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FlightDEK-D180
Installation Guide
This product is not approved for installation in type certificated aircraft
P/N 100600-000, Revision H
For use with firmware version 5.4
August, 2010
Copyright © 2003-2010 by Dynon Avionics, Inc.
Contact Information
Dynon Avionics, Inc.
19825 141st Place NE Woodinville, WA 98072
Phone: (425) 402-0433 - 7:00 AM – 5:00 PM (Pacific Time) Monday - Friday Fax: (425) 984-1751
Dynon Avionics offers online sales, extensive support, and continually-updated information on its products via its Internet sites:
www.dynonavionics.com/support –Dynon Avionics primary web site; including:
docs.dynonavionics.com – Current and archival documentation.
downloads.dynonavionics.com – Software downloads.
support.dynonavionics.com – Support resources.
store.dynonavionics.com – Dynon’s secure online store for purchasing all Dynon products 24 hours a day.
wiki.dynonavionics.com – Dynon Avionics’ Documentation Wiki provides enhanced, extended, continuously-updated online documentation contributed by Dynon employees and customers.
forum.dynonavionics.com – Dynon Avionics’ Internet forum where Dynon customers can interact and receive Dynon technical support outside of telephone support hours. A key feature of the forum is that it allows the exchange of diagrams, photos, and other types of files.
newsletter.dynonavionics.com – Dynon’s email newsletter.
blog.dynonavionics.com – Dynon’s blog where you can find new and interesting Dynon-related content.
Copyright
2003-2010 Dynon Avionics, Inc. All rights reserved. No part of this manual may be reproduced, copied, transmitted, disseminated or stored in any storage medium, for any purpose without the express written permission of Dynon Avionics. Dynon Avionics hereby grants permission to download a single copy of this manual and of any revision to this manual onto a hard drive or other electronic storage medium to be viewed for personal use, provided that such electronic or printed copy of this manual or revision must contain the complete text of this copyright notice and provided further that any unauthorized commercial distribution of this manual or any revision hereto is strictly prohibited.
Information in this document is subject to change without notice. Dynon Avionics reserves the right to change or improve its products and to make changes in the content without obligation to notify any person or organization of such changes. Visit the Dynon Avionics website (www.dynonavionics.com) for current updates and supplemental information concerning the use and operation of this and other Dynon Avionics products.
Limited Warranty
Dynon Avionics warrants this product to be free from defects in materials and workmanship for three years from date of shipment. Dynon Avionics will, at its sole option, repair or replace any components that fail in normal use. Such repairs or replacement will be made at no charge to the customer for parts or labor. The customer is, however, responsible for any transportation cost. This warranty does not cover failures due to abuse, misuse, accident, improper installation or unauthorized alteration or repairs.
THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE EXCLUSIVE, AND IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING ANY LIABILITY ARISING UNDER WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, STATUTORY OR OTHERWISE. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, WHICH MAY VARY FROM STATE TO STATE.
IN NO EVENT SHALL DYNON AVIONICS BE LIABLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER RESULTING FROM THE USE, MISUSE OR INABILITY TO USE THIS PRODUCT OR FROM DEFECTS IN THE PRODUCT. SOME STATES DO NOT ALLOW THE EXCLUSION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.
Dynon Avionics retains the exclusive right to repair or replace the instrument or firmware or offer a full refund of the purchase price at its sole discretion. SUCH REMEDY SHALL BE YOUR SOLE AND EXCLUSIVE REMEDY FOR ANY BREACH OF WARRANTY.
These instruments are not intended for use in type certificated aircraft at this time. Dynon Avionics makes no claim as to the suitability of its products in connection with FAR 91.205.
Dynon Avionics’ products incorporate a variety of precise, calibrated electronics. Except for replacing the optional internal backup battery in EFIS-based products per the installation guide, our products do not contain any field/user-serviceable parts. Units that have been found to have been taken apart may not be eligible for repair under warranty. Additionally, once a Dynon Avionics unit is opened up, it will require calibration and verification at our Woodinville, WA offices before it can be considered airworthy.
Table of Contents
Contact Information |
......................................................................................................................................................iii |
Copyright...................................................................................................................................................................... |
iii |
Limited Warranty ......................................................................................................................................................... |
iii |
1. Introduction |
1-1 |
OEM Installations...................................................................................................................................................... |
1-1 |
Warning ..................................................................................................................................................................... |
1-1 |
About this Guide........................................................................................................................................................ |
1-2 |
Menu Descriptions..................................................................................................................................................... |
1-2 |
2. Wiring Overview |
2-1 |
Recommended Wiring Practices................................................................................................................................ |
2-1 |
Power Requirements.................................................................................................................................................. |
2-1 |
Grounding.................................................................................................................................................................. |
2-2 |
+5V Excitation........................................................................................................................................................... |
2-3 |
Thermocouple Harness Preparation........................................................................................................................... |
2-3 |
Harness Mating.......................................................................................................................................................... |
2-3 |
25-Pin Female EFIS Harness..................................................................................................................................... |
2-4 |
37-Pin Female EMS Harness..................................................................................................................................... |
2-7 |
25-Pin Male EMS Harness ........................................................................................................................................ |
2-9 |
3. Transducer Installation |
3-1 |
Tools and Equipment Required ................................................................................................................................. |
3-1 |
Exhaust Gas Temperature (EGT) Probes................................................................................................................... |
3-2 |
Cylinder Head Temperature (CHT) Probes ............................................................................................................... |
3-3 |
Tachometer ................................................................................................................................................................ |
3-4 |
Manifold Pressure Sensor.......................................................................................................................................... |
3-5 |
Oil Pressure Sensor.................................................................................................................................................... |
3-6 |
Oil Temperature Sensor............................................................................................................................................. |
3-7 |
Fuel Pressure Sensor.................................................................................................................................................. |
3-7 |
Fuel Flow Sensor....................................................................................................................................................... |
3-9 |
Fuel Level Sensor ..................................................................................................................................................... |
3-11 |
Ammeter Shunt......................................................................................................................................................... |
3-12 |
General Purpose Inputs............................................................................................................................................. |
3-13 |
Contacts .................................................................................................................................................................... |
3-18 |
General Purpose Thermocouple ............................................................................................................................... |
3-19 |
4. Instrument Installation |
4-1 |
Selecting a Remote Compass Module Location |
........................................................................................................ 4-1 |
EDC-D10A Communication Cable ........................................................................................................................... |
4-2 |
Power Inputs.............................................................................................................................................................. |
4-3 |
Serial Communication Cables ................................................................................................................................... |
4-4 |
SL30 and/or GPS connection..................................................................................................................................... |
4-6 |
