AuRACLE II 6-Cyl Installation Manual XA-EngAna-AuRII6CylInst Rev. H. AuRACLE II 6-Cylinder Engine Management System Installation Manual - 1 -

Transcription

1 AuRACLE II 6-Cylinder Engine Management System Installation Manual - 1 -

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3 Table of Contents 1 Important Installation/Warranty Information About the AuRACLE Installation Manual Notes Warnings and Cautions Important Pre-Installation Information Product Introduction System Specifications Power Input Requirements Function Approval Definitions DU Environmental Classifications EIU Environmental Classifications System Safety Considerations Functional Hazard Analysis System Safety Assessment Installation Kit Contents Base System Definitions AuRACLE II 6-Cylinder Base System System Operating Parameters System Labels Sensors Carbureted 6-Cyl Lycoming Base Sensor Set ( ) Parts List for EGT Sensor (6 Req.) Parts List for CHT Sensor (6 Req.) CHT Sensor Mounting Hardware Parts List for Oil Temp Sensor (1 Req.) Parts List for OAT Sensor (1 Req.) Parts List for CT Sensor (1 Req.) Parts List for Oil Pressure Sensor (1 Req.) Parts List for Manifold Pressure Sensor (1 Req.) Parts List for Fuel Pressure Sensor (1 Req.) Parts List for Fuel Flow Sensor (1 Req.) Parts List for Current Shunt (1 Req.) Fuel Injected 6-Cyl Lycoming Base Sensor Set ( ) Parts List for EGT Sensor (6 Req.) Parts List for CHT Sensor (6 Req.) CHT Sensor Mounting Hardware Parts List for Oil Temp Sensor (1 Req.) Parts List for OAT Sensor (1 Req.) Parts List for Oil Pressure Sensor (1 Req.) Parts List for Manifold Pressure Sensor (1 Req.) Parts List for Fuel Pressure Sensor (1 Req.) Parts List for Fuel Flow Sensor (1 Req.) Parts List for Current Shunt (1 Req.)

4 6.2.3 Carbureted 6-Cyl Continental Base Sensor Set ( ) Parts List for EGT Sensor (6 Req.) Parts List for CHT Sensor (6 Req.) CHT Sensor Mounting Hardware Parts List for Oil Temp Sensor (1 Req.) Parts List for CT Sensor (1 Req.) Parts List for OAT Sensor (1 Req.) Parts List for Oil Pressure Sensor (1 Req.) Parts List for Manifold Pressure Sensor (1 Req.) Parts List for Fuel Pressure Sensor (1 Req.) Parts List for Fuel Flow Sensor (1 Req.) Parts List for Current Shunt (1 Req.) Fuel Injected 6-Cyl Continental Base Sensor Set ( ) Parts List for EGT Sensor (6 Req.) Parts List for CHT Sensor (6 Req.) CHT Sensor Mounting Hardware Parts List for Oil Temp Sensor (1 Req.) Parts List for OAT Sensor (1 Req.) Parts List for Oil Pressure Sensor (1 Req.) Parts List for Manifold Pressure Sensor (1 Req.) Parts List for Fuel Pressure Sensor (1 Req.) Parts List for Fuel Flow Sensor (1 Req.) Parts List for Current Shunt (1 Req.) Tachometer Option Sensors Parts List for Tachometer Sensor (1 Req.) Parts List for Tachometer Sensor (1 Req.) Pneumatic Instrument Power Option Sensors Parts List for Instrument Pressure Sensor (1 Req.) Parts List for Suction Sensor (1 Req.) Turbo Option Sensors Parts List for TIT Sensor (1 Req.) Parts List for IAT Sensor (1 Req.) Intercooler Option Sensors Parts List for CDT Sensor (1 Req.) Mounting Hardware ( ) DU Mounting Hardware Network Cable Mounting Hardware EIU Mounting Hardware Documentation Installation Instructions Display Unit (DU) Installation Choose THE Proper Installation Location Remove or Relocate Any Interfering Systems Cut-out DU Installation Holes

5 7.1.4 DU Connector Definitions Network Interface Cable Cockpit-Side Determine the Firewall Mounting Hole Position Cutout the Firewall penetration Connect the Cockpit Network Cable Install Cockpit Cable Connect Cockpit Cables Connect the Power Connect to the Lighting Bus Connect the OAT Sensor Connect Alarm Connect GPS Connect Navigation Computer Post Light Requirement Engine Interface Unit (EIU) Installation Attach the 6-Cyl Electronics Enclosure Install the Engine Compartment Network Cable Sensor Installation EIU Sensor Interface Cable J EIU Sensor Interface Cable J Sensor Wiring General Recommendations Thermocouple Wiring General Recommendations Pressure Sensor Mounting General Recommendations Install EGT Sensor Install CHT Sensors Install TIT Sensor(s) (if req.) Carburetor Temperature Sensor (if req.) Install Induction Temperature Sensor (if req.) Install Compressor Discharge Temperature Sensor (if req.) Install Oil Temperature Sensor Install Manifold Absolute Pressure (MAP) Sensor Install Instrument Air Pressure/Vacuum Sensor Install Fuel Pressure Sensor Install RPM Sensor Install Current Shunt Install Fuel Flow Sensor Compute the Total Weight and Moment Changes Load Operational Parameters Aircraft Configuration Verification Operation Verification Instructions for Continued Airworthiness (ICA) Pressurized Aircraft Installation Testing

6 12 Change History Installer COMMENTS

7 1 Important Installation/Warranty Information PLEASE READ THE LIMITED WARRANTY / AGREEMENT. There is information in the Limited Warranty / Agreement that may alter your decision to install and utilize this product. IF YOU DO NOT ACCEPT THE TERMS OF THE LIMITED WARRANTY/ AGREEMENT DO NOT INSTALL AND UTILIZE THE PRODUCT. WARRANTY DEFINITIONS LIABILITY - IT IS AN EXPRESS CONDITION OF SALE THAT LIABILITY IS LIMITED TO THE COST OF THE GOODS PROVED TO BE DEFECTIVE. UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE TO THE CUSTOMER OR TO THIRD-PARTIES FOR LOSS (INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFIT OR DATA), DAMAGE OR INJURY HOWSOEVER ARISING. THE CUSTOMER SHALL INDEMNIFY THE COMPANY IN RESPECT TO ALL DAMAGE OR INJURY OCCURRING TO ANY PERSONAL PROPERTY AND AGAINST ANY ACTIONS AND EXPENSES IN THAT CONNECTION FOR WHICH THE COMPANY MAY BECOME LIABLE IN RESPECT OF THE GOODS SOLD IF THE DAMAGE OR INJURY IS CAUSED BY NEGLIGENCE OF THE CUSTOMER OR HIS SERVANTS OR AGENTS. WARRANTIES - THE COMPANY OFFERS THE CUSTOMER THE BENEFIT OF THE WARRANTY PERIOD AS SHOWN BELOW. NO ADDITIONAL WARRANTIES ARE OFFERED. WARRANTY POLICY XERION AVIONIX, LLC, WARRANTS ALL MANUFACTURED HARDWARE TO BE FREE FROM DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF THREE (3) YEARS FROM THE DATE OF SHIPMENT. XERION AVIONIX, LLC, WARRANTS ALL SUPPLIED SENSORS AND SENDERS TO BE FREE FROM DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD DEFINED BY THE INDIVIDUAL SENSOR MANUFACTURER FROM THE DATE OFSHIPMENT. THIS WARRANTY COVERS REPAIR AND/OR REPLACEMENT, AT OUR OPTION, OF ANY PARTS FOUND TO BE DEFECTIVE, PROVIDED SUCH DEFECTS, IN OUR OPINION ARE DUE TO FAULTY MATERIAL OR WORKMANSHIP AND ARE NOT CAUSED BY TAMPERING OR ABUSE. THE WARRANTY DOES NOT INCLUDE CHARGES FOR REMOVAL, SHIPPING AND REINSTALLATION. ALL WARRANTIES ARE F.O.B. XERION AVIONIX, LLC 5297 Parkside Drive, 306 CANANDAIGUA, NY (585) XERION AVIONIX WILL NOT ACCEPT OR PAY FOR ANY CHARGES FOR WARRANTY WORK PERFORMED OUTSIDE OUR FACTORY WITHOUT PRIOR WRITTEN CONSENT

