EAGLE EMS ELECTRONIC ENGINE MANAGEMENT SYSTEM INSTALLATION MANUAL

Transcription

1 EAGLE EMS ELECTRONIC ENGINE MANAGEMENT SYSTEM INSTALLATION MANUAL August 18, _C.DOCX

2 The information contained in this publication is intended as a guide to install your Eagle EMS Engine Management System. Should you find that you need additional information, please contact the Engine Shop that you purchased the system from, or: Precision Airmotive LLC th Drive NE Arlington, WA Telephone: (360) NOTE: We will continue our efforts to add to the information in this manual. If you have suggestions or comments that would help us in that task, we ask that you contact Precision Airmotive's Product Support Department at the above address or go to our website. The Eagle EMS link will take you to frequently asked technical questions and answers. 2007,2009, and 2010 Precision Airmotive LLC. This publication may not be copied or reproduced without express written permission from Precision Airmotive LLC _C.DOCX

3 Table of Contents 1.0 System Overview Airframe/Engine Requirements Electrical Connections and Components Customer Supplied Items Component Description and Installation Throttle Body Fuel Distribution Block Electronic Control Unit (ECU) Speed Sensors Ignition Coil Assembly Cockpit Annunciator Power Management Unit (PMU) Electronic Fuel Injectors Fuel Lines Mixture Knob Manifold Absolute Pressure (MAP) Lines Eagle Battery Circuit Breakers Communication Ports (DB-9 Connectors) Harness Measurement ECU to Fuel Injectors ECU to Sensors ECU to Ignition Coils Ignition Coils to Spark Plugs ECU to Power/Communications PMU to Aircraft power/eagle Battery Harness Installation ECU to Fuel Injectors Fuel Flow and Tachometer Outputs ECU to Sensors ECU to Ignition Coils Ignition Coil to Spark Plugs ECU to Power/Communications PMU to Aircraft Power/Eagle Battery...15 Annunciator Cutout...16 DB-9 Connector and Mixture Knob Cutouts...17 Eagle Wiring Schematic i _C.DOCX

4 1.0 SYSTEM OVERVIEW 1.1 Airframe/Engine Requirements Four cylinder engines with evenly spaced firing order, 4 stroke, primarily Lycoming 320, 360 and 390 cubic inch engines System is designed for engines with peak engine horsepower between 140 and 210 horsepower Ignition spark is limited to 5000 Revolutions Per Minute (RPM) The fuel pressure required is dependent upon the maximum fuel flow needed. This fuel flow is based upon horsepower and the air fuel ratio (A/F). The installer of the Eagle Kit selects the engine driven fuel and backup pump to ensure that the minimum or HIGHER fuel pressure is met. See graph below Note: Fuel pressure must always be above 20 psi to minimize vaporization issues and below 60 psi to maintain fuel flow calibration Aircraft needs to have a 12 volt electrical system See Customer Supplied Items section of this manual for other details relating to needed and potentially needed components _C.DOCX

5 1.2 Electrical Connections And Components Electrical connections and components that need to be added to the existing aircraft are shown on the Eagle wiring diagram, which is found at the end of this document. Various panel template cutouts are also available toward the back of this document The ignition switch is actually two Single Pole Single Throw Toggle Switches. By switching off either the left or right toggle switches the two ignition systems can be checked separately which is identical to a mag check or RPM drop. If both toggle switches are placed in the off position then the ignition and fuel injection is turned off and the engine is stops. WARNING: EAGLE WIRES MUST BE SHIELDED AND ROUTED DIRECTLY TO THE TOGGLE SWITCHES TO PREVENT RADIO INTEFERENCE FROM ENTERING THE PMU ECU to computer communications uses a DB-9 connector. The mating DB-9 computer connector comes with the EMS harness and can be mounted into the instrument panel. The computer allows a person to monitor and re-calibrate the EMS System for a specific aircraft The mixture control knob replaces the manual mixture control mechanism. This 5k ohm potentiometer adjusts the fuel mixture leaner by reducing the pulse width from the ECU to the injectors. The system automatically compensates for altitude, the mixture control knob allows the operator to additional control over the fuel flow Tach Output. The RPM signal from the magnetos is replaced with an output from the EMS. The EMS output provides two pulses per revolution. The output is feed to customer s engine monitor Turbine Flow Meters. Our testing has shown that turbine flow meters give questionable readings since the flow out of the electronic fuel injectors is pulsed and therefore the fuel pressure oscillates. The turbine flow meter also acts as a flow restriction in the fuel. The EMS provides a calibrated output signal that replaces the turbine meter s sensor output. The signal is fed to the customer s fuel flow meter or engine monitor Smart Display. The Smart Display is an option that can be purchased. It displays data from the Eagle s ECU such as RPM, fuel pressure, inlet air temperature, fuel injector pulse. If the ECU system has an error, it automatically shows up on the display in words instead of error codes. Both a laptop computer s USB cable and a micro-sd memory card can be plugged into the display. The memory card is used for recording flight data. More information is available on the Precision Airmotive Web Site _C.DOCX

