in the aircraft manufacturer’s

manual

5) Record fuel gauge reading

6) Check both ignitions ON

7) Check ECU power supplies ON

8) Check fuel pump ON

9) Alternator master ON

10) Avionics off

15.3 Ground Run

Start the engine (see also 9.1). When the coolant temperature has reached 50 °C, carry out

and record the following ground run checks.

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Date:

A/C Reg:

Engine No:

Flight Hours:

Total Running Time (hrs meter):

QFE:

Outside Air Temperature:

Pressure

Temperature

Others

RCAO

Battery Fail Alarm

Low Fuel Pressure Alarm

Engine Coolant

Charge System Fail Alarm

OAT

ECU Error Warning

EGT 1 (optional)

Fuel Flow

Oil Low Alarm

15.4 Ground Run Check List (example)

ENGINE GROUND RUND RESULTS

Instrumentation – Gauge / Alarm Function Test

Record data after 1 minute steady running at each condition after warm – up

Engine Coolant RCAO Remarks

RPM Temp Temp

Warm – up ………. ………… ………… …………

Idle ………. ………… ………… …………

5000 ………. ………… ………… …………

6000 ………. ………… ………… …………

Max ………. ………… ………… …………

Idle ………. ………… ………… …………

Ign. 1 Ign. 2

Mag Drops at 6000 RPM ………… ……….

Acceleration tests (3 off) Remarks

(Idle to Max RPM response) ………………………………………………….

(1 sec throttle time) ………………………………………………….

Comments If any adjustments are made as a result of this ground run they

should be recorded and the ground run repeated

……………………………………………………………………………………………………….….

…………………………………………………………………………………………………….…….

………………………………………………………………………………………………….……….

Record results in engine maintenance file !

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16 MAINTENANCE AND OVERHAUL

For maintenance of particular system or for overhauling the engine please contact

Austro Engine GmbH or engine installer.

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17 TROUBLE SHOOTING

17.1 General

This section is included as an aid although some items may

be carried out by the owner / pilot, most would be carried

out by a maintenance organisation.

Replace alls gaskets, seals and joint material if disturbed!

Coolant, fuel & oil systems MUST be bled if disturbed!

If, during troubleshooting, any foreign object fall into the

engine internals, through the spark plug holes, the inlet or

exhaust ports, or the rotor air cooling inlet and exit

passages, they must be removed before attempting to turn

or run the engine!

Failure to do so may result in considerable damage to the

engine!

Do not stand within the area of the propeller AT ANY TIME,

unless it is essential and you have confirmed that both

ignition switches are ‘OFF’!

17.2 Rough Idle

Ignition failure – Check continuity of wiring and connectors.

– Check spark plugs.

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17.3 Engine Misfires on One Spark Plug

Dirty plug cap / terminal Clean / replace

Wiring fault - Wiring to earth or open circuit

Faulty spark plug - Clean / replace

HT fault - Check / replace spark plug / HT lead /

plug cap for arcing

17.4 Engine Cannot Develop Full Power

Incomplete throttle opening - Adjust throttle linkage

HT fault - Check/replace spark plug/HT lead/plug cap

Increase in exhaust back pressure - Investigate exhaust / replace

Loss of compression - Investigate

Blocked Induction Filter - Replace / clean filter

Low fuel pressure - Investigate fuel system / replace fuel filter

17.5 Excessive Rotor Cooling Outlet Temperatures

Excessive back pressure in outlet duct - Rectify before continuing running engine

Blocked rotor air inlet filter - Clean or replace filter

Slipping / broken fan belt - Adjust / replace

Fan failure / impeller failure

bearing failure - Replace assembly

Stuck side seal(s) - Investigate outlet for black carbon deposits

If found please contact Austro Engine GmbH.

Investigate possible exhaust leakage within the engine bay area.

17.6 Liquid Coolant Overheats on Medium and High Power

Restricted radiator core - Rectify

Constricted radiator hose - Rectify

Water pump drive failure - Overhaul pump

Air in system - Vent / bleed

Coolant leak - Rectify

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17.7 ECU Error Warning Light Flashes

See chapter 19.1.4.6

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18 NOTES FOR INSTALLERS OF ENGINES

18.1 General Notes

In order to maintain the warranty, use only genuine

Austro Engine GmbH parts.