Altitude Encoder Wiring ........................................................................................................................................... |
4-8 |
External EMS Warning Light................................................................................................................................... |
4-10 |
Audio Alert Outputs ................................................................................................................................................. |
4-10 |
Dynon Smart Avionics Bus (DSAB) Wiring............................................................................................................ |
4-11 |
Panel Location and Mounting................................................................................................................................... |
4-13 |
Connecting Static & Pitot Lines ............................................................................................................................... |
4-14 |
5. EFIS Calibration and Configuration |
5-1 |
Ensuring Proper Installation ...................................................................................................................................... |
5-1 |
Setting Zero Pitch (In flight)...................................................................................................................................... |
5-1 |
|
|
FlightDEK-D180 Installation Guide |
v |
Table of Contents
Compass Heading Calibration ................................................................................................................................... |
5-1 |
Configure Airspeed Color Thresholds....................................................................................................................... |
5-4 |
6. EMS Configuration |
6-1 |
Full-Page Setup Menu Overview............................................................................................................................... |
6-1 |
Alarm and Color Threshold Configuration................................................................................................................ |
6-2 |
Global Parameters Setup ........................................................................................................................................... |
6-3 |
Engine Type Configuration ....................................................................................................................................... |
6-4 |
Fuel Level Calibration ............................................................................................................................................... |
6-5 |
Trim Calibration ........................................................................................................................................................ |
6-6 |
Flaps Calibration ....................................................................................................................................................... |
6-7 |
Tachometer ................................................................................................................................................................ |
6-8 |
Manifold Pressure...................................................................................................................................................... |
6-8 |
Oil Pressure ............................................................................................................................................................... |
6-9 |
Oil Temperature......................................................................................................................................................... |
6-9 |
Exhaust Gas Temperature (EGT) ............................................................................................................................. |
6-10 |
Cylinder Head Temperature (CHT).......................................................................................................................... |
6-11 |
Fuel Level................................................................................................................................................................. |
6-13 |
Fuel Pressure ............................................................................................................................................................ |
6-13 |
Fuel Flow.................................................................................................................................................................. |
6-14 |
Voltage ..................................................................................................................................................................... |
6-15 |
Current...................................................................................................................................................................... |
6-15 |
General Purpose Inputs............................................................................................................................................. |
6-16 |
Contacts .................................................................................................................................................................... |
6-18 |
General Purpose Thermocouple ............................................................................................................................... |
6-19 |
7. DSAB Configuration |
7-1 |
Network Concepts ..................................................................................................................................................... |
7-1 |
Example Networks .................................................................................................................................................... |
7-2 |
Initial Setup ............................................................................................................................................................... |
7-4 |
Brightness Configuration........................................................................................................................................... |
7-5 |
Network Status .......................................................................................................................................................... |
7-6 |
8. Autopilot Installation and Configuration |
8-1 |
Additional Information and Updates ......................................................................................................................... |
8-1 |
DSAB Firmware Compatibility................................................................................................................................. |
8-2 |
Compass Calibration Critical For Certain AP Modes................................................................................................ |
8-2 |
Autopilot System Electrical Installation.................................................................................................................... |
8-3 |
Servo Mechanical Installation ................................................................................................................................... |
8-6 |
AP74 Mechanical Installation................................................................................................................................... |
8-11 |
Firmware Upgrades Required For AP Functionality ................................................................................................ |
8-13 |
AP Servo Configuration ........................................................................................................................................... |
8-14 |
AP74 Configuration.................................................................................................................................................. |
8-30 |
9. Appendix |
9-1 |
Appendix A: Ongoing Maintenance and Troubleshooting ........................................................................................ |
9-1 |
Appendix B: Dynon EFIS OAT Probe Installation and Usage.................................................................................. |
9-7 |
Appendix C: HS34 Installation and Configuration................................................................................................... |
9-10 |
Appendix D: Dynon AOA/Pitot Installation and Calibration................................................................................... |
9-24 |
Appendix E: Encoder Serial-to-Gray Code Converter Installation........................................................................... |
9-32 |
Appendix F: Capacitance-to-Voltage Converter Installation.................................................................................... |
9-35 |
Appendix G: Replacing the FlightDEK-D180 battery pack ..................................................................................... |
9-36 |
Appendix H: Weights ............................................................................................................................................... |
9-36 |
Appendix I: FlightDEK-D180 Specifications........................................................................................................... |
9-38 |
vi |
FlightDEK-D180 Installation Guide |
1. INTRODUCTION
This manual provides information about the physical, electrical, and plumbing installation of the FlightDEK-D180, EDC-D10A, optional AOA pitot probe, and all engine sensors purchased from Dynon Avionics. Additionally, this guide deals with setting up the installation-dependant firmware options. Because you may not have purchased all the components, you need only read through the relevant sections of this guide. Information about the operation of this instrument can be found in the FlightDEK-D180 Pilot’s User Guide.
The EFIS component of the FlightDEK-D180 uses solid-state sensor technology to give an accurate and easy-to-understand display. To ensure accuracy in its readings, it is very important that you install the instrument correctly and perform the specified calibration steps. This installation guide helps you through that process.
OEM Installations
If your FlightDEK-D180 is installed by an OEM distributor, you may find that you are unable to access some menus and settings. Some Dynon distributors customize various areas of the FlightDEK-D180 firmware to maintain a consistent pilot experience and minimize integration issues across a large number of installations. Currently, OEMs can customize access levels to the following settings on Dynon systems: EMS GLOBAL setup menu, EMS SENSOR setup menu, fuel calibration, trim calibration, flaps calibration, GPS/NAV setup menu, screen configurations, data logging, and checklists/data panels. OEM distributors have the option of customizing some or all of these areas. Please contact your aircraft’s manufacturer if you have any questions about how your unit has been customized.
