temporary revision em-tr-mdc-e1-195 engine control system
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ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System COVERPAGE
TEMPORARY REVISION
EM-TR-MDC-E1-195 Supersedes EM-TR-MDC-E1-191a
Engine Control System
This Temporary Revision EM-TR-MDC-E1-195 is approved in conjunction with the Design Change Advisory MDC-E1-195 and is valid in conjunction with the latest revision of the Engine Manual (EM) until this Temporary Revision has been incorporated into the EM. The limitations and information contained herein either supplement or, in the case of conflict, override those in the EM. The technical information contained in this document has been approved under the authority of DOA ref. EASA.21J.399.
Doc. Nr. Affected Section(s) Affected Page(s)s
E1.01.05 19
1a 2a
3a 4a
5a
6a 7a
10a 11a-b
12a-b
13a 14a
15a 16a-d
17a-b 18a
19a
20a 21a
22a 23a-b
24a
25a 26a
27a
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System COVERPAGE
Instruction:
- Print this document on yellow paper (single-sided)
- Insert this cover page as the first page of the EM
- Insert the other pages of this Temporary Revision adjacent to or in front of the corresponding EM pages
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-1a
19. Electrical System This page is amended to read:
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 pin assignment can be found in this document.
The ignition system is not self-contained, i.e. a battery or generator is
for operation. The Installer must provide a suitable indicator to give
warning of charge system failure, together with suitable warning of
battery failure.
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 chapter 19.1.4.3 ECU Pin
Assignment.
It is important to disconnect any electronic device if welding working
are applied on the aircraft or engine, otherwise the electronic devices
can be damaged.
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-3a
19.1 Engine Control System
The following section is amended to read:
The engine control system provided by Austro Engine includes the Engine Control Unit
(ECU), sensors and actuators.
The engine control unit activates the ignition and injection based on the information of
engine speed, manifold pressure and some correcting factors. The actuators are supplied
from the aircraft power supply bus/buses. 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 calculated from the ECU using the speed sensor signals.
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
correction factors.
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 MAP Sensor 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 speed sensor. If a
sensor should become defective the ECU will automatically select the other sensor and
provide a cockpit indication via a coded error warning signal.
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-3a
19.1.2.2 Ignition
The spark plug pair is fired simultaneously, each by its own ignition coil, triggered by the
output from the ECU.
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
Mounting of the ECU is possible via 4 elongated holes. M4 screws with washers on the side
of the ECU housing are suggested. ECU supplied should be carried on anti-vibration
mounting.
Maximum allowed vibration: see chapter 19.6.2 Environmental tests
Temperature Range ECU: see chapter 19.6.2 Environmental tests
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.
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-4a
19.1.4 Electrical installation of the ECU
Description Condition Min Typ Max Unit Power Supply --- 9 12 14.8 V
Power supply current ECU 0 rpm --- --- 500 mA
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
RX --- --- --- Ubatt V
Instrument +5V --- --- --- 2 mA
Fig. 1 ECU Dimensions (in mm)
*) System consists of ECU, Sensors and Actuators. Fuel pumps and instruments are not
included
19.1.4.1 Power demand electrical components and circuit breakers
Austro Engine provides no electrical circuit protection. The Installer must install suitable overcurrent
protection devices between all electrical components and the aircraft bus bar.
Description Current [A] typ
Circuit Breaker Comment
Ignition Coil A 1,5 5A -
Ignition Coil B 1,5 5A -
Injector 1 2A -
ECU and Sensors 1,5 2x 1A 2x 1A circuit breaker suggested for each supply line (see Fig. 16) of ECU bus bar
Instruments and
alarms *)
0,5 (assumed) Installer
responsibility Installer is responsible for fuse suitable to the
respective components /loads which are not
part of AE design Fuel pump **) 5,5 (assumed) Installer
responsibility
Total demand 11,5 (assumed) - -
*) Instruments and alarms are not provided by AE
**) Fuel pump not provided by AE
Battery capacity must be sufficient for 30 minutes engine and emergency system operation, in the event of a generator failure.