Use only clean screws and nuts and always check threads for damage. If in doubt, always

renew them.

Once loosened, always renew ‘stiff’’ nuts, i.e. self–locking nuts.

Always use the specified torque values.

Whenever components are disturbed, always renew gaskets, seals, jointing material, O–rings

and sealant

Do not use additives with the oils.

Copper slip anti–seize must be used on spark plug and exhaust flange nuts.

It is VITAL that all coolant and oil systems are bled before attempting to operate the engine

for the first time, or if they are subsequently disturbed in any way.

18.2 Notes for engine installers

COOLING SYSTEM

Arrangement must be made by the engine installer to carry the rotor cooling air out from the

front plate elbow, if fitted, to the oil separator or some suitable mean of removing the oil

entrained in the cooling air before allowing it to vent overboard.

Cooling air should be arranged to flow over the engine and exhaust system whenever the

engine is in operation.

An ample supply of cold air must be available to the induction air and rotor cooling fan filters

whenever the engine is in operation.

On no account should this rotor cooling air be used directly

for cabin heating it may contain products of combustion

including CO & CO2.

On no account should the engine be run without either of

the air intake filters in place.

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The liquid cooling system is designed to run at 0.9 bar (13 psi). The aircraft manufacturer or

engine installer should provide a relief valve. It should be fitted with a vacuum valve to ensure

that no undue negative pressure is generated on cooling after engines switch off. Therefore

the relief valve should open for reverse flow at -0.2 bar.

A VDO temperature sensor is fitted to the engine in the front end plate. Provision of a

compatible gauge is the responsibility.

Coolant 50/50 water / ethylene glycol mix (A corrosion inhibiting anti–freeze must be used,

refer to 5.2.7). This water/glycol mix will provide protection down to -36 °C.

Operating temperature is in the range of 60 °C to 90 °C after warm up. Maximum continuous

100 °C.

Heat rejection rate approximately 25 kW of heat is rejected to the coolant when the engine is

operated at max continuous power (50 BHP).

An integral water pump is provided with the engine. This provides a water flow of approx. 40

liters per minute at 7000 rpm.

Radiator. The optimum radiator design will vary with each

installation. It is the responsibility of the installer to provide

an adequate cooling system and thus ensure that the

maximum recommended coolant temperature is never

exceeded even under the most adverse operation

conditions. The design should also ensure that the minimum

operating temperature can be achieved under all flying

weather conditions.

Flight trials will probably be necessary to confirm that the

design caters for the above conditions.

18.3 Fuel System

18.3.1 Fuel Specification

Refer to chapter 5.2.8

18.3.2 Fuel delivery

No fuel pumps are provided by Austro Engine GmbH. Therefore electric pumps each capable

of delivering 80 liters an hour at three–bar pressure.

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18.3.3 Fuel filters

No fuel filters are provided by Austro Engine GmbH. Therefore a filter of 40 microns or better

with a flow capacity of least 80 liters per hour at 0.1 bar pressure drop must be fitted in the

fuel delivery line after the pumps.

18.3.4 Pressure Regulator

No fuel pressure regulator is supplied with this engine. It is the responsibility of the aircraft

manufacturer / installer to provide the injector with the fuel regulated at three bar pressure. A

manifold depression tapping points is provided at the throttle body spacer for connection to

the pressure regulator.

18.3.5 Water in Fuel

The fuel system shall incorporate suitable means if isolating, removing, and checking for the

presence of water in the fuel system before each flight.

18.3.6 Fuel Lines

Fuel lines must be routed away and protected from hot engine and exhaust components. Fuel

line should be of sufficient quality and appropriate to the pressures transmitted. Fuel hose end

connections must be of threaded taper seat type and should be permanently swaged to the

hoses. Push–on type hose connections are not acceptable for high–pressure fuel systems.

Return hose diameter from the fuel pressure regulator should not be smaller than the fuel

feed hose to the fuel rail.

No primer system is required with fuel injection.

The whole fuel system must be able to allow a minimum fuel

flow rate of 80 liters per hour.

18.4 Oil System

Oil tank is supplied by the aircraft manufacturer but must have a minimum usable capacity of

500 ml for each hour of engine running with a strainer of mesh size not larger than 0.5 mm.