8 THIS WARRANTY APPLIES ONLY TO PRODUCTS IN NORMAL USE. IT DOES NOT APPLY TO UNITS OR CIRCUIT BOARDS DEFECTIVE DUE TO IMPROPER INSTALLATION, PHYSICAL DAMAGE, TAMPERING, LIGHTNING OR OTHER ELECTRICAL DISCHARGE, UNITS WITH ALTERED SERIAL NUMBERS, OR UNITS REPAIRED BY UNAUTHORIZED PERSONS OR IN VIOLATION OF XERION AVIONIX INSTALLATION PROCEDURES. XERION AVIONIX WARRANTS NO PART OF THE INSTALLATION NOR THE ASSOCIATED COSTS ASSOCIATED WITH THE INSTALLATION. XERION AVIONIX, LLC, ASSUMES NO RESPONSIBILITY FOR ANY CONSEQUENTIAL LOSSES OF ANY NATURE WITH RESPECT TO ANY PRODUCTS OR SERVICES SOLD, RENDERED, OR DELIVERED. THE FOREGOING ARE THE ONLY HARDWARE WARRANTIES FOR THE AuRACLE I & AuRACLE II SYSTEMS, EXPRESSED OR IMPLIED. NO OTHER HARDWARE WARRANTIES EXIST. THE FOREGOING PARAGRAPHS DEFINE AND LIMIT XERION AVIONIX S SOLE RESPONSIBILTY AND LIABILITY AND PURCHASER S SOLE AND EXCLUSIVE REMEDIES RELATED TO THE PRODUCT. FOR FACTORY ASSISTANCE, PLEASE FEEL FREE TO CALL OUR CUSTOMER SERVICE DEPARTMENT FOR ASSISTANCE IN SERVICE OR INSTALLATION. CALL (585) BETWEEN 9:00 AM AND 5:00 PM EASTERN TIME, MONDAY THROUGH FRIDAY. WE DO NOT ACCEPT COLLECT CALLS. PLEASE HAVE THE SERIAL NUMBER OF THE UNIT AVAILABLE WHEN YOU CALL, ALONG WITH AS MANY DETAILS OF THE NATURE OF THE PROBLEM AS POSSIBLE. IF YOU PREFER, YOU MAY ALSO FAX US AT (585) HOURS A DAY. WE WILL RESPOND BY FAX OR TELEPHONE WITHIN ONE BUSINESS DAY OF RECEIVING YOUR FAX. REPAIR OF THE XERION AVIONIX AuRACLE SYSTEM IS PERFORMED AT THE FACTORY. FACTORY SERVICE INCLUDES A COMPLETE CHECKOUT AND RECALIBRATION. THE ONLY COSTS FOR FACTORY REPAIR OF A UNIT STILL UNDER WARRANTY ARE THE SHIPPING CHARGES, UNIT REMOVAL, AND RE- INSTALLATION. PRIOR TO RETURNING A UNIT FOR SERVICE, CALL THE FACTORY AND OBTAIN A RETURN MERCHANDISE AUTHORIZATION (RMA), NUMBER. PLEASE NOTE THAT XERION AVIONIX WILL NOT ACCEPT A UNIT RETURNED TO THE FACTORY WITHOUT AN RMA NUMBER. SECURELY PACK THE UNIT IN A SECURE SHIPPING CARTON, WRITE THE RMA NUMBER ON THE OUTSIDE OF THE CARTON, AND RETURN IT TO THE ADDRESS SHOWN IN ABOVE. INCLUDE YOUR NAME, COMPLETE SHIPPING ADDRESS AND DAYTIME TELEPHONE NUMBER, A COMPLETE DESCRIPTION OF THE PROBLEM, AND THE DESIRED RETURN DATE AND SHIPPING METHOD. IF A SUITABLE FOAM-PACKED CARTON IS NOT AVAILABLE, CONTACT XERION AVIONIX TO ARRANGE FOR PACKAGING MATERIALS. XERION AVIONIX, LLC, WILL NOT BE RESPONSIBLE FOR DAMAGE WHICH OCCURS DUE TO POORLY PACKAGED RETURNS

9 2 About the AuRACLE Installation Manual 2.1 Notes Warnings and Cautions Notes and warnings provide guidance for the use of the AuRACLE. For your own safety, Xerion Avionix strongly suggests that you pay close attention to notes and warnings. Note: Notes provide useful information about how to use the AuRACLE. CAUTION: Cautions denote information that can affect the operation of the system in an adverse way. WARNING: Warnings denote information that will affect the operation of the system in an adverse way and possibly cause damage to the instrument, erroneous readings, or unsafe conditions. 2.2 Important Pre-Installation Information It is possible for any instrument to fail and display inaccurate readings. The ability of this product to detect and display a problem is directly related to proper programming by an approved installer as well as the pilot s interpretation and observation skills. Before starting the installation, make sure that you planned installation will not interfere with the operating of any controls. The installer should use current aircraft standards and practices to install this produce. Refer to the following Advisory Circulars: AC B Inspection and Repair Techniques AC B Alteration Techniques To Whom It May Concern: Xerion Avionix LLC. Holder of STC SA02434NY: grants to the purchaser, of an AuRACLE Engine Management System covered by this Installation Manual, permission to install said system under the above STC. WARNING: This system may only be installed in Part 23 single piston engine aircraft under 6000Lbs. That is those airplanes classified as Class I in AC C. CAUTION: A copy of the AuRACLE Engine Management System Airplane Flight Manual Supplement to the aircraft Pilots Operating Handbook must be kept in the aircraft at all times

10 Note: All graphics contained within this document, including screenshots and other displays, are for reference use only and are subject to change. The graphics contained herein may differ slightly from your actual equipment or display. WARNING: This manual assumes that the reader is an appropriately licensed and authorized installation technician. If you have questions regarding the installation of this system, please contact Xerion Avionix at , prior to installing this product. WARNING: The aircraft battery MUST be disconnected during the installation of the AuRACLE Engine Management System. Any damage that occurs as a result of not disconnecting the battery during installation will NOT be covered by the product Warranty. WARNING: When wiring connections and securing the cable, be sure wiring does not obstruct the aircraft control movement under the instrument panel. This may present a safety hazard and will void your warranty. WARNING: AuRACLE II Systems may be factory configured to support two Current shunt inputs. This dual current sensor configuration is intended for all-electric aircraft installations. It is expected that in the near future many aircraft will not use pneumatic instruments. That is, they will have no vacuum pump. To regain the reliability that the vacuum pump provided a second alternator will be installed. This AuRACLE system option removes the Instrument Air function and replaces it with a current monitor for the second alternator. If an aircraft on which the AuRACLE is to be installed has a pneumatic instrument system, then this AuRACLE option is not approved. This option is only approved on aircraft with two alternators and no pneumatic system

11 3 Product Introduction The AuRACLE Engine Management System provides a graphical representation of all engine instrumentation as well as the precise multi-cylinder engine monitoring of Exhaust Gas Temperature (EGT) and Cylinder Head Temperature (CHT). The AuRACLE is designed to act as the PRIMARY engine instrumentation for your aircraft. The unit SHALL be configured properly to reflect OEM instrumentation scales, exceedance limitations, and warnings. Once configured to your respective airframe and engine combination, the AuRACLE will provide you with the most advanced monitoring available. The AuRACLE is intended to provide primary replacement for the following functions in single piston engine aircraft less than 6000lbs (AC C, class 1): Manifold Pressure RPM Fuel Flow Exhaust Gas Temperature Turbine Inlet Temperature Cylinder Head Temperature Oil Pressure Oil Temperature Instrument Air Pressure/Vacuum Induction Air Temperature Compressor Discharge Temperature Fuel Pressure Outside Air Temperature Amps Volts Tachometer Time Percent Horsepower Actual Horsepower Fuel Computer

12 Note: Consult the original Pilot s Operating Handbook (POH) provided with the aircraft and/or sensors prior to operation. The POH contains information specific to your aircraft and will contain operating limitations applicable to your aircraft. The AuRACLE has been programmed to meet the limits and exceedance requirements matching your original engine instruments. Your STC specific Instrument Marking Report should be referenced. Note: If an AuRACLE System is ordered with the option to measure and display two current readings there is a restriction to the approved installations. Such a system may only be installed if the aircraft does not have a required pneumatic power system for flight instruments. On power up, the system performs a brief hardware self-test. After the system initializes (about a minute after power-on), the Xerion splash page at which point the fuel entry screen is displayed along with the primary instrument page. WARNING: During the power up and screen self-tests, the system will display Wait for data prior to starting the engine. It is strongly recommended that the pilot wait until the hardware and software self-tests are completed prior to engine start

13 Figure 1: Typical System Overview (actual systems may vary)

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15 4 System Specifications The conditions and tests required for TSO approval of this article are minimum performance standards. It is the responsibility of those installing this article either on or within a specific type or class of aircraft to determine that the aircraft installation conditions are within TSO standards. TSO articles must have separate approval for installation in an aircraft. The article may be installed only if performed under 14 CFR Part 43 or the applicable airworthiness requirements 4.1 Power Input Requirements The AuRACLE II System will operate without modification in either 12V or 24V electrical systems. The worst case power draw of the system is 2.5A (during cold cranking) 4.2 Function Approval Definitions Parameter TSO Class Range EGT TSO-C43c IIa o F CHT TSO-C43c IIa o F TIT TSO-C43c IIa o F Oil T TSO-C43c IIIa +/-300 o F OAT TSO-C43c IIIa +/-100 o C IAT TSO-C43c IIIa +/-200 o F CDT TSO-C43c IIIa +/-300 o F CT TSO-C43c IIIa +/-200 o F Fuel Flow TSO-C44b N/A 0 60 GPH MAP TSO-C45a N/A 0 60 in-hg Oil P TSO-C47 N/A PSIG IP TSO-C47 N/A 0 20 in-hg FP TSO-C47 N/A 0 35 PSIG RPM TSO-C49b N/A RPM Display TSO-C113 N/A N/A Amps N/A N/A +/- 75 Amps Volts N/A N/A 0 40 Volts Horsepower N/A N/A HP % Horsepower N/A N/A 0-120% Fuel Computer - Load N/A N/A Gal Tach Time N/A N/A 0 10,000 Hrs