Warning
Dynon Avionics’ products incorporate a variety of precise, calibrated electronics. Except for replacing the optional internal backup battery in EFIS-based products per the installation guide, our products do not contain any field/user-serviceable parts. Units that have been found to have been taken apart may not be eligible for repair under warranty. Additionally, once a Dynon Avionics unit is opened up, it will require calibration and verification at our Woodinville, WA offices before it can be considered airworthy.
FlightDEK-D180 Installation Guide |
1-1 |
Introduction
About this Guide
In the electronic (.PDF) version of this manual, page and section references in the Table of Contents and elsewhere act as hyperlinks taking you to the relevant location in the manual. The latest version of this manual is available on the Dynon Avionics website at docs.dynonavionics.com.
The following icons are used in this guide:
Any text following this icon describes functionality available only with the HS34 HSI Expansion Module connected to your system.
Any text following this icon describes functionality available only with the AP74 Autopilot Interface Module connected to your system.
Any text following this icon describes functionality that is possible when multiple Dynon Avionics products are networked together via the Dynon Smart Avionics Bus (DSAB).
Any text following this icon refers to a setting or situation which merits particularly close attention.
Menu Descriptions
Throughout this guide, the “>“ character is used to indicate entering a deeper level of the menu system. For example, “EFIS > INFO > LEFT” indicates entering the EFIS menu, pressing MORE, then pressing INFO, and then pressing LEFT to enter the left info item menu. Note that the MORE button is not shown in the sequence, since pressing MORE reveals more options in the same level of the menu system.
1-2 |
FlightDEK-D180 Installation Guide |
2. WIRING OVERVIEW
Please follow these instructions explicitly as improper wiring can result in permanent damage to your instrument and/or the accompanying sensors.
All electrical power and EFIS-specific lines interface with the FlightDEK-D180 via the female 25-pin D-sub connector on the back of the instrument. All EMS-related sensor inputs enter the FlightDEK-D180 via the male 37-pin and female 25-pin D-sub connectors on the back of the instrument. Ensure that the unit powers on and that all indicators display expected values before completing the final physical assembly.
Recommended Wiring Practices
For all electrical connections, use correct wiring techniques, taking care to properly insulate any exposed wire. A short circuit between any of the wires may cause damage to the FlightDEK-D180 and/or your aircraft. Make all connections to your harness before plugging it into any of the components of the system. Do not make connections while power is applied at any point in the system.
Dynon Avionics sells wiring harnesses for all connections to the FlightDEK-D180. The harnesses are made up of 22 AWG wire and – with the exception of the thermocouple harnesses
– meet Mil Standard MIL-W-22759/16 (Tefzel insulation). If you have opted not to purchase these harnesses, please refer to the provided wiring diagrams for construction information. We recommend that all wire you use also meets Mil Standard MIL-W-22759/16; all wire supplied by Dynon Avionics (with the exception of thermocouple wire, which uses FEP insulation) meets this specification.
When using any pre-manufactured harness, verify that each pin has continuity with the expected wire on the wiring diagram. This test can be easily done with a multimeter. When verifying harnesses, use the wiring charts and diagrams in this guide as your ultimate authority on pin function (for any harness) and wire color (for harnesses purchased from Dynon Avionics).
Route all wiring through the engine compartment such that there are no spots where it could chafe or break. Use appropriate strain relief at all junctions between wires and connectors. We recommend that you secure all wires at regular intervals along wiring runs to accommodate vibration effects.
In the sections below, many connections have an associated legend, as shown at right. All connections on the EMS male 25-pin harness route to thermocouples and
Pin |
Color |
Function |
# |
Color |
function |
are color-coded to correspond to the thermocouple
coloring. All connections on the EFIS female 25-pin harness are described in the 25-Pin Female EFIS Harness section on page 2-4.
Power Requirements
22 AWG wire is normally sufficient for the power supply and ground lines, but we recommend that you consult a wire sizing chart and determine the size required for the wire routing in your particular aircraft. Ensure that the power lines include a circuit breaker or an appropriately sized
FlightDEK-D180 Installation Guide |
2-1 |
Wiring Overview
fuse for the wire you select. Power is fed to the FlightDEK-D180 via pins in the female D-25 connector as shown on the 25-Pin Female EFIS Harness diagram on page 2-4.
The FlightDEK-D180 system-wide power requirement is 14 watts typical and 19 watts maximum. On a 12-volt system, this translates to about 1.5 amps of maximum current draw. On a 24-volt system, this translates to about 0.8 amps maximum current draw. Normally, a 3-amp circuit breaker or fuse is sufficient.
Grounding
Many of the engine sensors require a connection to a |
|
|
EMS |
|
Color |
|
Function |
shared electrical ground with the FlightDEK-D180. There |
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DB37 |
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|
|
|
are many places on an aircraft where you could connect |
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Pin |
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||
these sensors. However, the ideal location to ground these |
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5 |
|
Black |
|
Ground |
||
sensors is near the FlightDEK-D180 to minimize voltage |
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16 |
|
Black |
|
Ground |
||
differences between the sensor and instrument grounds. |
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||||
Some sensors (e.g., oil pressure and oil temperature) |
17 |
|
Black |
|
Ground |
||
connect to ground via their cases’ contact with the engine or aircraft body. There must be a solid connection between
this “case ground” and the FlightDEK-D180 ground. The oil temperature sensor is very susceptible to voltage differences between the engine case and the negative terminal of the battery. Ensure that solid, thick electrical connections exist between the engine and battery ground. Other sensors (e.g., fuel pressure) do not have a grounded case and have two leads instead. One lead must be connected to ground, the other to the sensing input of the FlightDEKD180. The FlightDEK-D180 has 3 pins on the 37-pin harness which may be used for connecting such sensors to ground. More than one sensor’s ground may be connected to any of these three grounds using a splice.