Line connections:

The oil connection line between the tank and the pump should be calculated to provide AT

THE PUMP INLET a minimum flow of 8 ml per minute at -10 °C by gravity flow rate. The flow

rate of the pump is pre–set and will not require adjustment.

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18.5 Engine mounting

The engine mounting points on the engine have been designed and tested to meet the

required 15 g load test. Engine location and fitting remain the responsibility of the aircraft

manufacturer. Contact Austro Engine GmbH for installation details.

18.6 Exhaust system

Exhaust design and fitting remains the responsibility of the aircraft manufacturer / engine

installer. Limitations must be regarded.

18.7 Air Filters

Supplied by Austro Engine GmbH as part of design. For other air filters Austro Engine GmbH

must be consulted.

18.8 Drive interface

The output shaft is parallel, fitted with a woodruff key for load transmission. For more details

contact Austro Engine GmbH.

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19 ELECTRICAL SYSTEM

A reliable electrical supply broadly similar to DO160C section 16 Cat B

to the ECU must be granted at all time

If an ECU power supply according DO160C section 16 Cat Z is

required, two independent supply paths and buses are demanded.

See Fig. 16.

All working steps mentioned below have to be performed by skilled

and well qualified personnel with utmost care.

Pay attention that the entire electrical system and wiring harness is

protected against chafing at hot parts or sharp edges.

No engine harness is provided by Austro Engine GmbH. The wiring

harness is not included and must be provided by the installer. The

necessary information can be found in this document. No electrical

circuit protection is provided by Austro Engine GmbH.

All cables and single wires used for installation ECU, sensor and actors

should be suitable and capable in the aspect of mechanical strength

and ampacity. Installer of engine has to ensure that the routing of the

wires on the engine itself is protected against chafing, over

temperature and melting. All wire of the harness shall be to MIL-W-

22759; M27500. Recommended diameter for each ECU Pin, engine

system sensor / actuator can be found in the relevant chapter.

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19.1 Engine Control System

The electrical system provided from AE includes the Engine control unit (ECU), sensors and

actuators for controlling the engine.

The engine control unit activates the ignition and injection based on the information of

speed, manifold pressure and some correcting factors. The actuators are supplied from the

aircraft power supply bus/buses. The low side paths of the actuators are controlled by the

ECU. Communication interface of the ECU are CAN-Bus-Interface and RX/TX-Interface. A

signal output (TX-Output) is available from the ECU to display error warning information to

the pilot by means of a coded flashing light ( Details described in the designated chapter).

19.1.1 Fuel injection

19.1.1.1 Injection Timing

The throttle body assembly, including the throttle valve, injector, and fuel rail, is attached

to the rotor housing via a spacer block with tapping points for oil feeds and MAP sensors.

The correct fuel injection timing is provided by the same speed sensors, and the

appropriate amount of fuel is delivered by controlling the “on–time” of the injector. The

“on–time” is determined by the ECU reflect engine speed, manifold pressure and ambient

conditions.

19.1.1.2 Load Demand

Duplicated Manifold Absolute Pressure (MAP) sensors measure the load demand on the

engine. These sense the air pressure inside the throttle body as determined by the

combination of engine speed, throttle setting and ambient pressure. If either sensor should

become defective, the ECU will automatically select the other and provide a cockpit

indication via a coded error warning signal.

19.1.2 Ignition System

19.1.2.1 Ignition Triggering

Two steps in the rim of the flywheel, nominally 180° apart, trigger each timing sensor. If a

sensor should become defective the ECU will automatically select the other and provide a

cockpit indication via a coded error warning signal.

19.1.2.2 Ignition

The spark plug pair are fired simultaneously, each by its own coil, triggered by the output

from the ECU.

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19.1.3 Mechanical installation of the ECU

It is suggested to install the ECU outside of a dedicated fire zone.

Fig. 12: Mechanical installation of the ECU

Fig. 13 ECU Dimensions (in mm)

Mounting of the ECU is possible via 4 elongated holes. M4 screws with washers on the side

of the ECU housing are suggested.