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-5a
19.1.4.2 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
Description Manufacturer Part Number Manufacturer Description
ECU Harness
Connector TE 344111-1 36WAY Receptacle Housing Connector
Wire Seal TE 347874-1 Wire Seal AWG16 - AWG20
Anti Backout TE 344112-1 Anti Backout
Crimp TE 344113-1 Crimp AWG14 - AWG18
Crimp TE 171630-1 Crimp AWG20 - AWG23
Table 1
A1
B1
C1
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-6a
19.1.4.3 ECU Pin Assignment
ECU
PIN Description Signal Type Description Shielding
Cable
Diameter (Minimum)
A1 Injector 2 Low Side Switch not used for IAE50R-AA
A2 Ins Drive 3 Low Side Switch not used for IAE50R-AA
A3 MAP 1 Signal Input Signal Yes AWG 20
A4 CAN A High not for customer use Yes AWG 20
A5 MAP1, RCT &
IAT GND GND Sensor GND No AWG 20
A6 CAN A Low not for customer use Yes AWG 20
A7 GND GND ECU GND No AWG 16
A8 GND GND ECU GND No AWG 16
A9 ECU Power UBAT ECU Supply No AWG18
A10 ECU Power UBAT ECU Supply No AWG18
A11 Ins Drive 1 Low Side Switch Coolant Signal Out No AWG18
A12 Injector 1 Low Side Switch Injector 1 No AWG 20
B1 TX
Low Side Switch
2k2 Pull Up to
UBAT
Error Lamp Out / Communication
No AWG 20
B2 Pickup 2 PWR 12V Sensor
Supply Sensor Supply Yes AWG 20
B3 Pickup 1 PWR 12V Sensor
Supply Sensor Supply Yes AWG 20
B4 IAT Input Signal Sensor Signal No AWG 20
B5 Map 2 Signal Input Signal Sensor Signal Yes AWG 20
B6 Map 1 Power 5V Sensor
Supply Sensor Supply Yes AWG 20
B7 Map 2 GND GND Sensor GND Yes AWG 20
B8 CAN B High not used for IAE50R-AA
B9 Pickup 2 Signal
Input Signal Sensor Signal Yes AWG 20
B10 T3I Digital Input 2k2
Pull Up to 5V Instrument +5V No AWG 20
B11 Tacho Drive Low Side Switch Engine speed Out No AWG 20
B12 Ins Drive 2 Low Side Switch 2k2 Pull Up to
UBAT
Fuel Consumption Out No AWG 18
C1 Ignition Coil
A (-) Low Side Switch Ignition No AWG 16
C2 Spare Low Side Switch not used for IAE50R-AA
C3 Map 2 PWR 5V Sensor
Supply Sensor Supply Yes AWG 20
C4 Pickup 2 GND GND Sensor GND Yes AWG 20
C5 RX Serial Input incl.
Inverter Communication No AWG 20
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-7a
C6 CAN B not used for IAE50R-AA
C7 CAN 3 not used for IAE50R-AA
C8 RCT Signal Input Signal Sensor Signal No AWG 20
C9 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 No AWG 16
C12 Spare Low Side Switch not used for IAE50R-AA
19.1.4.4 Diagnostic Communication
Austro Engine provides an optional communication tool so called R1 Wizard for diagnostic and
monitoring ECU parameters.
Detailed information about installation and basic handling of Diagnostic Tool “R1 Wizard” can be found in document E1.08.09.
Hardware and Software can be ordered with information listed below.
Necessary Hardware (USB Dongle): AEP-00211-000
Necessary Software:
R1-Wizard (Latest Version)
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-10a
19.1.4.5 Error Codes
B1
ECU_Connector
10
k
12V
Depends on the LED
Figure 15a
If no error is pending, the led is „On“ when the ECU is supplied. If engine speed is measured
by the ECU and no failure is detected, the led is turned „Off“. If no failure is detected during
engine run, the led remains „Off“. If the led turns „ON“, a failure is detected by the ECU. To
read out the blink code, turn Off the engine, and switch On the ECU again. Read out of failure
via blink code, is only possible when engine is in standstill. Readout starts automatically after
several seconds. For the blink code refer to chapter 19.1.4.5.
Do not connect any other devices (e.g.: Serial to USB Converter,…) to output B1 in parallel if
the error lamp is installed. This lead to distorted lamp signals.
Description Condition Power Unit Voltage Unit Error Lamp (suggested) --- 3 W 12 V
Alternative LED (suggested with 10k min 250mW)
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-11a
19.1.4.6 Error Code Table
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 Sensor faulty None
Investigate after
landing
2-3
Engine Speed 2 Sensor faulty None
Investigate after
landing
3-2
Manifold Air Pressure
Difference
Difference between
MAP 1 and MAP 2
sensor too high
None
Investigate after
landing
Each error code consists of two numbers. They 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, each code will be flashed in sequence with 5 seconds between
codes.