6 1.3 Customer Supplied Items: Fuel Pumps. A primary and secondary pump is needed. The primary is usually a diaphragm or vane pump. The Secondary (sometimes called backup or boost pump) is usually electrically driven. The fuel pressure to the Eagle System needs to be within the range of psi at all times Fuel Lines. Specifics on fuel lines are noted in the Component Installation, Fuel Lines section Eagle Speed Sensor Hardware. The speed sensors require the use of previously existing hardware. However not every engine is the same and therefore some additional hardware may be needed. See Component Installation, Speed Sensor Assembly for specific hardware needed Miscellaneous Mounting Hardware. Various bolts, nuts and cable ties will be needed to mount things like ignition coils, ECU, PMU and the fuel distribution block. Read this manual carefully and look at the components supplied in the kit to minimize the trips to the aircraft hardware store ECU Charge Switch. This switch is a 12 volt 5 ampere single pole, single throw normally closed switch used to verify that the ECU will operate off the Eagle battery during preflight check out. This optional switch isolates the ECU from the aircraft bus during preflight checkout. If the switch is not installed the associated wire can be directly connected to the switched Aircraft Bus Five Amp Aircraft Quality Breakers. Two are required and should be mounted in the instrument panel in easy reach of the pilot. These breakers should not be replaced with fuses. There are two separate and redundant computers in the ECU. In order to provide that redundancy, it is necessary to automatically disconnect either ECU in case of an overload The Eagle Battery is a lead acid battery that supplies voltage to the EMS System. This battery is charged by the aircraft charging system during normal operation. The EMS System runs off the Eagle battery. The aircraft s main battery and charging system is used to maintain (charge) the Eagle battery _C.DOCX

7 2.0 COMPONENT DESCRIPTIONS AND INSTALLATION NOTE: The installation instructions provided here are only a guideline. Due to the wide variety of engine and airframe combinations that the EMS System may be installed on, it is up to the aircraft builder to determine the appropriate installation details for that specific application. 2.1 Throttle Body The throttle body is installed in place of the carburetor or fuel injection servo found on standard aircraft engines. It contains the throttle fly for controlling airflow into the engine, ports for inlet air temperature sensors, and ports to provide a manifold pressure signal to the EMS System The throttle body is installed onto the engine air intake using the studs, nuts, and washers supplied with the engine. A throttle body/engine gasket is supplied with the Eagle kit. The nuts are to be torqued in accordance with the engine manufacturer s specifications The intake airbox is connected to the throttle body using high quality ¼-20 bolts or screws. A throttle body/airbox gasket is supplied with the Eagle kit The throttle lever is connected to the throttle cable or linkage using whatever connection is deemed appropriate by the builder. The throttle lever may be repositioned on the throttle body at 15 intervals as needed to best fit the installation. If the lever is repositioned, the nut must be retorqued to in-lbs and a new MS cotter pin must be installed _C.DOCX