16 4.3 DU Environmental Classifications DO-160D Test (Section) Category Comments Temp. & Alt. (4) B1 Storage Temp High: +85C Short Term High Temp: +70C Op High Temp +55C Op Low Temp: -20C Storage Temp Low: -55C Temp Var (5) Humidity (6) Op-Shock & Crash (7) Vibration (8) Explosion Proofness (9) Waterproofness (10) Fluids Susceptibility (11) Sand & Dust (12) Fungus Resistance (13) Salt Spray (14) Magnetic Effect (15) Power Input (16) Voltage Spike (17) Audio Freq Cond Suscept Pwr In (18) Induced Sig Suscept (19) RF Susceptibility (20) RF Emission (21) Lightning Induced Trans (22) Lightning Direct Effects (23) Icing (24) ESD (25) C A B S, Curve M X X X X F X A B B B AB BB L A2C2 X X A

17 4.4 EIU Environmental Classifications DO-160D Test (Section) Category Comments Temp. & Alt. (4) B3 Storage Temp High: +125C Short Term High Temp: +125C Op High Temp +100C Op Low Temp: -45C Storage Temp Low: -55C Temp Var (5) A Humidity (6) C Op-Shock & Crash (7) A Vibration (8) S, Curve L Explosion Proofness (9) H Waterproofness (10) W Fluids Susceptibility (11) F Spray Test. Fuels and Lubricating Oils Only Sand & Dust (12) D Fungus Resistance (13) F Salt Spray (14) X Magnetic Effect (15) A Power Input (16) B Voltage Spike (17) B Audio Freq Cond B Suscept Pwr In (18) Induced Sig Suscept AB (19) RF Susceptibility (20) BB RF Emission (21) L Lightning Induced Trans A2C2 (22) Lightning Direct Effects X (23) Icing (24) A ESD (25) A

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19 5 System Safety Considerations 5.1 Functional Hazard Analysis The following Functional Hazard Assessment is based on the guidelines presented in AC C, figure 2 and Appendix A. The intended installation platforms for the Xerion Engine Management System are single-engine piston powered airplanes (normally aspirated or turbocharged/turbonormalized). That is those airplanes classified as Class I in AC C. Hazard Classification of Failure Condition Required Quantitative Probability Software Assurance Level Calculated Quantitative Probability Total Loss of Displayed Information Major <10-4 D 3.3 x 10-5 Total Loss of CHT Information Minor <10-3 D 1.7 x 10-8 Display of misleading CHT Information Minor <10-3 D 6.5 x 10-6 Loss of 1 CHT channel s Information Minor <10-3 D 6.0 x 10-6 Display of misleading 1 channel of CHT Minor <10-3 D 4.0 x 10-7 Information Total Loss of EGT Information Minor <10-3 D 1.7 x 10 5 Display of misleading EGT Information Minor <10-3 D 6.5 x 10-6 Loss of 1 EGT channel s Information Minor <10-3 D 1.6 x 10-5 Display of misleading 1 channel of EGT Minor <10-3 D 4.0 x 10-7 Information Total Loss of Oil Pressure Information Minor <10-3 D 2.3 x 10-8 Display of misleading Oil Pressure Information Minor <10-3 D 3.6 x 10-7 Total Loss of Oil Temperature Information Minor <10-3 D 1.0 x 10-6 Display of misleading Oil Temperature Minor <10-3 D 1.5 x 10-6 Information Total Loss of CT Information Minor <10-3 D 4.0 x 10-6 Display of misleading CT Information Minor <10-3 D 3.0 x 10-6 Total Loss of CDT Information Minor 1 <10-3 D 4.0 x 10-6 Display of misleading CDT Information Minor 1 <10-3 D 3.0 x 10-6 Total Loss of RPM Information Minor <10-3 D 2.0 x 10-6 Display of misleading RPM Information Minor <10-3 D 2.5 x 10-6 Total Loss of MAP Information Minor <10-3 D 2.3 x 10-8 Display of misleading MAP Information Minor <10-3 D 3.6 x 10-7 Total Loss of TIT Information Minor 1 <10-3 D 1.4 x 10-5 Display of misleading TIT Information Major 1 <10-4 C 1.3 x 10-5 Total Loss of FF Information Minor <10-3 D 2.0 x 10-6 Display of misleading FF Information Major <10-4 C 2.5 x 10-6 Total Loss of FP Information Minor <10-3 D 2.3 x 10-6 Display of misleading FP Information Minor <10-3 D 3.6 x 10-7 Total Loss of FL Information Minor <10-3 D 2.0 x 10-8 Display of misleading FL Information Minor <10-3 D 2.5 x 10-6 Total Loss of OAT Information Minor <10-3 D 4.0 x 10-6 Display of misleading OAT Information Minor <10-3 D 3.0 x 10-6 Total Loss of IAT Information Minor 1 <10-3 D 4.0 x 10-6 Display of misleading IAT Information Minor 1 <10-3 D 3.0 x 10-6 Total Loss of IP Information Minor <10-3 D 2.3 x

20 Hazard Classification of Failure Condition Required Quantitative Probability Software Assurance Level Calculated Quantitative Probability Display of misleading IP Information Major <10-4 C 3.6 x 10-7 Total Loss of AMP Information Minor <10-3 D 3.1 x 10-6 Display of misleading AMP Information Major <10-4 C 3.3 x 10-7 Total Loss of VLT Information Minor <10-3 D 6.5 x 10-8 Display of misleading VLT Information Major <10-4 C 3.6 x 10-7 Total Loss of Computed Fuel Management Data Minor <10-3 D 2.0 x 10-6 Display of misleading Computed Fuel Minor <10-3 D 2.5 x 10-6 Management Data 1 indicates item is not from AC C, they result from Xerion Analysis 5.2 System Safety Assessment The table above provides calculated probabilities of the occurrence of Functional Hazards (last column). Sensor Reliabilities estimated as: Pressure Sensors 5 x 10-8 (50.7 FITS) Low Temperature Thermocouples 1 x 10-6 High Temperature Thermocouples 1 x 10-5 Current Shunt 1 x 10-8 RPM Sensor 1 x 10-7 FF Sensor 1 x

21 6 Installation Kit Contents The following describes the parts of the AuRACLE system for installation into this aircraft. 6.1 Base System Definitions AuRACLE II 6-Cylinder Base System The system components are defined in XA SCI as Part # TAB-X. These items are covered by the Xerion TSO of this system. This consists of: TAB-X TAB-X TAB-X TAB-X DU EIU DU to Bulkhead Cable Bulkhead to EIU Cable Cockpit Cable J1-1 Cable TAB-X or TAB-X J1-2 Cable USB Flash Drive USB Dust Cover Trident Dust Cap System Operating Parameters Operating Parameters file must be obtained for the particular installation platform. This file must be loaded onto the USB Flash Drive included with the TAB-1. This file must be loaded into the AuRACLE after installation and before the first engine start (see the AuRACLE Pilot s Guide for detailed instructions) System Labels The Label provided by Xerion must be placed on the DU. The following is an example of this label. The System Part# is the document number for the System Configuration Index; the revision is defined as the revision of the System Configuration Index. The Op Parameters File Part# is the

22 document number for the Instrument Marking Report; the revision is defined as the revision of the Instrument Marking Report. The following are examples of the system labels: 6.2 Sensors Note: not all sensors are included in all installations. The following lists include typical sensors. To determine the exact contents of any particular installation see the system packing list Carbureted 6-Cyl Lycoming Base Sensor Set ( ) Parts List for EGT Sensor (6 Req.) (1) EGT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N Parts List for CHT Sensor (6 Req.) (1) Bayonet CHT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N

23 (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N CHT Sensor Mounting Hardware (6) Bayonet to Thread Adapters Xerion P/N Parts List for Oil Temp Sensor (1 Req.) (1) OT Sensor Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for OAT Sensor (1 Req.) (1) OAT Sensor Xerion P/N (4) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for CT Sensor (1 Req.) (1) CT Sensor Xerion P/N (4) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for Oil Pressure Sensor (1 Req.) (1) Oil Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Manifold Pressure Sensor (1 Req.) (1) Manifold Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied

24 Parts List for Fuel Pressure Sensor (1 Req.) (1) Fuel Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Flow Sensor (1 Req.) (1) Fuel Flow Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Current Shunt (1 Req.) (1) Current Shunt P/N Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 8-32 X 1 Xerion P/N (2) 8-32 Nyloc Nuts Xerion P/N (4) #8 Flat Washers Xerion P/N Fuel Injected 6-Cyl Lycoming Base Sensor Set ( ) Parts List for EGT Sensor (6 Req.) (1) EGT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N Parts List for CHT Sensor (6 Req.) (1) Bayonet CHT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N CHT Sensor Mounting Hardware (6) Bayonet to Thread Adapters Xerion P/N Parts List for Oil Temp Sensor (1 Req.) (1) OT Sensor Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N

25 Parts List for OAT Sensor (1 Req.) (1) OAT Sensor Xerion P/N (4) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for Oil Pressure Sensor (1 Req.) (1) Oil Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Manifold Pressure Sensor (1 Req.) (1) Manifold Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Pressure Sensor (1 Req.) (1) Fuel Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Flow Sensor (1 Req.) (1) Fuel Flow Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Current Shunt (1 Req.) (1) Current Shunt P/N Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 8-32 X 1 Xerion P/N (2) 8-32 Nyloc Nuts Xerion P/N (4) #8 Flat Washers Xerion P/N Carbureted 6-Cyl Continental Base Sensor Set ( ) Parts List for EGT Sensor (6 Req.) (1) EGT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N