The ECU must be grounded using two independent wires of 16AWG minimum. The

mounting bolts can be used to fix terminals. Remove paint from box under terminals and

ensure that good contact is achieved. Reprotect after tightening bolts with suitable paint or

other corrosion protection. Ground wires must be connected to independent ground points

on the airframe or directly to the battery GND Terminal

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Description

Condition

Min

Typ

Max

Unit

Power Supply

--- 9 12

14.8

Power supply current ECU *)

---

500

Power supply current System **)

3000 rpm

---

--- 2 A

GND connection ECU

---

100

mOhm

C-Meter Low side switch

---

--- 1 A

C-Meter Low side switch

---

--- 5 V

P-Meter Low side switch

---

--- 1 A

P-Meter Low side switch

---

--- 5 V

F-Meter Low side switch

---

--- 1 A

F-Meter Low side switch

---

--- 5 V

Tacho Low side switch Pull-up 2k2 to Ubatt

---

--- 1 A

TX Low side switch (Error Lamp) Pull-up 2k2 to Ubatt

---

--- 1 A

---

Ubatt

CAN Bus Termination

---

120

---

Ohm

CAN Bus Baud Rate

---

500

---

kBaud

Instrument +5V

---

--- 2 mA

19.1.4 Electrical installation of the ECU

*) The suggested circuit breaker for each supply line 1 amp circuit breaker (2 x 1 amp

circuit breakers)

**) System consists of ECU, Sensors and Actuators

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Description

Manufacturer

Part Number

Manufacturer Description

ECU Harness

Connector

344111-1

36WAY Receptacle Housing Connector

Wire Seal

347874-1

Wire Seal AWG16 - AWG20

Anti Backout

344112-1

Anti Backout

Crimp

344113-1

Crimp AWG14 – AWG20

19.1.4.1 Harness Connector for ECU

The picture and the table below shall give installer information which type of connector and

accessories are suitable for engine harness manufacturing.

The connector and accessories described in this section are not part of Austro Engine delivery.

Fig. 14: ECU harness connector

Table 1

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ECU PIN

Description

Signal Type

Description

Shielding

Cable

Diameter

(Minimum)

Injector 2

Low Side Switch

not used for IAE50R-AA

Ins Drive 3

Low Side Switch

not used for IAE50R-AA

MAP 1 Signal

Input Signal

Yes

AWG 20

CAN A

High

only for diagnostic

Yes

AWG 20

CAN A

Low

MAP1, RCA &

Intake Air

Temp GND

GND

Sensor GND

AWG 20

GND

ECU GND

AWG 16

GND

ECU GND

AWG 16

ECU Power

UBAT

ECU Supply

AWG18

A10

ECU Power

UBAT

ECU Supply

AWG18

A11

Ins Drive 1

Low Side Switch

Coolant Signal Out

AWG18

A12

Injector 1

Low Side Switch

Injector 1

AWG 20

Low Side Switch

2k2 Pull Up to

UBAT

Error Lamp Out

AWG 20

Serial Input incl.

Inverter

Communication

AWG 20

Pickup 2 PWR

12V Sensor

Supply

Sensor Supply

Yes

AWG 20

Pickup 1 PWR

12V Sensor

Supply

Sensor Supply

Yes

AWG 20

Intake Air

Temp Signal

Input Signal

Sensor Signal

AWG 20

Map 2 Signal

Input Signal

Sensor Signal

Yes

AWG 20

Map 1 Power

5V Sensor

Supply

Sensor Supply

Yes

AWG 20

Map 2 GND

GND

Sensor GND

Yes

AWG 20

CAN B

High

not used for IAE50R-AA

Pickup 2

Signal

Input Signal

Sensor Signal

Yes

AWG 20

B10

T3I

Digital Input 2k2

Pull Up to 5V

Instrument +5V

AWG 20

B11

Tacho Drive

Low Side Switch

Engine speed Out

AWG 20

B12

Ins Drive 2

Low Side Switch

2k2 Pull Up to

UBAT

Fuel Consumption Out

AWG 18

Ignition Coil

A (-)

Low Side Switch

Ignition

AWG 16

Spare

Low Side Switch

not used for IAE50R-AA

Map 2 PWR

5V Sensor

Supply

Sensor Supply

Yes

AWG 20

Pickup 2 GND

GND

Sensor GND

Yes

AWG 20

19.1.4.2 ECU Pin Assignment

The table below gives information for installers how to connect ECU to sensor / actuators. It is

not allowed to use other diameters for electrical installation than minimum required by Austro

Engine.

Only Austro Engine qualified sensors and actuators are allowed to be used with ECU.