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-11b
19.1.4.7 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 figure 16:
12V Generator Bus 12V Battery Bus
12V Battery
ECU
StarterGenerator Generator Regulator
Bus Tie Max 25Amp
+ +- -+ -
IGN1A IGN2A
INJ1
Basic Recommended Installation of ECU Supply Bus to fulfill Do160 Sec.16 CAT Z
Fig. 16: Electrical Supply Topology
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.
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-12a
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.
Enginehousing
12V Battery
Capacitor
+ -
GeneratorRegulator
+-+ -
Aircraft GND
ECU+-
Starter+-
Fig. 17: GND concept
GND connection Points
) Regulator see Chapter Generator Regulator ) Engine: Connecting points for the engine GND
Connect the GND return line for the starter motor directly to the mounting
bolt of starter. Connect the GND return line for the ignition current on the rotary housing
(Fig.18)
For any other points on the engine contact Austro Engine GmbH
Max allowed contact resistance for engine GND connection 50 mOhm Wire recommendation:
2 x AWG 12 GND: Engine housing to Battery negative terminal, 1x AWG 6 GND: for electrical starter connection.
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-12b
Fig. 18: Engine GND
AWG 6
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-13a
19.3 Sensors and actuators
19.3.1 Intake Air Temperature sensor (IAT)
The sensor should be installed with its probe in the induction airflow.
Type of Air Temp Sensor:
Part Number QTY per engine
E4A-40-000-804 1
Pin Assignment Air Temp Sensor:
Fig. 19
Pin Description IAT (ECU Pin)
1 Signal B4
2 GND A5
Connector for Air Temp Sensor:
Description Manufacturer Part Number QTY (per sensor)
Connector Set Bosch 1 287 013 003 1
Connector Set consist of:
1x Connector Housing 1x Seal (Dust Cover) 2x Crimp
Alternative Connector for Air Temp Sensor:
Description Manufacturer Part Number QTY (per sensor)
Connector Female Housing Kostal 09 4404 01 1
Crimp Kostal 2 21 24 49205 0 2
Seal Herth + Buss 50281050 2
Protective Gasket Kostal 1 08 00 44452 2 1
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-14a
19.3.2 Rotor cooling air out temperature sensor (RCT)
The sensor should be mounted as defined in the following figures:
Fig.20
approx. 10 mm
approx. 5,3 mm
approx. 27 mm
RCT flange surface
Temp. Sensor
Temp. Sensor
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-15a
Type of Rotor Cooling Air out Temp Sensor(s):
Part Number QTY per engine
E4A-40-000-804 1
Pin Assignment of Rotor Cooling Air out Temp Sensor:
Fig. 21
Pin Description RCT (ECU Pin)
1 Signal C8
2 GND A5
Connector for of Rotor Cooling Air out Temp Sensor:
Description Manufacturer Part Number QTY (per sensor)
Connector Set Bosch 1 287 013 003 1
Connector Set consist of:
1x Connector Housing 1x Seal (Dust Cover) 2x Crimp
Alternative Connector for Rotor Cooling Air out Temp Sensor:
Description Manufacturer Part Number QTY (per sensor)
Connector Female Housing Kostal 09 4404 01 1
Crimp Kostal 2 21 24 49205 0 2
Seal Herth + Buss 50281050 2
Protective Gasket Kostal 1 08 00 44452 2 1
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-16a
19.3.3 Map Sensors R1A-09-100-801 (not for new design / installation)
Both MAP sensors must have the same part number.
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.
VCC
VOUT
GND
Fig. 22
Type of MAP Sensor(s):
Part Number QTY per engine
R1A-09-100-000 2
Pin Assignment MAP Sensor(s):
Pin Description
VCC 5V Sensor Supply
VOUT Output Signal
GND Ground
Connector for MAP Sensor:
Description Manufacturer Part Number QTY (per sensor)
Seal Delphi 15324983 3
Crimp Delphi 12089040-L 3
Connector Housing Delphi 12015793 1
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-16b
19.3.4 Map Sensors AEP-00283-901
The following section is amended to read:
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 6 mm) must be at least oil resistant (fuel, engine oil) and
does not change the inner diameter at inlet pressures of 20 kPa. Both MAP Sensor must have
the same part number.