The case of the FlightDEK-D180 is connected to its supply ground. If your panel is connected to aircraft ground, the connection between the instrument’s case and the panel dramatically helps minimize voltage differences between the instrument and sensor grounds. If your panel is not metal, or is otherwise isolated from engine ground, connect a 14 AWG or larger wire to the instrument case. The most convenient place to do this is at the back of the mounting tray. Additionally, connect any unused EMS ground leads to a convenient ground. Keep all ground leads as short as possible.
Because of the current drawn by the FlightDEK-D180, even very small resistances between battery ground and instrument ground can cause voltage differences which adversely affect engine sensor readings. An easy way to test the quality of the instrument’s ground is to measure voltage between the ground pin at the FlightDEK-D180 and the ground lead at your aircraft’s battery. With the FlightDEK-D180 powered on, connect one lead of your voltmeter to a free ground lead coming from the FlightDEK-D180. Connect the other lead of your voltmeter to the ground terminal of your battery. The voltage between these two points should measure very close to 0 mV (within 5 mV). If it does not, you must improve the ground connection between the ground of your battery and that of your avionics bus.
2-2 |
FlightDEK-D180 Installation Guide |
Wiring Overview
+5V Excitation
Some of the sensors require either a direct connection, or connection via a resistor, to the +5V excitation circuit. We recommend that you allow for more than one splice into this line.
EMS |
|
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|
|
DB37 |
|
|
Color |
Function |
Pin |
|
|
|
|
18 |
|
|
White/red |
+5V |
|
|
excitation |
Thermocouple Harness Preparation
Refer to the 25-Pin Male EMS Harness section on page 2-9 during this procedure. Strip 1” of brown outer insulation off each thermocouple wire pair on the supplied 25-pin thermocouple harness. Strip ¼” of insulation from each of the thermocouple wires inside. Crimp the supplied male Fastons onto each wire on the thermocouple harness. These will later be inserted into the female Fastons on each thermocouple.
Do not connect the Fastons on the harness with those on the thermocouples until you have routed the wires and mounted the thermocouples at the desired location.
The thermocouple wires can be cut to a desired length if your application requires. If you need to extend the length of the thermocouple, you must use the correct type (J or K) thermocouple wire to accomplish this. It is acceptable to use non-thermocouple fasteners to join two pieces of thermocouple pair wire, provided the junction does not extend very far or have large temperature differences across it. Please contact Dynon Avionics to order extension wire.
Harness Mating
The following diagram shows the 3 electrical connectors on the back of the FlightDEK-D180. The two horizontal connectors are used for the EMS portion of the product; the vertical connector is used for the EFIS portion. The main EMS harness (for all connections except EGT & CHT thermocouples) should terminate in a 37-pin female D-sub connector. The EGT/CHT thermocouple harness should terminate in a 25-pin male D-sub connector. The EFIS harness (also used to provide power to the instrument) should terminate in a 25-pin female D-sub connector. The following pages provide wiring diagrams and details for each of these harnesses.
FlightDEK-D180 Installation Guide |
2-3 |
25-Pin Female EFIS Harness
Below is the wiring diagram of the EFIS 25-pin female harness. If you purchased your harness from Dynon Avionics, it is color coded according to the chart on the following page. Unless noted otherwise, all wires are 3 feet long on the Dynon-provided harness.
2-4 |
FlightDEK-D180 Installation Guide |
The pin assignments for the female 25-pin harness are repeated below. Note that the pin numbers are labeled on the face of both the female and male connector. Each connection on the harness supplied by Dynon is color-coded. These colors are listed in the following chart.
Female |
|
|
Dynon Harness |
|
Function |
Details |
DB25 |
|
|
Wire Color |
|
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|
Pin# |
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|
1 |
|
|
Red |
|
Master Power (10-30 volts) |
Page 4-2 |
2 |
|
|
Yellow |
|
Keep Alive Power (10-30 volts, always on) |
Page 4-2 |
3 |
|
|
Black |
|
Master Ground |
Page 4-2 |
4 |
|
|
Green |
|
DSAB-A |
Page 4-11 |
5 |
|
|
Blue |
|
DSAB-B |
Page 4-11 |
6 |
|
|
N/A |
|
No Connect |
|
7 |
|
|
N/A |
|
No Connect |
|
8 |
|
|
N/A |
|
No Connect |
|
9 |
|
|
Black (bundled) |
|
PC Serial Ground – EFIS logging only |
Page 4-5 |
10 |
|
|
Orange (bundled) |
|
FlightDEK-D180 Transmit / PC Serial |
Page 4-4 |
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Receive (RS-232) – EFIS logging only |
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||
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11 |
|
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White/Orange (Red |
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EDC-D10A Data B |
Page 4-2 |
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on some harnesses) |
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12 |
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White/Blue (Black |
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EDC-D10A Power (12V) |
Page 4-2 |
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on some harnesses) |
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13 |
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Blue/White (black |
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Serial Encoder Transmit (RS-232) |
Page 9-32 |
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on some harnesses) |
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14 |
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N/A |
|
No Connect |
|
15 |
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N/A |
|
External Backup Power |
Page 4-2 |
16 |
|
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Black |
|
Ground |
|
17 |
|
|
N/A |
|
No Connect |
|
18 |
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|
Green |
|
Audio Alert Out |
Page 4-10 |
19 |
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N/A |
|
No Connect |
|
20 |
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N/A |
|
No Connect |
|
21 |
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White (Bundled in |
|
Serial Encoder Ground |
Page 9-32 |
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Encoder cable) |
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||
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22 |
|
|
Yellow (Bundled) |
|
FlightDEK-D180 Receive / PC Serial |
Page 4-5 |
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Transmit (RS-232) – EFIS logging |
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||
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23 |
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White/Green (Green |
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EDC-D10A Data A |
Page 4-2 |
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on some harnesses) |
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24 |
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White |
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EDC-D10A GND |
Page 4-2 |
25 |
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|
N/A |
|
No Connect |
|
FlightDEK-D180 Installation Guide |
2-5 |
Wiring Overview
WIRING SYSTEM OVERVIEW
The following block diagram depicts the basic layout of the EFIS DB25 electrical connections and is for reference only. Read the specific instructions for each connection prior to installation. The colors shown refer to the Dynon-supplied EFIS harness.