8 2.2 Fuel Distribution Block The Fuel Distributor Block contains a replaceable 10 micron fuel filter and distributes the fuel supply to individual injector lines. It also contains dual fuel pressure sensors. NOTE: The brackets and instructions provided are intended for installation on the backbone of a Lycoming style engine. Other engines may require a different installation technique Attach the distributor mounting bracket ( ) to the bottom of the distribution block using the two screws (79216) provided. Torque screws to in-lbs and install safety wire Loosely install the filter housing clamp ( ), screw (MS ) and lock nut (MS21044-N3) onto the housing Remove two adjacent engine case bolts from the backbone of the engine and install the distribution block at this location. The two brackets should be installed on opposite sides of the engine backbone. Re-torque the engine case bolts in accordance with the engine manufacturer s specifications Tighten the filter housing clamp screw and nut until the clamp will not rotate on the distribution block _C.DOCX

9 2.3 Electronic Control Unit (ECU) The ECU is the main controller for the EMS System. It is intended to be installed on the firewall or inside the cockpit. Other locations may be suitable if the ECU case temperature does not exceed 175 F. Thermal sensors or temperature dots can be used to determine the ECU case temperature in flight. Temperature dots are available from Tempil, B.J. Wolf Enterprises, Thermindex or QTEK. NOTE: The ECU will not function properly if installed in a pressurized compartment Drill holes on the selected mounting surface and attach the ECU with high quality non-corrosive hardware Fabricate and install a heavy high quality 20 Ampere grounding strap or multistrand 8 gage wire from the grounding stud on the face of the ECU to a primary aircraft ground location. Torque ECU ground stud to in-lbs Install the ECU such that the case vent points down and is protected from water ingress. Adding tubing to the barb on the end of the vent increases that protection _C.DOCX

10 2.4 Speed Sensors The speed sensors are installed in place of the magnetos found on standard aircraft engines. They provide a speed and timing signal to the EMS System The engine should be configured with studs intended for use with nonimpulse coupled magnetos. No spacer is used between the speed sensor and the engine Install standard magneto drive gears (from non-impulse coupled magnetos) and woodruff keys onto the speed sensor shaft. Torque the nut per the engine service manual and install cotter pin Set the engine for TDC for either cylinder #1 or #2. Either one will work because the cylinders are opposed and the Eagle System has a wasted spark ignition system. A spark plug does NOT have to be removed to verify that the cylinder is on the compression stroke. Often a Lycoming engine will be at TDC when the mark on the starter ring gear (looks like a flywheel) lines up with a pin hole on the starter nose housing On the side of the speed sensor and toward the top of the housing there is a 1/8 diameter hole. Look down the hole while turning the drive shaft of the sensor slowly. Rotate until a 1/8 oval looking hole appears. Do not get confused with larger gaps. This oval hole is midway on a long continuous segment of metal Take a 1/8 diameter pop rivet (or similar) and insert its head through the housing and into the oval hole. Verify that the rivet is in the timing hole by lightly attempting to rotate the drive gear by hand (do not apply excess force). If the gear turns then the rivet is between teeth on the trigger wheel and not in the timing hole. Once the rivet is in the correct location, place a piece of tape over the rivet, thus puncturing the tape with the shaft of the rivet. The tape will hold the rivet in the housing. Repeat the steps for the second speed sensor Place a LARGE warning tag on the propeller AND on the starter button in the cockpit. This step will ensure the engine is not rotated for the next step, because the rivet that is install in the speed senor will be damaged and possibly the speed sensor Install the timing sensors and attach with standard non-impulse coupled magneto mounting hardware and gasket on the engine. Torque nuts per engine manufacturer s specifications and remove alignment rivet or similar The warning tag on the propeller and starter button is then removed _C.DOCX

11 2.5 Ignition Coil Assembly The ignition coils may be installed in any orientation and in any manner that is suitable to the aircraft. The coils should be placed close to the engine to minimize wire lengths. The longest spark plug wires available from Precision Airmotive are 63 inches. See EMS wire harness order form _C.DOCX

12 2.6 Cockpit Annunciator The Cockpit Annunciator provides feedback to the pilot with system status. Only the area around the label and the screw holes protrude thru the dash Select a prominent location in the instrument panel in plain view of the pilot. A one to one scale print for the cutoutt is available at the back pages of this document for the instrument panel mounting Temporarily install the Annunciator Panel using the screws provided. NOTE: The Annunciator Panel will not be permanently installed until after the wiring harness is installed and connected _C. DOCX