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CAN B

Low

not used for IAE50R-AA

CAN 3

not used for IAE50R-AA

Rotor Air Out

Temp Signal

Input Signal

Sensor Signal

AWG 20

Pickup 1 GND

GND

Sensor GND

Yes

AWG 20

C10

Pickup 1

Signal

Input Signal

Sensor Signal

Yes

AWG 20

C11

Ignition Coil

B (-)

Low Side Switch

Ignition

AWG 16

C12

Spare

Low Side Switch

not used for IAE50R-AA

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CAN Termination in

Installation

120R

EECU

120R

CAN

nodes

CAN

nodes

CAN Low

CAN High

CAN termination

19.1.4.3 CAN Bus

The diagnostic interface is a High Speed CAN Bus (with 500k Baud) which is used to transmit all information to a CAN node.

A BUS termination is required at the physical end of the BUS.

For Example:

CAN-termination resistors 60R (2x 120R in parallel, 120R in EECU included) (CAN Bus according ISO 11898)

Fig. 15: CAN Bus termination

According to the CAN BUS Protocol each ECU sends its own engine information. For details of the protocol contact Austro Engine GmbH.

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12V Generator Bus 12V Battery Bus

12V Battery

ECU

Starter

Generator Generator Regulator

Bus Tie Max

25Amp

+ +- -

IGN1A IGN2A

INJ1

Basic Recommended Installation of ECU Supply Bus to fulfill

Do160 Sec.16 CAT Z

19.1.4.4 Option: Installation of ECU according D0160 section 16 CAT Z

If installation according DO160C section 16 CAT Z is required an independent power supply is required. Suggestion for such installation is shown in the following figure:

Fig. 16: Cat Z

To meet category Z as tested in certification progress you have to ensure that the ECU is

supplied directly from alternator and battery with two separate lines. The installation shall

ensure power supply to ECU in case of fault of alternator or battery.

The proposal of wiring principal is shown in the figure above. These protect against a short to

ground in the supply wires to the ECU, preventing high current drain from the ECU internal

bus bar from the other supply which would cause the ungrounded breaker to “pop”.

For further information contact Austro Engine GmbH.

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Description

Condition

Power

Unit

Voltage

Unit

Error Lamp (suggested)

--- 3 W

19.1.4.5 Error Codes

When the engine is stopped and fault–free, the ECU output B1 (TX) will be on continuously

switched to UBAT whilst the ECU is powered.

When the engine is running and fault–free, the output B1 (TX) will be switched to GND.

When an error is detected by the ECU unit, due either to a sensor failure, an out-of-range

indication or an internal unit fault, the ECU output B1 (TX) will give an indication of the

failure. Error warning display is continuously lit during engine operation. When the engine is

stopped, and there are errors, the ECU output B1 (TX) will flash with a coded message to

indicate which fault has occurred whilst the ECU is powered. Each error code consists of two

numbers. These are indicated via flashes in two groups (E.g. the code for 2 3: ECU output B1

(TX) will flash twice – then on steady for one second – and then flash three times).

If there is more than one error then each code will be flashed in sequence with 5 seconds

between codes.

The error lamp must be provided by the installer if required.

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CODE

FAILURE ITEM

DESCRIPTION

ACTION BY PILOT

DURING FLIGHT

1 1

Manifold Press 1

Sensor

Sensor faulty

Not connected –

Out of range

None

Investigate after

landing

1 2

Manifold Press 2

Sensor

Sensor faulty

Not connected –

Out of range

None

Investigate after

landing

1 3

Air Temperature

Sensor

Sensor short circuit or

sensor low

None

Investigate after

landing

1 4

Rotor Cooling Air

Sensor

Sensor open circuit or

reading high

None

Investigate after

landing

2 1

Supply Voltage

Supply volts decrease

Switch off non–

essential electrical

devices -> then

investigate after

landing

2 2

Engine Speed 1

Error or electronic

noise has been

detected

None

Investigate after

landing

2 3

Engine Speed 2

Error or electronic

noise has been

detected

None

Investigate after

landing

3 2

Manifold Air Pressure

Difference

Difference between

MAP 1 and MAP 2

sensor too high

None

Investigate after

landing

19.1.4.6 Error Code Table

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Engine

housing

12V Battery

Capacitor

Generator

Regulator

+ -

Aircraft

GND

ECU

Starter

19.2 GND Concept IAE50R

A common Ground (GND) concept is required for the installation of the IAE50R. This means all electrical GND are connected together. Best practice is a star layout, which can be seen in the following figure. The aircraft GND shall be included.