Fig.22a
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-16c
Type of MAP Sensor(s):
Part Number QTY per engine
AEP-00283-901 2
Pin Assignment MAP Sensor(s):
Pin Description MAP 1 (ECU Pin) MAP 2 (ECU Pin)
1 5V Sensor Supply B6 C3
2 Output Signal A3 B5
3 Ground A5 B7
4 Shield Connect to GND
Connector for MAP Sensor:
Description Manufacturer Part Number QTY (per sensor)
Connector Female Housing TE 282088-1 1
Crimp TE 183035-1 4
Seal TE 281934-4 4
Protective Gasket TE 493581-1 1
Pipe Adapter for installation:
To connect sensor mechanical to the flexible pressure pipes installer has to provide an adapter. Tightening torque of adapter max. 25Nm.
7mm
AEP-00283-901 provided by AE
Pipe adapter proposal, not provided by AE
Flexible Pipe not provided by AE
Sealing Washer proposal according DIN 7603
Figure 22b
A sealing washer between pipe adapter and sensor AEP-00283-901 is required. AE suggest a suitable sealing ring according to DIN 7603.
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-16d
Environmental Qualification Form RTCA DO-160D / ED-14D (Change 3 dated Dec 5th, 2002)
Description (S + A engine mounted) Section Category
Temperature and Altitude 4.0 B3*
Temperature Variation 5.0 B
Humidity 6.0 A
Operational Shocks and Crash Safety 7.0 B
Vibration 8.0 S, test curve U
Waterproofness 10.0 R
Fluid Susceptibility 11
F (Coolant, Jet A1, Avgas, Engine oil) Tested according to DO-160G
Salt Spray 14.0 S
Radio Frequency Susceptibility 20.0 Y
Emission of Radio Frequency Energy 21.0 M
Electrostatic Discharge ESD 25.0 A
*B3-Temp: Operating Low: -45°C; Ground survival Low: -55°C; Ground Survival High 105°C, Short time Operating High 85°C, Operating High 85°C.
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-17a
19.3.5 Speed Sensors (Pickup1 & Pickup2)
The following section is amended to read:
Mounting provisions are given on the engine.
Type of Speed Sensor(s) (Pickup):
Part Number QTY per engine
R1A-09-000-802 2
Pin Assignment Speed Sensor(s):
Fig. 23
Pin Wire Color Description Pickup 1 (ECU PIN) Pickup 2 (ECU PIN)
VCC Brown Sensor Supply B3 B2
VOUT Black Output Signal C10 B9
GND Blue GND C9 C4
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.
Proposal for sensor connector:
Description Manufacturer Part Number QTY (per sensor)
Seal Tyco / TE 281934-4 3
Crimp Tyco / TE 183024-1 3
Connector Housing Tyco / TE 282105-1 1
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-17b
Proposal for engine harness mating connector:
Description Manufacturer Part Number QTY (per sensor)
Seal Tyco / TE 281934-4 3
Crimp Tyco / TE 282404-1 3
Connector Housing Tyco / TE 282087-1 1
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-18a
19.3.6 Ignition Coils
This section is amended to read:
Power supply ignition coil: The installer should provide independent switches to interrupt the
power supply for each ignition coil separately if required. (Note the maximum length of
ignition cable R1A-09-000-501 -> 200 mm)
Type of Ignition Coil:
Part Number QTY per engine
R1A-09-000-804 2
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. Recommended circuit breaker for each ignition coil supply line 10A.
Pin Assignment Ignition Coil:
Fig. 4
Fig. 5
Negative
To spark plug
Positive
Fig. 24: Ignition coil
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-19a
Pin Assignment Connector
Terminal COIL A COIL B Manufacturer Part Number Description
Positive
Supply Bus Supply Bus
TE 735160
Insulated
Receptacle
Crimp 6,4 x
0,8mm
Negative
C1
(ECU Pin)
C11
(ECU Pin) TE 735160
Insulated
Receptacle
Crimp 6,4 x
0,8mm
19.3.6.1 Ignition Cable
The inductive ignition coils are connected to the spark plugs by copper–cored ignition cable.
The cable is provided by AE.
Part Number QTY per engine
R1A-09-000-501 2
19.3.6.2 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.
Pin Assignment Connector
Terminal Spark Plug A Spark Plug B Manufacturer Part Number Description
Spark Plug Coil A Coil B AE R1A-09-000-
501
Connection to
Spark Plug
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-20a
19.3.7 Injector
This section is amended to read:
One injector is used for the IAE50R-AA Engine.