26 (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N Parts List for CHT Sensor (6 Req.) (1) Bayonet CHT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N CHT Sensor Mounting Hardware (6) Bayonet to Thread Adapters Xerion P/N Parts List for Oil Temp Sensor (1 Req.) (1) OT Sensor Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for CT Sensor (1 Req.) (1) CT Sensor Xerion P/N (4) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for OAT Sensor (1 Req.) (1) OAT Sensor Xerion P/N (4) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for Oil Pressure Sensor (1 Req.) (1) Oil Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied

27 Parts List for Manifold Pressure Sensor (1 Req.) (1) Manifold Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Pressure Sensor (1 Req.) (1) Fuel Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Flow Sensor (1 Req.) (1) Fuel Flow Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Current Shunt (1 Req.) (1) Current Shunt P/N Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 8-32 X 1 Xerion P/N (2) 8-32 Nyloc Nuts Xerion P/N (4) #8 Flat Washers Xerion P/N Fuel Injected 6-Cyl Continental Base Sensor Set ( ) Parts List for EGT Sensor (6 Req.) (1) EGT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N Parts List for CHT Sensor (6 Req.) (1) Bayonet CHT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N CHT Sensor Mounting Hardware (6) Bayonet to Thread Adapters Xerion P/N

28 Parts List for Oil Temp Sensor (1 Req.) (1) OT Sensor Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for OAT Sensor (1 Req.) (1) OAT Sensor Xerion P/N (4) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for Oil Pressure Sensor (1 Req.) (1) Oil Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Manifold Pressure Sensor (1 Req.) (1) Manifold Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Pressure Sensor (1 Req.) (1) Fuel Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Flow Sensor (1 Req.) (1) Fuel Flow Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Current Shunt (1 Req.) (1) Current Shunt P/N Xerion P/N (2) Ring Terminals Xerion P/N

29 (2) Screws 8-32 X 1 Xerion P/N (2) 8-32 Nyloc Nuts Xerion P/N (4) #8 Flat Washers Xerion P/N Tachometer Option Sensors Note: One or the other of the following sensor sets will be included in the sensor kit Parts List for Tachometer Sensor (1 Req.) (1) RPM Hall Effect Sensor (Bendix Mag.) Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Parts List for Tachometer Sensor (1 Req.) (1) RPM Hall Effect Sensor (Slick Mag.) Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Pneumatic Instrument Power Option Sensors Note: One or the other of the following sensor sets will be included in the sensor kit Parts List for Instrument Pressure Sensor (1 Req.) (1) Instrument Pressure Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Suction Sensor (1 Req.) (1) Suction Sensor Xerion P/N (3) Butt Splices Xerion P/N (1) Protective Sleeve Xerion P/N (2) Tie Wraps Xerion P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Turbo Option Sensors Parts List for TIT Sensor (1 Req.) (1) EGT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N Parts List for IAT Sensor (1 Req.) (1) IAT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N

30 (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N Intercooler Option Sensors Parts List for CDT Sensor (1 Req.) (1) CDT Sensor (Protective Sleeve & Tie Wraps) Xerion P/N (2) Ring Terminals Xerion P/N (2) Screws 6-32 X 3/16 Xerion P/N (2) 6-32 Nuts Xerion P/N (2) #6 Star Washers Xerion P/N Mounting Hardware ( ) DU Mounting Hardware (1) Installation Template Xerion P/N (4) Socket Head Cap Screws 6-32 X 3/8 Xerion P/N (4) #6 Split Lock Washers Xerion P/N Network Cable Mounting Hardware (4) Screws 6-32 X 1/2 Xerion P/N (4) 6-32 Nyloc Nuts Xerion P/N (1) Trident Gasket Shell 16 Xerion P/N EIU Mounting Hardware (4) Mounting Spacers Xerion P/N (4) 8-32 X 1 Pan Head Machine Screws Xerion P/N (4) 8-32 Nyloc Nuts Xerion P/N (8) #8 Locking Washers Xerion P/N Documentation (1) AuRACLE Pilot s Guide Xerion P/N (1) AuRACLE Generic AFMS Xerion P/N (1) AuRACLE II 6-Cyl Installation Manual Xerion P/N

31 7 Installation Instructions 7.1 Display Unit (DU) Installation Choose THE Proper Installation Location The DU is best located within the natural scan and easy reach of the pilot. The recommended mounting location is defined as an imaginary box defined with respect to the Primary Flight Instrument T and the control wheel axle. The recommended optimal mounting location is within a box (see Figure 2: Suggested AuRACLE Mounting Area) as defined below: HORIZONTAL ORIENTATION: The centerline of the AuRACLE LCD display may be mounted from the left side of the Instrument panel to a maximum of 21 to the right of the vertical centerline (Control Wheel center of rotation). The idea is mount the centerline of the AuRACLE LCD display no more than 21 to the right of the Pilot s centerline; so that the Pilot may easily read and interact with the AuRACLE. VERTICAL ORIENTATION: The AuRACLE may be mounted within +/- 7 from the horizontal centerline of the Primary Flight Instrument T. The installer should insure that the AuRACLE display is not obstructed by either the glare shield or the control wheel. Note: Any installation that requires that the AuRACLE be mounted outside of the Box will require FAA involvement for installation approval

32 Figure 2: Suggested AuRACLE Mounting Area Remove or Relocate Any Interfering Systems The following is a picture of a typical instrument panel (A36) prior to installation

33 Figure 3: Typical Panel Prior To Installation 1. Remove the Instruments in the chosen installation area that are replaced by the AuRACLE (For the example shown above: Tachometer, Fuel Flow, MAP. For a list of possible replacements see section 4.2).This will provide most, if not all, of the space required to install the AuRACLE. Remove or relocate other instruments that will interfere with the following steps. In the example above these Include: the two Fuel Gages (center left and middle), the JPI Engine Analyzer and associated switch (center right), the Auto Pilot (square unit lower left, switch, and the lower center oblong unit), and the Stormscope (bottom of instrument panel next to ADF). This location is for reference only. The installing A&P and IA should decide that where the installation is to occur does not conflict with the viewing angle suggestions listed above and is consistent with all applicable Advisory Circulars. Note: This installation does not allow the AuRACLE Engine Management System to replace the approved fuel quantity indicating system

34 Note: Any appliances that are installed under the original Type Certificate (TC) that requires relocation should be relocated in accordance with the guidance provided in AC B, Section 15.4 (presented below). Special care should be exercised to insure that proper pilot visibility of displays and pilot access to controls in not interfered with, with respect to relocated instruments and non-relocated instruments. Note: Any appliances that are installed under a Supplemental Type Certificate (STC) that requires relocation should be relocated in accordance with the original STC installation instructions or in accordance with the guidance provided in AC B, Section 15.4 (presented below). Special care should be exercised to insure that proper pilot visibility of displays and pilot access to controls in not interfered with, with respect to relocated instruments and non-relocated instruments. Excerpt from AC B 15.4 Recommended Location for Displaying Information Table 1 contains the recommended location for displaying information intended for new panel layout with integrated electronic displays; however, these guidelines should be followed for other installations as practicable. Deviations beyond these limits may be approved for individual flight instruments depending on the combination of factors listed in section These deviations need a display installation evaluation. It may not be practicable for retrofit installations with new electronic displays, such as with ATC, STC, and field approvals, to comply with the values in the table. This is due to limitations in the systems and incompatible technologies between the aircraft and the system being added. In such cases, for any given item, the angular deviations should not increase from what was originally found to be acceptable, and the display characteristics should be at least as good as the original display. For retrofit installations, it may be acceptable for installations to fall outside the recommended data in Table 1. These deviations may need an evaluation by the certification authority. Factors to consider during this evaluation include the distinguish ability, attention-getting quality, readability, etc. The field-of-view angles should be applied for installation approvals where a design eye reference point exists. For installation approvals where no design eye reference point is defined, the linear panel distances from center in Table 1 should be used. Data Recommended Field-of-View FOV, Deg from Pilot View Centerline (NOTE 1) Approx. Distance(inches) From Reference Center Line (NOTE 1) PFI Basic T Electronic or Mechanical 4 (NOTE 2) 2 (NOTE 2)

35 Navigation Course Error Data (HSI, 15 8 CDI, FD) Autopilot and /Flight Director Modes 15 8 Navigation Source Annunciation 15 (NOTE 3) 8 (NOTE 3) System Warnings and Cautions- 15 (NOTE 4) 8 (NOTE 4) Including failure annunciation Required Powerplant Advisories Annunciations Standby Instruments 35 (NOTE 5) 21 (NOTE 5) Reversionary Display for PFI Electronic Map Display that is not used to replace the CDI/HSI/FD 35 (NOTE 6) 21 (NOTE 6) NOTE 1. The FOV angles and Approximate Distance from Center Reference Line, based on a viewing distance of 30 inches from the panel, are defined as acceptable angles and distance to each data source from the center of basic T, or pilot view centerline. Distances are measured center-to-center of the display in question, measured horizontally. Vertical placement in the panel can be from just below the basic T to the glare shield. NOTE 2. Display PFI as close to the center of reference as possible. NOTE 3. The navigation source annunciation should be on or near the affected display and should appear on the same side of the basic T as the affected display. The guidelines for the proximity to the affected display depend on the size, color, and distinguishing characteristics of the source annunciation. NOTE 4. Warnings and cautions can be presented within 35 degrees if they are associated with a unique aural tone or a master warning/caution light that is within 15 degrees. The warnings and cautions should be in a consistent location, such as on an annunciator panel. If an aural tone is used, it should be readily distinguishable from all other cockpit sounds and provide unambiguous information to direct the pilot s attention to a visual indication of the condition. Consider the number of aural alerts. NOTE 5. Install the standby instruments as close as practicable to the PFI Cut-out DU Installation Holes If the panel has too many holes for a clean installation, it is recommended that an Aluminum overlay panel be constructed and installed (4 to screws) over the original instrument panel and the AuRACLE DU be installed into this overlay panel. The photo below shows a typical overlay panel type installation. Note: relocated Fuel Gages