Fig. 17: GND concept

Possible GND connection Points

) Regulator see Chapter Generator Regulator ) Engine: Possible connecting points for the engine GND

 Engine backplate see Fig. 18  Screw for starter motor mounting  For any other points on the engine contact Austro Engine GmbH

Max allowed contact resistance for engine GND connection 50 mOhm Wire suggestion 4x AWG14 GND; Engine housing to Battery negative terminal.

Fig. 18: Engine GND

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Part Number

QTY per engine

E4A-40-000-804

Description

GND

Signal

Description

Manufacturer

Part Number

QTY (per sensor)

Seal

Bosch

1 987 280 106 / 1 987 280 107

Crimp

Bosch

1 987 280 103 / 1987 280 105

Connector Housing

Bosch

1 237 000 036

19.3 Sensors and actuators

19.3.1 Air Temperature sensor

The sensor should be installed with its probe in the induction airflow.

Type of Air Temp Sensor(s):

Pin Assignment Air Temp Sensor(s):

Fig. 19

Mating Connector for Air Temp Sensor:

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approx. 10 mm

approx. 5,3 mm

approx. 27 mm

RCAO flange surface

Temp.

19.3.2 Rotor cooling air out temperature sensor

The sensor should be mounted as defined in the following figures:

Fig. 20

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Part Number

QTY per engine

E4A-40-000-804

Description

Signal

GND

Description

Manufacturer

Part Number

QTY (per sensor)

Seal

Bosch

1 987 280 106 / 1 987 280 107

Crimp

Bosch

1 987 280 103 / 1987 280 105

Connector Housing

Bosch

1 237 000 036

Type of Rotor Cooling Air out Temp Sensor(s):

Pin Assignment of Rotor Cooling Air out Temp Sensor(s):

Fig. 21

Mating Connector for of Rotor Cooling Air out Temp Sensor:

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VCC

VOUT

GND

Part Number

QTY per engine

R1A-09-100-000

Description

VCC

5V Sensor Supply

VOUT

Output Signal

GND

Ground

Description

Manufacturer

Part Number

QTY (per sensor)

Seal

Delphi

12015899 / 15324983

Crimp

Delphi

12089040-L

Connector Housing

Delphi

12015793

19.3.3 Map Sensors

The sensor must be mounted by the installer with the pressure inlet at the bottom and the

flexible pipes running down the throttle body spacer, thus allowing any fuel in the pipe to

drain back into the engine.

The flexible pipe (Inner-Diameter 6mm) must be at least oil resistant (fuel, engine oil) and

does not change the inner diameter at inlet pressures of 20kPa.

Fig. 22

Type of MAP Sensor(s):

Pin Assignment MAP Sensor(s):

Mating Connector for MAP Sensor:

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Part Number

QTY per engine

R1A-09-000-802

Wire Color

Description

VCC

Brown

Sensor Supply

VOUT

Black

Output Signal

GND

Blue

GND

Description

Manufacturer

Part Number

QTY (per sensor)

Seal

Tyco / TE

281934-4

Crimp

Tyco / TE

AWG20: 183024-1

AWG22: 183036-1

Connector Housing

Tyco / TE

282105-1

Description

Manufacturer

Part Number

QTY (per sensor)

Seal

Tyco / TE

281934-4

Crimp

Tyco / TE

AWG22: 183035-1

AWG20: 282404-1

Connector Housing

Tyco / TE

282087-1

19.3.4 Speed Sensors

Mounting provisions are given on the engine.

Type of Speed Sensor(s):

Pin Assignment Speed Sensor(s):

Fig. 23

Connector for Sensor:

Sensor is supplied with open wires. It is recommended to use dust and water protected

connectors for engine harness adaption. An adequate connector type can be found in the

following tables.

Possible Sensor connector:

Possible Mating connector:

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Part Number

QTY per engine

R1A-09-000-804

Pin Assignment Ignition Coil:

Fig. 4

Fig. 5

Negative

To spark plug

Positive

19.3.5 Ignition Coils

It hast to be mentioned that the ignition coils are close enough to spark plugs

(Note the maximum length of ignition cable R1A-09-000-501 -> 200 mm)

Power supply ignition coil: The installer should provide independent switches to interrupt the

power supply for each ignition coil separately if required.