2-6 |
FlightDEK-D180 Installation Guide |
Wiring Overview
37-Pin Female EMS Harness
Below is the wiring diagram of the EMS 37-pin female harness. If you purchased your harness from Dynon Avionics, pins 1, 2, 34, 35, 36, and 37 have wires inserted, but are not used. You may clip the wires or remove the pins as needed. Refer to the following page for detailed pin out descriptions.
FlightDEK-D180 Installation Guide |
2-7 |
Wiring Overview
The pin assignments for the female 37-pin harness are repeated below. Note that the pin numbers are labeled on the face of both the female and male connector. Each connection on the harness supplied by Dynon is color-coded. These colors are listed in the following chart.
DB37 harness |
Dynon Harness |
Function |
Details |
Pin# |
Wire color |
|
|
1 |
Red |
Do not connect |
|
2 |
Yellow |
Do not connect |
|
3 |
Black |
Ground |
Page 2-2 |
4 |
Purple/blue |
GP 1 (general purpose resistive) |
Page 3-13 |
5 |
Black |
Ground |
Page 2-2 |
6 |
White/yellow |
Oil pressure |
Page 3-6 |
7 |
White/brown |
Oil temperature |
Page 3-7 |
8 |
Brown |
Fuel pressure |
Page 3-7 |
9 |
Brown/blue |
Contact 1 |
Page 3-18 |
10 |
Brown/yellow |
Contact 2 |
Page 3-18 |
|
Orange |
FlightDEK-D180 Transmit / PC Serial |
Page 4-5 |
11 |
|
Receive (RS-232) – EMS logging only |
|
|
Yellow |
FlightDEK-D180 Receive / PC Serial |
Page 4-5 |
12 |
|
Transmit (RS-232) – EMS logging only |
|
13 |
Black |
Ground (Fuel Flow) |
Page 3-9 |
14 |
Yellow |
Fuel flow input |
Page 3-9 |
15 |
Red |
Fuel flow power (12V) |
Page 3-9 |
16 |
Black |
Ground |
Page 2-2 |
17 |
Black |
Ground |
Page 2-2 |
18 |
White/red |
5V excitation circuit |
Page 2-3 |
19 |
White/black |
Auxiliary Serial Receive (RS-232) |
Page 4-6 |
20 |
Orange/brown |
Fuel level 1 |
Page 3-11 |
21 |
Orange/blue |
Fuel level 2 |
Page 3-11 |
22 |
Purple/yellow |
GP 2 (General Purpose Resistive) |
Page 3-13 |
23 |
Purple/green |
GP 3 (General Purpose Resistive) |
Page 3-13 |
24 |
Orange/green |
Amps High |
Page 3-12 |
25 |
Orange/purple |
Amps Low |
Page 3-12 |
26 |
Green/red |
Manifold pressure |
Page 3-5 |
27 |
Not supplied |
General purpose thermocouple (J or K-type) |
Page 3-19 |
28 |
Not supplied |
General purpose thermocouple (J or K-type) |
Page 3-19 |
29 |
Yellow/green |
External warning light |
Page 4-10 |
30 |
Black |
PC Serial ground – EMS logging only |
Page 4-5 |
31 |
White/orange |
Intercom audio alert |
Page 4-10 |
32 |
White/green |
RPM left |
Page 3-4 |
33 |
White/blue |
RPM right |
Page 3-4 |
34 |
Blue |
Do not connect |
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35 |
Green |
Do not connect |
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36 |
Blue |
Do not connect |
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37 |
Green |
Do not connect |
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2-8 |
FlightDEK-D180 Installation Guide |
Wiring Overview
25-Pin Male EMS Harness
Below is the EMS 25-pin harness wiring diagram. The 4-cylinder harness only has EGTs 1 through 4 and CHTs 1 through 4 wired. The Rotax harness only has EGTs 1 and 2 wired, as the EMS measures the Rotax-supplied resistive CHTs through its GP inputs. On the supplied harness, each pair of wires is encased in brown insulation and labeled with corresponding cylinder number. Inside the outer insulations, each wire in the pair has the color listed on the diagram below. If you are making your own harness, utilize J & K type thermocouple wire as indicated in the diagram.
FlightDEK-D180 Installation Guide |
2-9 |
3. TRANSDUCER INSTALLATION
This section explains the steps required to install and connect all transducers supplied by Dynon Avionics. Additionally, connection instructions are given for some transducers that Dynon Avionics does not sell, like the tachometer, fuel level, flaps, trim, and contacts.
Tools and Equipment Required
The following list contains commonly used tools and equipment; however some of the tools or equipment listed below may not apply to your installation.
Wire strippers
22 AWG wire (if harness not purchased or extending harness beyond 6 feet)
D-sub pin crimper
Faston/ring terminal crimp tool
oAvailable from www.bandcspecialty.com – (316) 283-8000 – part number RCT-1
Weather Pack crimp tool (common slip joint pliers will also work)
oAvailable from www.whiteproducts.com/tools.shtml
#2 Phillips screwdriver
Flathead screwdriver
¼” ID tubes, any necessary adapters, and clamps for routing manifold pressure to the sensor.
Drill and 1/8” bit
FlightDEK-D180 Installation Guide |
3-1 |
Transducer Installation
Exhaust Gas Temperature (EGT) Probes
Correct placement of EGT probes on the exhaust manifold is critical to obtaining accurate readings. Placement differs between engine types, and even specific models. Consult your specific engine’s manual for proper EGT locations.
ROTAX ENGINES
For Rotax 912 engines, only two of the four cylinders are typically monitored for EGT. Unlike the CHT probes which are mounted on diagonal cylinders, the EGT probes should be mounted on the two rear cylinders’ exhaust manifolds. It is critical that the EGT probes be mounted to parallel cylinders’ exhaust manifolds for proper temperature comparison.
ALL ENGINES
Once you have determined the appropriate EGT locations for your engine, drill 1/8” diameter holes at the specified positions in the exhaust manifold. Usually, this spot is 2 to 8 inches from the cylinder. This spot should be on a straight portion of the exhaust manifold, as this provides a better fit for the hose clamps. For best results, mount all probes the same distance from each cylinder.