36 Figure 4: Overlay Panel Type Installation 1. Once the general site for the AuRACLE DU is determined, a small hole is drilled in the instrument panel in the approximate center of the large hole in the template. A screw and fender washer is then used to hold the template, through hole E, in place against the instrument panel. 2. It is now possible to fine tune the position of the template. Once the final position is determined tighten the mounting screw to firmly secure the installation template. 3. Using the template holes as a guide, drill all eight (8) holes C and D using the respective specified sized drill (see Figure 5: Installation Template). 4. Connect the holes D with straight-lines and cut-out the mounting hole accordingly. File as required. 5. Install the DU in the Instrument panel using the four supplied 6-32 Socket Head Cap Screws ( ) and split lock washers ( )

37 Figure 5: Installation Template

38 Figure 6: Display Unit Cutout Dimensions

39 7.1.4 DU Connector Definitions P1 P2 P3 Figure 7: Connector Definition Network Interface Cable Cockpit-Side CAUTION: The AuRACLE II Network Cable is pre-manufactured for you and requires no modifications, crimping, or stripping. Please do not disassemble the cable for any reason. This will void your warranty and the ability to install the system in a certificated aircraft as the integrity of the strain-relief and sealing mechanisms may be compromised. Note: If this installation is in a pressurized aircraft see section 11 for additional instructions

40 Figure 8: Cockpit Network Cable Pin Function Pin # CAN A + A CAN A - B CAN B + C CAN B - D Filtered Aircraft PWR S RPM LED + (Left Engine) E RPM LED - (Left Engine) F OP LED + (Left Engine) G OP LED - (Left Engine) H AMP LED + (Left Engine) J AMP LED - (Left Engine) K VAC LED + (Left Engine) L VAC LED - (Left Engine) U Right Engine Select (Active Low) N Left Engine Select (Active Low) P Filtered Aircraft PWR RTN T Network Reset + V Network Reset - R Cable Shield Figure 9: Cockpit Network Cable Connector Pin Definition

41 7.1.6 Determine the Firewall Mounting Hole Position Determine where the firewall penetration will be. This should be chosen so that: The cockpit side network cable can be routed from the DU to the cockpit side of the firewall without interfering with any aircraft systems (especially the control mechanisms) The penetration will not interfere with anything mounted on the engine side of the firewall The penetration will not interfere with the proposed mounting location of the Engine Interface Unit (EIU) The engine side network cable can be routed from the EIU to the engine side of the firewall without interfering with any aircraft systems Note: For pressurized models (Cessna P210 and Piper PA-46) See Section 11 for specific installation instructions and penetration locations. Figure 10: EIU & Cable Typical Installation

42 Figure 11: Firewall Penetration Dimensions Cutout the Firewall penetration 1. Cut Holes in the firewall in the approximate position shown in the photo above. The dimensions are as shown in the drawing above. Insure that the area on the other side of the firewall is clear before making any cuts. 2. Slip the gasket provided over the connector. 3. Insert the metal connector end into the firewall from the cockpit side. 4. Secure with the four 6-32 screws and #6 nyloc nuts Connect the Cockpit Network Cable 1. Connect the network cable to the P2 connector on the back of the DU. 2. Insure that there is a dust cover over the DU P3 Connector. If not do not power up the unit until one is obtained from Xerion Install Cockpit Cable Note: The AuRACLE II Cockpit Cable is pre-manufactured for you with labeled flying leads for each of the respective connections. Modifications for length can be made at the installer s discretion

43 Figure 12: DU Cockpit Cable Pin Function Pin # Wire Label Power A 2-Conductor #1 White Power Power GND B 2-Conductor #1 White/Blue Power Lighting Bus C 1-Conductor #1 White Lighting Bus Fuel Data (RS-232 Out) D 2-Conductor #2 White Fuel Data GPS Data (RS-232 IN) E 2-Conductor #3 White GPS Data RS-232 GND F 2-Conductor #2 White/Blue Fuel Data RS-232 GND G 2-Conductor #3 White/Blue GPS Data OAT + (Yellow) H Type K #1 Yellow OAT OAT (Red) J Type K #1 Red OAT NC K Case GND L 1-Conductor #1 Green Case GND Alarm (Sink to GND) M 1-Conductor #2 White Alarm (GND)

44 Figure 13: Cockpit Cable Connector Pin Definition Connect Cockpit Cables WARNING: When wiring connections and securing the cable, be sure wiring does not obstruct the aircraft control movement under the instrument panel Connect the Power WARNING: This system is designed to be connected DIRECTLY to the aircraft MASTER power bus NOT the avionics bus. The AuRACLE system must have power applied and be completely though its power-on sequence and self-tests prior to engine start. The AuRACLE automatically accommodates both 12 and 24-volt electrical systems. 1. Using the 2-Conductor #1 Cable from the P1 connector, connect the Power lead (WHITE) to a separate 5-amp circuit breaker connected to the MASTER power bus. 2. Using the 2-Conductor #1 Cable from the P1 connector, connect the Power Ground lead (WHITE/BLUE) to an Electrically Clean Ground. 3. Connect the Case Ground wire (GREEN) to the airframe as near the DU as is possible Connect to the Lighting Bus The AuRACLE automatically adjusts the LCD screen back-lighting based on the monitored Lighting Bus voltage. 1. Using the 1-Conductor #1 Cable from the P1 connector harness, connect the Lighting Bus lead (WHITE) to the Cockpit Lighting Bus Connect the OAT Sensor 1. Remove the existing OAT thermometer. Locate the OAT sensor in the existing OAT location. 2. Attach the sensor using the supplied hardware. 3. Identify the proper wire in the harness. 4. Cut the extension wires to length. Strip the harness wires and crimp on Ring connectors. 5. Slip the insulating sleeve on the wire. 6. The transducer wires are now connected to the cockpit harness. Be sure to connect wires YELLOW to Yellow and RED to RED with 6-32 Screws, Nuts and Toothed (star) Washers. Place the star washer BETWEEN the ring terminals, not under the nut. If there is any doubt about the color of the wire; the RED wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic

45 7. Slide the protective sleeve over the electrical connections and secure in place Connect Alarm The AuRACLE is supplied with an ALARM connection. This is actually an input which will sink (connect) to GROUND when the alarm is activated. The connection can be wired as the ground connection of a status light or audible annunciator. Note: the other end of the device to be activated must be connected to power; the AuRACLE provides a current path to ground not power. This supports WIRED-OR type connections. 1. Connect the 1-Conductor #1 Cable from the P1 connector harness connections labeled ALARM (WHITE) to the device to be actuated (Cockpit Alarm, Master Cautionary Light) ground side. Alarm Connection limitations are as follows: Voltage: 32 Volts Current: 250 ma (at 32V) Connect GPS Contact Xerion for GPS System Specific installation instructions Connect Navigation Computer Contact Xerion for Navigation Computer System Specific installation instructions Post Light Requirement The installing A&P shall determine if the existing instrument panel lighting is sufficient to illuminate the legends associated with the pushbutton and the knob on the AuRACLE bezel. If the illumination is insufficient the A&P shall install a post light in a fashion that will properly illuminate these legends and controls

46

47 7.2 Engine Interface Unit (EIU) Installation Attach the 6-Cyl Electronics Enclosure P1 J1-2 J1-1 Figure 14: EIU Connector Definitions Note: The AuRACLE II EIU should not be mounted with the J1-1 and J1-2 connectors pointing UP. This may compromise the units sealed connectors as fluids may pool. The heat-sinks referenced below are not used or present on the AuRACLE II EIU. Note: If this installation is in a pressurized aircraft see section 11 for additional instructions. 1. Determine the proper location for mounting the EIU. Be sure that you will have access to the mounting hardware on the cockpit side of the Firewall and that provides access to the connectors for wiring. 2. Drill mounting Holes A on the firewall using the Installation Template (see Figure 5: Installation Template). 3. The EIU should be mounted using #8-32 structural screws and flat washers with nyloc nuts. The spacers ( ) should be installed between the feet of the EIU and the firewall if it is necessary to avoid contact with the strengthening ribs. 4. Insure Mounting screws are tightened snugly. Do not over-tighten. The following picture shows the EIU mounted on the Firewall and the Network Cable and Firewall penetration