Type of Ignition Coil:

Mechanical and electrical connection

For the mechanical mounting of the coils two M5 screws with washers should be used.

Connect the power supply for the coil on the positive terminal and the ECU-signal on negative

terminal of the coil.

Fig. 24: Ignition coil

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Connector

Description

Positive

Plain Connector 6.3mm

DIN 46 244

Ubatt

Negative

Plain Connector 6.3mm

DIN 46 244

Signal from ECU

Spark Plug

R1A-09-000-501

Connection to Spark Plug

Part Number

QTY per engine

R1A-09-000-501

19.3.5.1 H.T. Leads

The inductive H.T. coils are connected to the spark plugs by copper–cored cable and resistive

plug caps. The cable is provided by AE.

19.3.5.2 Spark plugs

The specified spark plug type must be used; substitution with a non–approved type may

reduce engine power and reliability, and may cause mechanical damage to the engine.

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Part Number

QTY per engine

R1A-30-000-801

Description

ECU Signal

Injector Supply (+UBAT)

19.3.6 Injector

One injector is used for the IAE50R-AA Engine.

Type of Injector:

Pin Assignment Injector:

Fig. 25

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Description

Manufacturer

Operating temp

Ohm @90°C

Thermistor

VDO

120°C

51,2 ±5,3

Connector

Plain Connector 6.3mm

DIN 46 244

19.3.7 Coolant Temperature Sensor for instruments

A temperature sensor R1A-10-000-803 is fitted to the engine in the front plate, for connecting

to a temperature gauge, or an external instrumentation panel.

This sensor is a provision for the installer. It is not connected to the ECU.

Fig. 26: Coolant temperature sensor

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Description

Condition

Min

Typ

Max

Unit

Power supply Current

---

Description

Condition

Min

Typ

Max

Unit

GND connection Gen. Regulator

---

mOhm

19.4 Generator regulator and Generator wiring

Generator regulator and generator are supplied by Austro Engine GmbH. The flywheel

mounted brushless / bearing less generator is mounted on the engine. The separate voltage

control regulator / rectifier unit must be connected and mounted by the installer.

19.4.1 Mechanical installation of the Generator Regulator

Mounting of the Regulator is possible via M8 screws on both sides of the Regulator.

Install the regulator on a well-ventilated place. The temperature on the regulator should never

exceed +80°C measured at point T shown in Fig. 27.

The housing of the regulator must be electrical connected to GND. Connect the GND directly

with the mounting bolts or with two independent wires (>AWG14 minimum). The mounting

bolts can be used to fix terminals.

Fig. 27: Regulator housing

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GEN

BATT

12V

yellow

white

red red

black

12V -3W

Not requsted

22000 µF

40-65V+-

> AWG 14

AWG 16

No Load on Black Terminal

Load

+ -

Regulator

Voltage Regulator Cable

Connected to:

Yellow

Yellow Cable Generator

Yellow

Yellow cable Generator

Red

Power (+12V)

Red

Power (+12V)

White

12V Lamp (Not requested)

Black

Power (+12V) Switchable (ON / OFF)

19.4.2 Electrical installation of the Regulator

The wiring for connecting the generator and generator regulator is described in following

figure:

Fig. 28: Wiring diagram Generator and Regulator

10.1.2 Charge Circuit Fail Alarm

The installer is responsible for a wiring which indicate a charge circuit failure alarm. In the

unlikely event of a charging circuit failure, indicated by the appropriate alarm, the electrical

bus bar will be fed automatically from the battery. Any non–essential electrical items should

be switched off.

The battery should be capable of providing sufficient power to run the ECU unit etc. for a

minimum of ½ hour. Reducing power will not significantly increase engine–running time.

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Description

Condition

Min

Typ

Max

Unit

Start Current (Battery 12,5V 18Ah)

---

Description

Electrical Connection

GND

Ground connection of starter via housing to engine

Bolt1

Switch able 12V starter actuation

Bolt 1

19.5 Starter

The starter R1A-90-000-000 is an electric nominal 12V / 0,6kW. It is of a Bendix Type,

engaging the gear when operated (refer to drawing no. R1A-90-000-000).