1.Make sure the hole is placed to ensure that the probe does not interfere with the cowl or spark plug. Also, when making holes, keep in mind that the probe could inhibit the ability to perform routine maintenance if placed incorrectly.
2.Place probe in exhaust manifold, and secure it by tightening the clamp with a flathead screwdriver. Make sure the clamp is tight and provides a secure fit, but do not over-tighten such that visible stress is put on the pipe.
Now, plug each thermocouple wire into its corresponding wire on the thermocouple harness. Ensure that you match the wire color pairs on the harness to those on the thermocouple. All thermocouple harnesses supplied by Dynon have each function (e.g., CHT1, EGT1) labeled on each thermocouple pair.
A loose probe could allow exhaust to leak. This can lead to carbon monoxide poisoning in the cabin and/or a potential fire. Have a knowledgeable mechanic inspect the installation.
The probe can come lose during flight, and could potentially come in contact with rotating engine parts or the propeller. We suggest a safety wire to keep the probe in place.
3-2 |
FlightDEK-D180 Installation Guide |
Transducer Installation
Cylinder Head Temperature (CHT) Probes
Dynon Avionics sells and supports a variety of CHT probes. All thermocouple harnesses supplied by Dynon have each function (e.g., CHT1, EGT1) labeled on each thermocouple pair.
LYCOMING/CONTINENTAL
Dynon Avionics sells bayonet style CHT probes (used in Lycoming and Continental engines). With each probe we sell, a bayonet adapter is included. Your specific engine manual should describe where to mount these bayonet adapters, but normally, there is a threaded hole (CHT well) near the bottom of the cylinder close to the lower spark plug. Screw the bayonet adapter into this hole. Screw the locking collar up or down the spring surrounding the probe such that the tip of the probe is pressed against the bottom of the CHT well when the collar is attached to the adapter. Insert the CHT probe into the well and lock the collar to the adapter. Now, plug each thermocouple wire into its corresponding wire on the thermocouple harness. Ensure that you match the wire color pairs on the harness to those on the thermocouples.
ROTAX
Rotax 912 engines use 2 resistive CHT probes that are included with the engine. These probes are preinstalled, but you need to route the connections from them to the FlightDEK-D180. See the CHT General Purpose Installation section on page 3-15 for information on making the physical connection to the sensor.
JABIRU
Jabiru engines require a 12mm ring-terminal CHT probe for each cylinder. First, slide the compression washer off the spark plug. Slide the 12mm ring-terminal probe onto the plug. Now, slide the spark plug compression washer back onto the spark plug. Reinstall the spark plug into the spark plug hole. Please refer to the documentation that came with your engine for more information. Now, plug each thermocouple wire into its corresponding wire on the thermocouple harness. Ensure that you match the wire color pairs on the harness to those on the thermocouples.
FlightDEK-D180 Installation Guide |
3-3 |
Transducer Installation
Tachometer
Dynon Avionics does not sell a tachometer transducer. |
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Depending upon existing equipment and engine type, |
32 |
White/green |
RPM Left |
you have a few options for connecting the tachometer |
33 |
White/blue |
RPM Right |
inputs on the FlightDEK-D180. See the relevant subsections below for your particular method. You may
connect different types of signals to the two different RPM inputs (e.g., p-lead to RPM Left and a 12V transducer to RPM Right). Once you have connected the tachometer inputs according to your engine and transducer type, you must set the appropriate pulses/revolution as described on page 6-8.
TACHOMETER TRANSDUCER
If you have a standard tachometer transducer (usually with a 12V output), you may simply connect its output to the RPM Left input on the FlightDEK-D180. Ensure that you follow all recommendations given in the manual for your individual tachometer transducer.
P-LEAD PICKOFF (LYCOMING AND CONTINENTAL)
If you do not have a standard tachometer pickoff, you must follow the instructions below. The magneto P-lead has high voltages which can very easily damage the FlightDEK-D180 if not dealt with properly.
Use the two included 30kΩ resistors (color bands: orange, black, brown, red, brown; connect in either direction) to attach left and right P-leads to the RPM Left
and RPM Right inputs on the FlightDEK-D180. Connect them as shown in the following diagram. It is important to connect each resistor as close as possible to the spot where you tap into the P-lead. This minimizes the length of cable carrying high voltage spikes. 6 cylinder Lycoming engines sometimes need more inline resistance to prevent false readings by the FlightDEK-D180.
If, after setting the PULS/REV R and L values as described on page 6-8, you see higher than expected RPM or unstable values, you may need to increase the series resistance to as high as 150kΩ.
TRIGGER COIL (ROTAX)
The Rotax 912 engines have a 5th trigger coil for the purposes of electrically monitoring rev counts. This trigger coil outputs to a two-wire harness. Connect either of the two wires to ground; connect the other to one of the included 30kΩ resistors (color bands: orange, black,
3-4 |
FlightDEK-D180 Installation Guide |
Transducer Installation
brown, red, brown; connect in either direction). Connect the other end of the resistor to the RPM Left input on the FlightDEK-D180.
ALTERNATOR WIRE (JABIRU)
The most common tachometer pickoff location for Jabiru 2200 and 3300 engines is one of the alternator wires. Splice a wire off one of the two white alternator wires, connect it through a 1- amp fuse to the RPM Left input on the FlightDEK-D180.
DIGITAL IGNITION AND OTHER PICKOFFS
The FlightDEK-D180 can read frequency-based RPM signals, provided the peak voltage is at least 10 volts above ground. If the peak voltage exceeds 50 volts, use the included 30kΩ resistors as described in the P-lead Pickoff section above. Like the other methods above, you must know the number of pulses per revolution for your RPM transducer.
Manifold Pressure Sensor
The manifold pressure sensor is an integral |
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assembly consisting of three pins, a rubber |
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+5V |
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seal, and a connector housing. Strip 3/16” |
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excitation |
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listed at right. Slide the three rubber seals |
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pressure |
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ends of the wires. Crimp the 3 provided pins |
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Ground |
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onto the ends of the wires, ensuring that the long tabs that cradle the rubber seal wrap
around the seal (see picture at right for example). For more details on preparing and crimping the Weather Pack pins, see www.whiteproducts.net/faqs.shtml.