48 Figure 15: EIU & Network Cable Installation Install the Engine Compartment Network Cable Note: The AuRACLE II Network cable is pre-manufactured for you and requires no modifications, crimping, or stripping. Please do not disassemble the cable for any reason. This will void your warranty and the ability to install the system in a certificated aircraft as the integrity of the strainrelief and sealing mechanisms may be compromised

49 Figure 16: Engine Compartment Network Cable Pin Function Pin # CAN A + A CAN A - B CAN B + C CAN B - D Filtered Aircraft PWR S RPM LED + (Left Engine) E RPM LED - (Left Engine) F OP LED + (Left Engine) G OP LED - (Left Engine) H AMP LED + (Left Engine) J AMP LED - (Left Engine) K VAC LED + (Left Engine) L VAC LED - (Left Engine) U Right Engine Select (Active Low) N Left Engine Select (Active Low) P Filtered Aircraft PWR RTN T Network Reset + V Network Reset - R Cable Shield Figure 17: Engine Compartment Network Cable Connector Pin Definition

50 1. Route the pre-fabricated Network Interface cable from the firewall to the P1 connector on the EIU. Insure connectors are fully inserted and attachment rings are fully engaged. 7.3 Sensor Installation EIU Sensor Interface Cable J1-2 Note: The AuRACLE II EIU Sensor Interface Cable J1-2, 6-Cylinder cable is pre-manufactured for you with labeled flying leads for each of the respective connections. Modifications for length can be made at the installer s discretion. DO NOT attempt to remove or add additional wire connections to the connector. This will compromise the integrity of the connector and will void your warranty preventing legal installation in certificated aircraft as the integrity of the connector seal can no longer be guaranteed. Note: This connector is keyed, insure you are inserting it in the proper position and in the proper orientation. Failure to perform this insertion properly will result in damage to the EIU

51 Figure 18: EIU J1-2 Sensor Cable Pin Function Pin # Wire Label EGT Cyl #6 + L-1 Type K #1 Yellow EGT 6 (Yellow) EGT Cyl #6 - (Red) L-2 Type K #1 Red EGT 6 NC L-3 Insert Sealing Plug Chassis GND M-1 Single Cond. #1 Green GND Chassis GND M-2 Single Cond. #1 Green GND NC M-3 Insert Sealing Plug TIT + (Yellow) N-1 Type K #2 Yellow TIT TIT - (Red) N-2 Type K #2 Red TIT OT + (Yellow) N-3 Type K #3 Yellow OT CT (Red) P-1 Type K #4 Red CT CT + (Yellow) P-2 Type K #4 Yellow CT OT (Red) P-3 Type K #3 Red OT CHT Cyl #1 + (White) R-1 Type J #1 White CHT 1 NC R-2 Insert Sealing Plug NC R-3 Insert Sealing Plug CHT Cyl #2 - (Red) S-1 Type J #2 Red CHT 2 CHT Cyl #2 + (White) S-2 Type J #2 White CHT 2 CHT Cyl #1 - (Red) S-3 Type J #1 Red CHT 1 CHT Cyl #3 + (White) T-1 Type J #3 White CHT 3 CHT Cyl #3 - (Red) T-2 Type J #3 Red CHT 3 CHT Cyl #4 + (White) T-3 Type J #4 White CHT 4 CHT Cyl #5 - (Red) W-1 Type J #5 Red CHT 5 CHT Cyl #5 + (White) W-2 Type J #5 White CHT 5 CHT Cyl #4 - (Red) W-3 Type J #4 Red CHT 4 CHT Cyl #6 + (White) X-1 Type J #6 White CHT 6 CHT Cyl #6 - (Red) X-2 Type J #6 Red CHT 6 CDT + (Yellow) X-3 TAB-1 Insert Sealing Plug CDT TAB-2 Type K #5 Yellow TAB-3 Type K #5 Yellow NC Y-1 Insert Sealing Plug NC Y-2 Insert Sealing Plug CDT - (Red) Y-3 TAB-1 Sealing Plug TAB-2 Type K #5 Red TAB-3 Type K #5 Red CDT Figure 19: EIU Sensor Interface Cable J1-2, Connector Pin Definition

52 7.3.2 EIU Sensor Interface Cable J1-1 Note: The AuRACLE II EIU Sensor Interface Cable J1-1, 6-Cylinder cable is pre-manufactured for you with labeled flying leads for each of the respective connections. Modifications for length can be made at the installer s discretion. DO NOT attempt to remove or add additional wire connections to the connector. This will compromise the integrity of the connector and will void your warranty preventing legal installation in certificated aircraft as the integrity of the connector seal can no longer be guaranteed. Note: This connector is keyed, insure you are inserting it in the proper position and in the proper orientation. Failure to perform this insertion properly will result in damage to the EIU. Figure 20: EIU J1-1 Sensor Cable

53 Pin Function Pin # Wire Label RPM GND A-1 3-Conductor #1 White/Blue RPM AMP - A-2 2-Conductor #1 White/Blue AMP AMP + A-3 2-Conductor #1 White AMP RPM Signal B-1 3-Conductor #1 White RPM RPM Power B-2 3-Conductor #1 White/Orange RPM FF GND B-3 3-Conductor #2 White/Blue FF FF Signal C-1 3-Conductor #2 White FF FF Power C-2 3-Conductor #2 White/Orange FF OP GND C-3 3-Conductor #3 White/Blue OP OP Signal D-1 3-Conductor #3 White OP OP Power D-2 3-Conductor #3 White/Orange OP MAP GND D-3 3-Conductor #4 White/Blue MAP MAP Signal E-1 3-Conductor #4 White MAP MAP Power E-2 3-Conductor #4 White/Orange MAP VAC GND E-3 3-Conductor #5 White/Blue VAC VAC Signal F-1 3-Conductor #5 White VAC VAC Power F-2 3-Conductor #5 White/Orange VAC FP GND F-3 3-Conductor #6 White/Blue FP FP Signal G-1 3-Conductor #6 White FP FP Power G-2 3-Conductor #6 White/Orange FP EGT Cyl #1 + (Yellow) G-3 Type K #1 Yellow EGT 1 EGT Cyl #2 - (Red) H-1 Type K #2 Red EGT 2 EGT Cyl #2 + (Yellow) H-2 Type K #2 Yellow EGT 2 EGT Cyl #1 - (Red) H-3 Type K #1 Red EGT 1 EGT Cyl #3 + (Yellow) J-1 Type K #3 Yellow EGT 3 EGT Cyl #3 - (Red) J-2 Type K #3 Red EGT 3 EGT Cyl #4 + (Yellow) J-3 Type K #4 Yellow EGT 4 EGT Cyl #5 - (Red) K-1 Type K #5 Red EGT 5 EGT Cyl #5 + (Yellow) K-2 Type K #5 Yellow EGT 5 EGT Cyl #4 - (Red) K-3 Type K #4 Red EGT 4 Figure 21: EIU Sensor Interface Cable J1-1 Connector Pin Definitions Sensor Wiring General Recommendations ALL sensor wiring should be routed away from high temperature areas ALL sensor wiring should NOT be routed with ignition, alternator, or other high-current carrying connections. When the installation is complete, all wires should be secured and carefully checked for interference, chaffing, etc. Use best practice wiring techniques

54 Note: If any sensors are not installed. The associated wire may be cut short. In any case, insulate individual conductors so that they do not short to each other or anything else Thermocouple Wiring General Recommendations When cutting the pair of leads to the proper length to connect to the sensors, leave enough slack in the wiring so that sensors may be interchanged to an adjacent cylinder if necessary for trouble-shooting and servicing. Thermocouple wire length is not critical and should be trimmed to any length as required for a clean installation. The Temperature sensor must be wired with the correct polarity. The temperature sensor connects to its temperature indicator with thermocouple wire supplied. Strip the wires as shown below observing color-coding. Terminate each wire with a crimp-on ring terminal. The ring terminals may be crimped with a service-type tool, however AMP part number crimp tool is recommended. Verify the quality of each crimp with a sharp tug on the wire. The terminal should be impossible to pull off when crimped correctly. Place a ¼ x 4-inch sleeve over each pair of wires in the wiring. Connect the wire ring lug to the sensor ring lug using the supplied number 4 screws and nuts, placing the star washer between the ring lugs, not against the nut. Slide the protective sleeve over the joint and secure with tie-wraps. Note: On both Type-J and Type-K thermocouples one wire of the pair is magnetic and the other is not. One can always determine how to connect wires with a small magnet. Always connect magnetic wire to magnetic wire and connect non-magnetic wire to non-magnetic wire. WARNING: Do not extend thermocouple wire with copper wire Pressure Sensor Mounting General Recommendations The AuRACLE pressure senders are all the same sensor type, with different pressure ranges

55 Figure 22: Pressure Sensor Figure 23: Pressure Sensor Remote Mounting WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5)

56 7.3.6 Install EGT Sensor Figure 24: EGT Sensor 1. Locate the EGT sensors not less than 2 or more than 6 below the exhaust stack attachment flange. 3 to 4 is optimum. CAUTION: All sensors must be mounted an equal distance from the exhaust flanges. On curved exhaust stacks, assume the sensor tip is on the stack centerline for determining the distance to the exhaust flange. 2. Carefully center punch the sensor hole locations such that the portions of the sensors external to the exhaust pipes will not interfere with any parts of the engine or cowling. Drill holes with a #33 drill. 3. Carefully insert the sensors and clamp snugly with screwdriver. 4. Identify the proper wire in the harness for a single EGT sensor. 5. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 6. Cut the extension wires to length. Strip the harness wires and crimp on Ring connectors. 7. Slip the protective sleeve on the wire. 8. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. If there is any doubt about the