Voltage of Battery drops down during cranking. Inrush current can reach up to 350A for some

milliseconds.

19.5.1 Mechanical installation

The starter is mounted on the engine. Two M8 screws are used.

19.5.2

Fig. 29: Mechanical installation of the starter

Electrical connection of starter

Fig. 30: Starter

For fastening torque of bolt 1 see chapter 11.2.1.

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19.6 Electronic Components Capability

The electronic components have been tested to meet environmental requirements as

specified in RTCA 160 C/D. The following information is to assist the engine installer.

To show that the ECU is not susceptible to failure when exposed to external electrical or

environmental effects, a number of tests were performed.

19.6.1 Electrical tests

 Power Input Test DO-160C, Section 16 Cat Z.

The two power supply lines were connected to independent

power sources. One supply line was always powered.

 Voltage Spike Test DO-160C, Section 17 Cat A.  Audio Frequency Conducted Susceptibility DO-160C, Section 18 Cat Z.  Induced Signal Susceptibility Test DO-160C, Section 19 Cat Z.  Conducted RF Susceptibility Test DO-160D, Section 20.4 Cat Y  Radiated RF Susceptibility Test DO-160C/D, Section 20.5 Cat Y  Emission of Radio Frequency Energy Conducted DO-160C, Section 21.4

Cable Bundl to ECU Cat Z and A

Power Lines to ECU Narrowband Cat Z and A

Broadband Cat B

Broadband not required in

Do-160D

 Emission of Radio Frequency Energy Radiated DO-160C, Section 21.5

 Lightening Induced Transient Susceptibility DO-160C, Section 22 Cat Z3  Magnetic Effect DO-160C, Section 15,

The compass safe distance for 1° deflection was established as:

0° at 5cm (EUT X-axis)

0,5° at 8cm (EUT Y-axis)

0,5° at 10cm (EUT Z-axis)

Cat A, B and Z

Equipment Class Z

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19.6.2 Environmental tests

 Operation Shock & Crash Safety Tests. DO-160D, Section 7. Category B  Sinusoidal Vibration Tests. DO-160D, Section 8 Cat. S

Curve M

Standard vibration test

fixed wing aircraft

 Humidity Tests DO-160C; Section 6.3.2 Cat. B

Category B severed

humidity environment

65°C @ 95% humidity.

 Waterproofness (Drip) Tests DO-160D, Section 10, Cat W,

falling water test

The ECU has been designed to operate between -15 °C and +70 °C. For the purposes of this

test, the ECU was operated at -45 °C and tested to -55 °C for ground survival (non –

operating).

 Temperature & Altitude Tests DO-160C, Sections 4.5.1, 4.5.2,

4.5.3 and 4.6.1;

Cat B2

 Temperature Variation Test DO-160C, Section 5 Cat B2

 Fluids Susceptibility DO-160D, Section 11.*

The ECU and associated equipment is compatible with fluids liable to be found in

the vicinity of the engine.

The ECU and a sample of the cable loom complete with ident sleeve and tag were

subjected to the following fluids:

AVGAS 100LL, leaded and unleaded motor fuel, Jet A1 turbine fuel, “Comp-2” and

”SRG-75” lube oil, “Procool” coolant, “Aeroshell” fluids 31, 41 and “Skydrol 500B”

Hydraulic oils, Ethylene Glycol and “Kilfrost ABC-3” De-icing fluids, Isopropyl Alcohol,

Denatured Alcohol, and Trichoroethane solvents.

The ECU was not affected by the application of fluids.

The ECU was tested to determine its magnetic effect to assist the installer in choosing

the proper location of the equipment in the aircraft.

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General information about D0160 tests.

Sensors and actuators are tested during basic certification with the test levels stated

above. For the requalification of the new AE ECU for the IAE50R the test levels from the

basic certification are assumed and applied dedicated to the ECU.

*DO-160D Section 11 was tested during the basic certification from Midwest Company.

19.6.3 Control System Reliability

19.6.3.1 Control system reliability objective.

Certification requirements states a reliability objective to be quoted in the engine manual.

The control system has been designed to meet AMJ20X–target reliability of 1 in 100,000 hours

when operated in accordance with Austro Engine GmbH stated maintenance and installation

specification.

19.6.3.2 Software Quality level

In accordance with DO 178B level C.