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TEMPORARY REVISION EM-TR-MDC-E1-195 Engine E1.01.05 ENGINE MANUAL EM-TR-MDC-E1-195 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 1a 2a 3a 4a 5a 6a 7a 10a 11a-b 12a-b 13a 14a E1.01.05 19 15a 16a-d 17a-b 18a 19a 20a 21a 22a 23a-b 24a 25a 26a 27a Issue Date: 16.Nov.2018 Engine Control System COVERPAGE E1.01.05 ENGINE MANUAL EM-TR-MDC-E1-195 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 Issue Date: 16.Nov.2018 Engine Control System COVERPAGE E1.01.05 ENGINE MANUAL EM-TR-MDC-E1-195 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. Issue Date: 16.Nov.2018 Engine Control System Seite : 19-1a E1.01.05 ENGINE MANUAL EM-TR-MDC-E1-195 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. Issue Date: 16.Nov.2018 Engine Control System Seite : 19-3a E1.01.05 ENGINE MANUAL EM-TR-MDC-E1-195 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. Issue Date: 16.Nov.2018 Engine Control System Seite : 19-3a E1.01.05 ENGINE MANUAL EM-TR-MDC-E1-195 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 --- --- --- 1 A Pull-up 2k2 to Ubatt TX Low side switch --- --- --- 1 A (Error Lamp) Pull-up 2k2 to Ubatt 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] Circuit Breaker Comment typ 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 0,5 (assumed) Installer Installer is responsible for fuse suitable to the alarms *) responsibility respective components /loads which are not Fuel pump **) 5,5 (assumed) Installer part of AE design 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. Issue Date: 16.Nov.2018 Engine Control System Seite : 19-4a E1.01.05 ENGINE MANUAL EM-TR-MDC-E1-195 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. A1 B1 C1 Fig. 14: ECU harness connector Description Manufacturer Part Number Manufacturer Description ECU Harness TE 344111-1 36WAY Receptacle Housing Connector 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 Issue Date: 16.Nov.2018 Engine Control System Seite : 19-5a E1.01.05 ENGINE MANUAL EM-TR-MDC-E1-195 19.1.4.3 ECU Pin Assignment Cable ECU Description Signal Type Description Shielding Diameter PIN (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 MAP1, RCT & A5 GND Sensor GND No AWG 20 IAT GND 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 Low Side Switch Error Lamp Out / B1 TX 2k2 Pull Up to No AWG 20 Communication UBAT 12V Sensor B2 Pickup 2 PWR Sensor Supply Yes AWG 20 Supply 12V Sensor B3 Pickup 1 PWR Sensor Supply Yes AWG 20 Supply B4 IAT Input Signal Sensor Signal No AWG 20 B5 Map 2 Signal Input Signal Sensor Signal Yes AWG 20 5V Sensor B6 Map 1 Power Sensor Supply Yes AWG 20 Supply B7 Map 2 GND GND Sensor GND Yes AWG 20 B8 CAN B High not used for IAE50R-AA Pickup 2 B9 Input Signal Sensor Signal Yes AWG 20 Signal Digital Input 2k2 B10 T3I Instrument +5V No AWG 20 Pull Up to 5V B11 Tacho Drive Low Side Switch Engine speed Out No AWG 20 Low Side Switch B12 Ins Drive 2 2k2 Pull Up to Fuel Consumption Out No AWG 18 UBAT Ignition Coil C1 Low Side Switch Ignition No AWG 16 A (-) C2 Spare Low Side Switch not used for IAE50R-AA 5V Sensor C3 Map 2 PWR Sensor Supply Yes AWG 20 Supply C4 Pickup 2 GND GND Sensor GND Yes AWG 20 Serial Input incl.
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