57 color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 9. Slide the protective sleeve over the electrical connections and secure in place. 10. Repeat seeps 4 through 9 for each EGT Sensor Install CHT Sensors Figure 25: CHT Sensor 1. Find the Cylinder head temperature mounting hole for all cylinders. 2. Screw the bayonet adapter into this hole in each cylinder. 3. Insert the CHT sensor into each well. Adjust the locking collar attached to the sensor such that the tip of the sensor is pressed against the bottom of the CHT well when the collar is attached to the adapter. Lock the collar to the adapter. 4. Identify the proper wire in the harness for a single CHT sensor. 5. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 6. Cut the extension wires to length. Strip the harness wires and crimp on Ring connectors. 7. Slip the protective sleeve on the wire. 8. The sensor wires are now connected to the EIU harness. Be sure to connect wires WHITE to WHITE and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed

58 washer goes BETWEEN the ring terminals, not under the nut. Be sure to place the If there is any doubt about the color of the wire; the White wire of a Type J thermocouple is magnetic and the Red is not. Always connect magnetic to magnetic and non-magnetic to nonmagnetic. Note: There is a possibility that an older color code is used on the CHT sensors this will be Yellow and Black. In this case connect Black to White (both magnetic) and Yellow to Red (both nonmagnetic). 9. Slide the protective sleeve over the electrical connections and secure in place. 10. Repeat seeps 4 through 9 for each EGT Sensor Install TIT Sensor(s) (if req.) Figure 26: TIT Sensor 1. Carefully center punch the sensor hole locations such that the portions of the sensors external to the exhaust pipes will not interfere with any parts of the engine or cowling. Drill holes with a #33 drill. 2. Carefully insert sensor and clamp snugly with screwdriver. 3. Identify the proper wire in the harness for the TIT sensor. 4. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS

59 5. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 6. Slip the protective sleeve on the wire. 7. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. Be sure to place the If there is any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 8. Slide the protective sleeve over the electrical connections and secure in place Carburetor Temperature Sensor (if req.) Figure 27: Carburetor Temperature Sensor 1. Carefully insert sensor and tighten snugly. 2. Identify the proper wire in the harness for the CT sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 5. Slip the protective sleeve on the wire. 6. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. Be sure to place the If there is

60 any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 7. Slide the protective sleeve over the electrical connections and secure in place Install Induction Temperature Sensor (if req.) The Induction Air Temperature sensor is installed just after the inter-cooler. The sensor is installed similarly to an EGT sensor. Figure 28: IAT Sensor 1. Carefully center punch the sensor hole location such that the portions of the sensor so it will not interfere with any parts of the engine or cowling. Drill hole with a #33 drill. 2. Carefully insert sensor and clamp snugly with screwdriver. 3. Identify the proper wire in the harness for the IAT sensor. 4. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 5. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 6. Slip the protective sleeve on the wire. 7. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. Be sure to place the If there is

61 any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 8. Slide the protective sleeve over the electrical connections and secure in place Install Compressor Discharge Temperature Sensor (if req.) The Compressor Discharge Temperature sensor, (CDT), is installed just before the inter-cooler. The sensor is installed similarly to an EGT sensor. Figure 29: CDT Sensor 1. Carefully center punch the sensor hole location such that the portions of the sensor so it will not interfere with any parts of the engine or cowling. Drill hole with a #33 drill. 2. Carefully insert sensor and clamp snugly with screwdriver. 3. Identify the proper wire in the harness for the CDT sensor. 4. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 5. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 6. Slip the protective sleeve on the wire. 7. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. Be sure to place the If there is

62 any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 8. Slide the protective sleeve over the electrical connections and secure in place Install Oil Temperature Sensor Figure 30: Typical Oil Temperature Sensor 1. Carefully install the oil temperature sensor into the appropriate (OEM) location. Tighten snugly to insure there will be no leaks. 2. Identify the proper wire in the harness for the OT sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 5. Slip the protective sleeve on the wire. 6. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut.. Be sure to place the If there is any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 7. Slide the protective sleeve over the electrical connections and secure in place

63 AuRACLE II 6-Cyl Installation Manual Install Manifold Absolute Pressure (MAP) Sensor Figure 31: Manifold Absolute Pressure Sensor 1. Mount the Manifold Absolute Pressure sensor in accordance with the general recommendations above (see Section 7.3.5). 2. Identify the proper wire in the harness for the MAP sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor Wires. 5. Slip protective sleeves onto the wires. 6. Wire connections using butt splices as listed: Sensor Harness WHITE/ORANGE WHITE - - WHITE/BLUE WHITE/ORANGE WHITE - WHITE/BLUE 7. Slip protective sleeve over splices secure in place

64 AuRACLE II 6-Cyl Installation Manual WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5) Install Instrument Air Pressure/Vacuum Sensor WARNING: The Vacuum or Instrument Pressure system should be properly checked for leaks and verified per the OEM requirements after the installation of the AuRACLE sensor. Note: In a Vacuum System use sensor , in a Pressure System use sensor Figure 32: Instrument Air Pressure Sensor 1. Mount the Instrument Air Pressure/Vacuum sensor in accordance with the general recommendations above (see Section 7.3.5). 2. Identify the proper wire in the harness for the IP/VAC sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor Wires. 5. Slip protective sleeves onto the wires. 6. Wire using butt splices as listed:

65 AuRACLE II 6-Cyl Installation Manual Sensor Harness WHITE/ORANGE WHITE - - WHITE/BLUE WHITE/ORANGE WHITE - WHITE/BLUE 7. Slip protective sleeve over splices secure in place. WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5) Install Fuel Pressure Sensor Figure 33: Fuel Pressure Sensor 1. Mount the Fuel Pressure (FP) sensor in accordance with the general recommendations above (see Section 7.3.5). 2. Identify the proper wire in the harness for the FPP sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor Wires

66 5. Slip protective sleeve onto the wire. 6. Wire connections using butt splices as listed: Sensor Harness WHITE/ORANGE - WHITE/ORANGE WHITE - WHITE WHITE/BLUE - WHITE/BLUE 7. Slip protective sleeve over splices secure in place. WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5) Install RPM Sensor Figure 34: RPM Sensor 1. Carefully screw the sensor into the inspection port on a magneto. Tighten snugly to insure there will be no leaks. 2. Identify the proper wire in the harness for the RPM sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor Wires. 5. Slip protective sleeves onto the wires. 6. Wire connections using butt splices as listed: Sensor Harness WHITE/ORANGE - WHITE/ORANGE WHITE - WHITE WHITE/BLUE - WHITE/BLUE

67 7. Slip protective sleeve over splices secure in place. Note: On a Bendix Magneto install the sensor in the inspection port closest to the engine block. Note: If your aircraft utilizes an electronic ignition system, contact the factory for additional assistance Install Current Shunt The following Wiring diagram shows schematically how to connect the Current Shunt. Figure 35: Current Shunt Schematic 1. Remove the existing current shunt from the inboard side of the Battery Box. 2. Mount the provided current shunt in place of the original current shunt with the 8-32 screws, locking washers, and nuts provided. 3. Identify the proper wire in the harness for the Shunt. 4. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 5. Cut the extension wires to length. Strip the harness wires and crimp on Ring connectors. 6. Connect the WHITE conductor of the wire Labeled Amps to the Battery side of the Current Shunt. 7. Connect the WHITE/BLUE conductor of the wire Labeled Amps to the Bus side of the Current Shunt

68 WARNING: There should be fuses in both signal lines from the current shunt to the AuRACLE. If no such fuses are present Xerion recommends ½ Amp fast acting fuses be installed Install Fuel Flow Sensor The inlet and outlet ports in the fuel flow transducer have ¼ NPT threads. Use only ¼ NPT hose or pipe fittings to match. When assembling fittings into the inlet and outlet ports DO NOT EXCEED a torque of 180 inch lbs, or screw the fittings in more than 2 full turns past hand tight WHICHEVER HAPPENS FIRST. If possible, secure the transducer using two 0.25-inch bolt holes through the body of the transducer to the structure of the aircraft. This will provide the most secure installation. Please be aware of any heat sources the transducer might be subjected to during operation. If the installation prevents you from bolting the transducer as mentioned above, you may suspend the transducer within an existing grouping of fuel lines as long as they are supported with Adel clamps or something similar. The Floscan flowmeter is designed to allow fuel to continue to flow with minimal pressure drop if the rotor becomes seized. If the rotor becomes seized, the displayed Fuel Flow on the AuRACLE will drop off dramatically with little or no recognizable decrease in engine power. Additionally, you may witness a drop in the monitored fuel pressure if installed, provided the fuel flow sensor is located on the METERED side rather than the UN-METERED side. Once the Fuel Flow transducer installation is completed, an engine run-up should be performed verifying the minimum Fuel Flow based on the aircraft POH. Post-installation Calibration is necessary only in the programming of the AuRACLE with respect to the transducer K-Factor. This is documented on the tag that is attached to the sensor and should be recorded in this manual for use later. Figure 36: Fuel Flow Sensor