Type of Injector:
Part Number QTY per engine
R1A-30-000-801 1
Pin Assignment Injector:
Fig. 25
Pin Description INJ1 INJ2
1 ECU Signal A12 (ECU PIN) A1 (ECU PIN)
2 Injector Supply (+UBAT) Supply Bus Supply Bus
Connector for Injector:
Description Manufacturer Part Number QTY (per sensor)
Connector Set Bosch 1 287 013 003 1
Connector Set consist of:
1x Connector Housing 1x Seal (Dust Cover) 2x Crimp
Alternative Connector for Injector:
Description Manufacturer Part Number QTY (per sensor)
Connector Female Housing Kostal 09 4404 01 1
Crimp Kostal 2 21 24 49205 0 2
Seal Herth + Buss 50281050 2
Protective Gasket Kostal 1 08 00 44452 2 1
ENGINE MANUAL E1.01.05
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Issue Date: 16.Nov.2018 Engine Control System Seite : 19-21a
19.3.8 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.
Description Manufacturer Operating temp Ohm @90°C
Thermistor VDO 120°C 51,2 ±5,3
Description Manufacturer Part Number
Crimp Terminal TE 735160
Insulated
Receptacle Crimp
6,4 x 0,8mm
Fig. 26: Coolant temperature sensor
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-22a
19.4 Generator regulator and Generator
The following section is amended to read:
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.
Description Condition Min Typ Max Unit Power supply Current --- --- 18 --- A
19.4.1 Mechanical installation of the Generator Regulator
Mounting of the Regulator is possible via M8 screws on both sides of the Regulator. There
must be a very good earth bond between the units and the airframe.
Install the regulator on a well-ventilated place. The temperature on the regulator should never
exceed +60°C measured at point T shown in Figure 16. Regulator must be installed in the
engine bay in a position where this value will not be exceeded in the most extreme operating
conditions. The regulator should be mounted on metal bracket to assist heat dissipation.
19.4.2 Electrical installation of the Generator Regulator
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.
Description Condition Min Typ Max Unit GND connection Gen. Regulator --- --- --- 50 mOhm
Fig. 27: Regulator housing
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-23a
The wiring for connecting the generator and generator regulator is described in following
figure:
GEN
BATT12V
yellow
yellow
white
redred
black
12V -3WNot requsted
22000 µF
40-65V
+
-
> AWG 14
AWG 16
AWG 16
AWG 16
AWG 16
AWG 16
AWG 16No Load on Black Terminal
Load
+ -
Reg
ula
tor
Fig.28: Wiring diagram Generator and Regulator
A 22,000 µF, 40-65V DC capacitor must be incorporated in the charging system to smooth the
voltage and prevent an over voltage condition arising when the battery is disconnected from
the bus bar.
Alternator regulator is designed to be used with lead battery. Austro Engine assumes no liability for alternator regulator if other battery types are connected.
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)
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-23b
Recommended connector for cable between generator and regulator.
Description Manufacturer Part Number QTY
Seal TE 281934-3 4
Crimp (Female) TE 282466-1 2
Connector Housing (Female) TE 282080-1 1
Crimp (Male) TE 183024-1 2
Connector Housing (Male) TE 282104-1 1
Rubber Plug (Dust Cover) TE 880810-1 2
19.4.3 Charge Circuit Fail Alarm
The installer is responsible for a wiring which indicate a charge circuit failure alarm.
In order to maintain the dual safety aspect of the ignition and injection system two in
depended 12V supply feeds to the ECU from the aircraft bus bars must be installed. This may
be done in accordance with the recommendation Fig.16 Electrical supply topology. 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.
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-24a
19.5 Starter
This section is amended to read:
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).
Description Condition Min Typ Max Unit
Start Current
(Battery 12,5V 18Ah)
--- --- 80 --- A
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.
Fig. 29: Mechanical installation of the starter
19.5.2 Electrical connection of starter
Fig.30: Starter
Description Electrical Connection
GND Ground connection of starter via housing to engine,
or direct line to GND Battery Terminal
Bolt1 Switch able 12V starter actuation
For fastening torque of bolt 1 see chapter 11.2.1
Bolt 1
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-25a
19.6 Electronic Components Capability
The following chapter is amended to read:
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
Cat A, B and Z
Lightening Induced Transient Susceptibility DO-160C, Section 22 Cat Z3
Magnetic Effect DO-160C, Section 15,
Equipment Class Z
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)
The ECU was tested to determine its magnetic effect to assist the installer in choosing the proper location of the equipment in the aircraft.
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-26a
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 R1A-92-000-000 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.
*DO-160D Section 11 was tested during the basic certification from Midwest
Company.
The ECU R1A-92-000-000 was not affected by the application of fluids.
ENGINE MANUAL E1.01.05
EM-TR-MDC-E1-195
Issue Date: 16.Nov.2018 Engine Control System Seite : 19-27a
General information about DO160 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.
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