Note that you will need access to the +5V excitation circuit for |
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other sensor installations, so make allowances for breaking out |
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the connection to other areas. Route the three wires to the |
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sensor. |
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Figure 1 Connection diagram for |
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provided Weatherpack connector. |
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Figure 3: Detail view of properly |
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pressure sensor requires 1/4” inner |
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diameter tubing for a secure fit. You may need to use adapters to |
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convert down to smaller inner diameter tubing for your specific engine. We recommend that you use pipe clamps at every transition point, including at the sensor itself.
FlightDEK-D180 Installation Guide |
3-5 |
Transducer Installation
If you notice fluctuations on the manifold pressure reading on the FlightDEK-D180, you may need to install a restrictor with a small hole inline between the sensor and the head where the manifold pressure line is split off.
Oil Pressure Sensor
The FlightDEK-D180 supports several oil pressure sensor installations. The Dynon-supplied sensor and the Rotax and Jabiru pre-installed sensors are the most common.
DYNON-SUPPLIED OIL PRESSURE SENSOR
First, mount the oil pressure sensor to a fixed location using an Adel clamp (see picture at lower right) or other secure method. The oil pressure sensor must not be installed directly to the engine due to potential vibration problems. Dynon Avionics’ sensor is supplied with a
1/8” NPT pipe thread fitting. An adapter might be necessary for some engines. Please see the manual supplied by the engine’s manufacturer. You must use appropriate pipe fitting adapters and ensure that the case of the sender has a connection to ground. This is critical for functionality.
Pin |
6
Color Function
White/yellow Oil
pressure
Crimp a standard #8 ring terminal onto the white/yellow wire from pin 6. Unscrew the stud cap from the threaded stud. Place the ring terminal on the stud and secure the cap down sandwiching the ring terminal.
Due to vibration issues, never connect the sensor directly to the engine.
If you use Teflon tape or other seal, ensure the sensor casing still maintains a good connection to ground.
1/8-27 NPT 0-150 PSI
JABIRU AND ROTAX OIL PRESSURE
If you are installing on a Jabiru or Rotax engine, your engine comes with a pre-installed oil pressure sensor.
Prior to mid-2008, Rotax provided an oil pressure sensor with 2 tabs for electrical connection. In mid2008, Rotax switched to a new type of oil pressure sensor (Rotax P/N 956413) with an integrated 2-wire cable. Connect this newer sensor according to the wiring diagram at right. Connect the red wire of the new sensor to EMS DB37 Pin 15 (12V). Connect the white wire of the new sensor to EMS DB37 Pin 6. Then, connect one end of a 200Ω resistor to pin 6,
and the other end to ground. The Jabiru and both types of Rotax oil pressure sensors are compatible with the FlightDEK-D180. Select the correct sensor type as described in the Oil Pressure Configuration section on page 6-9.
3-6 |
FlightDEK-D180 Installation Guide |
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Transducer Installation |
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Oil Temperature Sensor |
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The oil temperature sensor needs to be installed |
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Oil |
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according to the directions of the engine |
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manufacturer. Dynon Avionics sells oil |
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temperature sensors with both 5/8-18 UNF (Dynon P/N 100409-001) and 1/8-27 NPT
(Dynon P/N 100409-000) threads. Ensure that you have the right sensor for your engine. Using a crush washer (not provided) between the sensor and the engine case, tighten the
sensor according to your engine manufacturer’s recommendations.
Route the wire from pin 7 on the 37-pin harness to where the oil temperature sensor is mounted. When routing the wires, make sure that they are secured, so they will not shift position due to vibration. Strip ¼” of insulation off the end of the wire. Crimp a #10 ring terminal onto the end of the wire, ensuring
that a good connection is made between the wire and the connector. Unscrew the nut from the stud on the oil temperature sensor. Slip the ring terminal onto the stud and secure the nut over it.
As mentioned in the Grounding section on page 2-2, the oil temperature sensor is very susceptible to voltage differences between the engine case and the negative terminal of the battery. Ensure that solid, thick, and short electrical connections exist between the engine and battery ground.
Fuel Pressure Sensor
First, mount the fuel pressure sensor to a fixed location |
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using an Adel clamp or other secure method. The fuel |
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pressure sensor must not be installed directly to the |
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connect the fuel sensor to the engine using appropriate
hoses and fittings. Its pressure port has a 1/8-27 NPT pipe thread fitting; you may need adapters to connect to the pressure port on your engine. Locate the correct fuel pressure port for your engine. This port must have a pressure fitting with a restrictor hole in it. This restrictor hole ensures that, in the event of a sensor failure, fuel leakage rate is minimized, allowing time for an emergency landing.
Carbureted engines: Use the 0-30 PSI sensor (Dynon P/N 100411-000). Crimp a standard ¼” female Faston onto one of the ground wires (see the Grounding section on page 2-2) coming from the 37-pin harness. Crimp another ¼” female Faston onto the brown wire from pin 8. Push the two Fastons onto the two terminals on the fuel pressure sensor. Polarity is not important. If you
1/8-27 NPT |
1/8-27 NPT |
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0-80 PSI |
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FlightDEK-D180 Installation Guide |
3-7 |
Transducer Installation
are converting from a GRT EIS system, you must disconnect the external resistor pull-up from the fuel pressure output. This will make the sensor output equivalent to the sensor supplied by Dynon Avionics.
Injected engines: Use the 0-80 PSI sensor (Dynon P/N 100411-001). Crimp a standard #8 ring terminal onto the brown wire from pin 8. Unscrew the stud cap from the threaded stud. Place the ring terminal on the stud and secure the cap down sandwiching the ring terminal. If the connection between the sensor and your engine is non-metallic, you must connect the sensor case to ground through other means. The best way to accomplish this is by sandwiching a groundconnected ring terminal between the sensor and the mating fitting.
Due to vibration issues, never connect the sensor directly to engine.
If you use Teflon tape or other seal, ensure the sensor casing still maintains a good connection to ground.