69 WARNING: Use only aircraft Fuel Lube or equivalent on the NPT fittings

70 5-inch hose minimum UP 5-inch hose minimum TO ENGINE Approved Fire Sleeve FROM FUEL TANK Figure 37: Fuel Flow Sensor Installation WARNING: Never use Teflon tape in an aircraft fuel system. WARNING: Never connect a fuel flow sensor directly to the engine. WARNING: Always cover the fuel flow sensor with an approved fire sleeve. A screen or filter should be installed upstream of the flow sensor to screen out debris which could affect rotor movement or settle in the V-bearings. Mount the fuel flow sensor in a position so the three wire leads are pointed straight up. Use only smooth radius curves in the fuel line and place the sensor with 5 of straight line before and after. The sensor should be mounted according to the fuel metering device manufacturer s recommendations. Based on the aircraft fuel system, one of the following sensor locations should be chosen: Previous installations have yielded exceptional results when the following conditions have been met: 1. The sensor is mounted in a stationary location in line between the electric boost pump and the engine driven pump. 2. The sensor is mounted in a stationary location in line between the fuel injection servo and the distribution block. 3. The sensor is mounted in a stationary location inline between the Engine driven pump and the Carburetor. Previous installations have yielded excellent results when the following conditions have been met:

71 The sensor should be mounted such that he fuel will travel uphill by one to two inches after leaving the transducer. The sensor wires will then be connected to the respective J1-1 EIU harness. The shield need not be connected. Sensor Harness RED - WHITE/ORANGE BLACK - WHITE/BLUE WHITE - WHITE 7.4 Compute the Total Weight and Moment Changes Compute the change in the aircraft weight and total moment using the methods detailed in AC B chapter 10. Record the results in the POH. Nominal weights are provided for convenience only. The installer must weigh all components installed and removed. Item Weight (Lbs) AuRACLE II DU 1.9 AuRACLE II EIU 1.4 EGT Thermocouples (6) 0.1 CHT Thermocouples (6) 0.1 OT Thermocouple 0.2 IAT Thermocouple 0.2 CT Thermocouple 0.2 OAT Thermocouple 0.2 RPM Sensor 0.1 MAP Sensor 0.2 OP Sensor 0.2 Inst. Press. Sensor 0.2 VAC Sensor 0.2 FP Sensor 0.2 FF Sensor 0.2 Current Shunt 0.1 Circuit Prot. Device Negligible Wire and Cable 2.0 Figure 38: Nominal AuRACLE Component Weights 7.5 Load Operational Parameters Download the Operating Parameters on the provided USB flash drive. See the AuRACLE Pilot s Guide for complete instructions

72

73 8 Aircraft Configuration Verification Once the Operational Parameter file has been downloaded to the AuRACLE, it is the responsibility of the installation technician to verify the AuRACLE is configured properly against the appropriate Instrument Marking Report. The Pilot s Guide will guide you through the SETUP page and sub-menus. You can use these procedures to make any required changes as well as to verify settings. The scales, caution limits and warning limits must be verified for every instrument. Failure to do so could present improper readings. WARNING: The scales, caution limits and warning limits must be verified for every instrument. Failure to do so could potentially damage the engine or put the pilot and occupants in a potentially dangerous situation. Until the configuration is confirmed and the Box and Signature line below checked, the installation cannot be signed off as Airworthy. Please contact Xerion Avionix at with any questions. AuRACLE Configuration Confirmed: NO YES Confirmed By: (Print Name) (Signature)

74 9 Operation Verification After completing the installation of the AuRACLE the Installer must verify its basic operation. The following procedure will verify the basic operation of the device Instructions If a sensor is not present in the current installation fill space with an N/A. Fill in an approximate number for a referenced value on this form. If multiple values are referenced, EGT for example, record an eyeball average on this form. Fill in all other values with a check mark. Test Pilot Name: Date of test: Tail Number: Ambient Temperature: Barometric Pressure: Field Elevation: 1. With the engine cold and tanks full apply Power to the AuRACLE i. Three Screens appear one after the other (red, green, blue) ii. Xerion Splash screen appears showing the proper tail number iii. Fuel Load screen appears b. Enter Fuel tanks full on the AuRACLE. Verify fuel load is as programmed c. Examine Temperatures all should be close to ambient temperature i. All EGT ii. All CHT iii. TIT iv. OT v. CDT vi. CT/IAT vii. OAT d. Examine MAP reading. It should be the Barometer corrected to elevation e. Examine Volts reading. It should read approximately battery voltage f. Examine Amps reading. It should show a small discharge g. Examine Oil P Reading. It should be approximately zero. h. Examine VAC/IP reading. It should be approximately zero

75 i. Examine Fuel P Reading. It should be approximately zero. j. Are LED Indicators functioning properly (Oil P and INST red) k. Turn on Cockpit lights very dim. Insure Display and LEDs dim 2. Point the aircraft in the four cardinal compass directions Insure there is no interaction between the AuRACLE and the compass. 3. Set AuRACLE to INST mode and Start Engine and Idle a. Insure Oil P Rises to normal pressure in a reasonable time b. Examine Amps reading. It should show a charge c. RPM should be reading idle speed d. MAP should be reading idle speed MAP value e. FF should be showing an idle FF Value f. EGTs should all be reading normal EGT readings g. TIT Should be reading close to EGTs h. CHTs should rise slowly and stabilize i. Oil T should rise slowly and stabilize j. CT/IAT should rise slowly and stabilize k. CDT should rise slowly and stabilize l. Volts should read a normal operating voltage m. Amps should decrease and stay around zero n. Vac/IP should read in the normal range o. Fuel P should read in the normal range p. OAT should not change from ambient q. Are LED Indicators functioning properly (all green) r. Fuel load decreasing slowly 4. Perform the following EMC/EMI tests. This test must be conducted outside, with the Engine running. Correct any issues that are discovered in these tests. Note: The equipment list below is provided as an example of a typical installation. Test all electronic equipment in a given installation (record results of equipment not listed in the comments section of this document). Use blank spaces to record test on aircraft specific equipment (Source and Victim). Source Equipment Monitor Equipment (Victim) Remarks Source Function Victim Equip Function Audio Visual Equip VHF 1 Transmit AuRACLE On VHF 1 Transmit AuRACLE On VHF 1 Transmit AuRACLE On

76 Source Equipment Monitor Equipment (Victim) Remarks Source Function Victim Equip Function Audio Visual Equip VHF 1 Transmit AuRACLE On VHF 2 Transmit AuRACLE On VHF 2 Transmit AuRACLE On VHF 2 Transmit AuRACLE On VHF 2 Transmit AuRACLE On Autopilot Engage AuRACLE On Strobe Lights On AuRACLE On VOR/ILS Tune Local AuRACLE On DME Tune Local AuRACLE On ADF Tune Local AuRACLE On GPS On AuRACLE On Transponder On AuRACLE On All Lights On AuRACLE On AuRACLE On VHF 1 Receive AuRACLE On VHF 1 Receive AuRACLE On VHF 1 Receive AuRACLE On VHF 1 Receive AuRACLE On VHF 2 Receive AuRACLE On VHF 2 Receive AuRACLE On VHF 2 Receive AuRACLE On VHF 2 Receive AuRACLE On Autopilot Engage AuRACLE On Strobe On Lights AuRACLE On VOR/ILS Tune Local

77 Source Equipment Monitor Equipment (Victim) Remarks Source Function Victim Equip Function Audio Visual Equip AuRACLE On DME Tune Local AuRACLE On ADF Tune Local AuRACLE On GPS On AuRACLE On Transponder On AuRACLE On All Lights On AuRACLE On VHF 1 Receive AuRACLE On VHF 1 Receive With the engine at a normal cruise power setting apply an expected Night IFR equipment load (Maximum number of equipment expected to be operating) on the electrical system. (See AC B, Chapter 11) a. Is the electrical system is able to supply this load (ammeter reading does not change) 6. Take a test flight, staying in the pattern until the Pilot In Command is comfortable with the operation of the AuRACLE. a. Did the readings appear proper and steady at high power settings b. Is the display clear and readable in various aircraft-sun orientations

78 7. If the aircraft is GPS equipped, verify (by calculation) that the fuel remaining at some preprogrammed waypoint is reasonable. 8. Land aircraft a. Top off tanks. Verify fuel remaining is correct If any of the above tests fail troubleshoot the circuit. If assistance is required contact Xerion Avionix, LLC. Signature:

79 10 Instructions for Continued Airworthiness (ICA) There are no field adjustments and or calibration requirements for the AuRACLE Engine Management System once installed properly, configured using the supplied Xerion Avionix encrypted data file and the installation inspected and signed-off by the respective authority. ICA is not required. Maintenance of nonfunctioning or malfunctioning components is limited to removal and replacement of Xerion Avionix factory supplied new or repaired components as described by these installation instructions

80 11 Pressurized Aircraft (Cessna P210, Piper PA-46) 11.1 Penetration Location Locate Cable penetration in the general locations shown; keeping the penetration at least 1 away from strength members. Assure that there are no interfering items on the other side of the pressure bulkhead. For alternate locations, contact Xerion Avionix or an FAA DER for approval. Figure 39: Network Cable Penetration Location Cessna P

81 Figure 40: Network Cable Penetration Location Piper PA Installation Excerpt from AC A

82 AuRACLE II 6-Cyl Installation Manual