3-8 |
FlightDEK-D180 Installation Guide |
Transducer Installation
Fuel Flow Sensor
Dynon Avionics supplies two different fuel flow |
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Function |
transducers: |
13 |
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Black |
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Ground |
Floscan 201B (Dynon P/N 100403-001) |
14 |
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Yellow (or |
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Fuel flow |
Electronics International FT-60 (Dynon P/N 100403- |
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input |
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003) |
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Fuel flow |
GENERAL PLACEMENT RECOMMENDATIONS |
15 |
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Red |
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power |
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(14V) |
When placing either sensor, ensure that the three wire leads
are pointed straight up. A filter should be placed upstream from the sensor to screen out debris. Placement of the fuel flow sender relative to other items in the fuel system like fuel pumps is left to the builder. The manufacturer of the fuel flow sender does not make strong recommendations on this point. It is not uncommon, though, to place the sender downstream of any auxiliary electric boost pumps but upstream of the engine driven fuel pump. For best measuring performance, the fuel should travel uphill by one to two inches after leaving the fuel flow sender.
Due to vibration issues, never connect the sensor directly to engine. Do NOT use Teflon tape when screwing in any of the fittings.
FLOSCAN TRANSDUCER INSTALLATION
The FloScan fuel flow transducer has ¼” female NPT threads at both the inlet and outlet. Only use ¼” NPT fittings to match. When installing, do not screw fittings more than two full turns past hand tightened. The torque should not exceed 180 inchlbs.
Make note of the numbers on the tag attached to the fuel flow sensor. You will need it in the Fuel Flow Configuration section on page 6-14.
¼” NPT Female
EI “RED CUBE” INSTALLATION
The Electronics International “Red Cube” FT-60 flow transducer has ¼” female NPT ports. Do not exceed a torque of 300 inch-lbs when installing fittings into the transducer. The fuel line on the outlet port should not drop down after exiting the transducer. This configuration can trap bubbles in the transducer, causing jumpy readings.
The inlet port, outlet port, and flow direction are marked on the top of the FT-60.
ROTAX PLACEMENT RECOMMENDATIONS
If installing on a Rotax 912, review the following page for recommendations specific to these engines.
FlightDEK-D180 Installation Guide |
3-9 |
Transducer Installation
3-10 |
FlightDEK-D180 Installation Guide |
Transducer Installation
Fuel Level Sensor
Dynon Avionics does not sell fuel level sensors.
The FlightDEK-D180 supports both resistive type sensors as well as capacitive sensors which output a voltage (e.g., Princeton). If you have a capacitive sensor which does not output a voltage on its own, you may be able to use Dynon’s Capacitance-to- Voltage Converter. Read the relevant section below for the type that you are installing.
Once you have installed your fuel level sensors, you will need to calibrate each of them, as described in Fuel Level Calibration on page 6-5.
RESISTIVE FUEL LEVEL SENSOR
Pin Color Function
Fuel level 1 20 Orange/brown (resist or
cap)
Fuel level 2 21 Orange/blue (resist or
cap)
See General Purpose Inputs section
4 |
Purple/blue |
GP 1 |
22 |
Purple/yellow |
GP 2 |
23 |
Purple/green |
GP 3 |
You may connect up to four resistive fuel level sensors to the FlightDEK-D180. Simply connect the output of the sensor you would like to be Fuel Level 1 (left tank) to pin 20 and the sensor you would like to be Fuel Level 2 (right tank) to pin 21. You may also connect third and fourth fuel level transducers to the general-purpose inputs of your choice. See the General Purpose Inputs section on page 3-13 for more information.
CAPACITIVE FUEL LEVEL SENSOR
Capacitive fuel level sensors are only supported on the Fuel Level 1 and Fuel Level 2 inputs. Additionally, your capacitive sensor needs to output a variable voltage within the ranges of 0- 5Vdc. First, supply the sensor with power according to the manufacturer’s instructions. If the sensor manufacturer requires a sensor calibration, perform that calibration first. Connect the sensor’s output to pin 20 or 21, depending on whether you want the tank to display as left (Fuel Level 1) or right (Fuel Level 2) tank. Do not connect capacitive fuel level sensors to any of the general-purpose inputs. Be sure to configure the firmware to recognize the capacitive fuel level sensor on the fuel level input(s) you’ve chosen as described in the Fuel Level Configuration section on page 6-13.
If you are installing Dynon’s Capacitance-to-Voltage Converter (most commonly used with the capacitive plates in some RVs), please read Capacitance-to-Voltage Converter Installation on page 9-35.
FlightDEK-D180 Installation Guide |
3-11 |
Transducer Installation
Ammeter Shunt
The ammeter shunt should be mounted so that the metal part of the shunt cannot touch any part of the aircraft. The ammeter shunt can be installed in your electrical system in one of three locations as shown in the (simplified) electrical diagram below.
Pin |
Color |
Function |
24 |
Orange/green |
amps high |
25 |
Orange/purple |
amps low |
Position A: Ammeter indicates current flow into or out of your battery. In this position, it will show both positive and negative currents. (-60A to 60A)
Position B: Ammeter indicates only the positive currents flowing from the alternator to both the battery and aircraft loads. (0A-60A)
Position C: Ammeter indicates the current flowing only into the aircraft loads. (0A-60A)
Note that the ammeter shunt is not designed for the high current required by the starter and must not be installed in the electrical path between the battery and starter.
Electrically, the shunt should be placed so that it does not receive power when the master switch is off. If it does receive power in this case, it is possible for your aircraft battery to slowly discharge over a few weeks or months.
Use two ¼” ring terminals sized appropriately for the high-current wire gauge you will be routing to and from the ammeter shunt. Cut the wire where you would like to install the ammeter shunt. Strip the wire and crimp on the ring terminals. Using a Phillips screwdriver, remove the two large screws (one on either end of the shunt), slip the ring terminals on, and screw them back into the base.
We highly recommend that you fuse both the connections between the shunt and the FlightDEKD180. There are two methods for accomplishing this. You may simply connect two 1 amp fuses in-line between the shunt and the FlightDEK-D180. Or, you may use butt splices to connect 1” to 2” sections of 26 AWG wire between the shunt and each of the Amps leads connecting to the
3-12 |
FlightDEK-D180 Installation Guide |
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