13 2.7 Power Management Unit (PMU) The PMU contains the circuitry necessary to provide redundant power to the ECU. It is connected to the aircraft bus and Eagle battery. The PMU also charges and maintains the Eagle battery Select a location that is relatively close to the ECU, the keyswitch, the two 5 amp circuit breakers and the Eagle battery. As with the ECU, the location shall be chosen such that the temperature of the PMU case will not exceed 175 F Drill holes on the selected mounting surface and attach the PMU with high quality hardware _C.DOCX

14 2.8 Electronic Fuel Injectors Lubricate the pipe threads with clean engine oil and install the injectors in the fuel injection ports in the cylinder heads. Torque the injectors to in-lbs. Use care not to damage the wires or connector on the injector After torqueing the injector in the cylinder head install the included cable tie around the nozzle body and wires as shown. Cable Tie 2.9 Fuel Lines Fuel lines are not supplied with the Eagle Kit The fuel line between the fuel pump and the fuel distribution block should be an aircraft quality, fuel compatible, fire sleeved, and flexible #6 hose with AN flare fitting ends The fuel lines between the fuel distribution block and the injectors should be the same as noted above except use a #4 hose and the end that attaches to the injector needs to have a 90 bend The hoses shall be clamped appropriately to minimize stress on the injectors and other components. The approach angle of the hose to the injector should be such that it tends to tighten the injector in the head not loosen it Hoses and fittings in the aircraft upstream of the engine driven fuel pump should be #8 or larger. The fuel selector valve (if used) should be a high quality aircraft selector valve with #8 or larger fuel passages. NOTE: No components should be installed in the lines, which will add any significant pressure drop. This includes turbine type flowmeters. These flowmeters will not function properly due to the pulsing nature of the fuel flow and will add an unacceptable pressure drop _C.DOCX

15 2.10 Mixture Knob The mixture knob has its own connectors which plug into the Precision supplied wiring harness. Select a location within easy reach of the pilot and provide a 3/8 center hole and 1/8 hole for mounting and locking. The distance between the holes is.541 inches Manifold Absolute Pressure (MAP) Lines MAP lines are not supplied with the system. The MAP lines should be aircraft quality #4 flexible hoses with AN flare fitting ends. An example is: Aeroquip hose with MS D fittings Connect the MAP lines to the appropriate fittings on the throttle body and ECU and clamp the hoses adequately. Ensure that there is enough length and flexibility to account for movement between the engine and airframe. Bend radius must not be smaller than the hose manufacturer s specification Eagle Battery The Eagle battery is not supplied with the system. The Eagle battery should be sized to meet the needs of the particular aircraft. It should be assumed that the system will draw 1.6 amps, so a 5 amp-hour battery would provide a 3-1/8 hour Eagle capability, a 10 amp-hour battery would provide a 6-1/4 hour Eagle capability, etc. WARNING: THE AMP-HOUR CAPACITY RATING IS BASED ON A BATTERY MEETING ITS PUBLISHED SPECIFICATION The Eagle battery should be a standard lead-acid aircraft battery and should be securely mounted relatively close to the PMU Do not install a dead or discharged battery. The PMU is not a high current charger. A separate charger can be used to bring the battery up to full charge if the Eagle battery s + leads are disconnected first! This must be done to avoid damaging the PMU Circuit Breakers Circuit breakers are not provided as a part of the kit. Two 5 amp aircraft quality circuit breakers should be installed in the cockpit within reach of the pilot. See the wiring schematic at the end of this document for their locations _C.DOCX

16 2.14 Communication Ports (DB-9 Connectors) The DB-9 connectors are part of the Eagle wiring harness connect. They connect the left and right side of the ECU to a laptop computer. The computer can be used to monitor and adjust fuel delivery, ignition timing and other functions of the ECU. Go to explore the Eagle EMS and read Using a Laptop Computer with a USB or Serial Port Adapter to Communicate with the Eagle System. 3.0 HARNESS MEASUREMENT Fill out the Wire Harness Order Form and send to Precision Airmotive. The form will come with the Eagle Kit or can be obtained from the Precision Airmotive Website, A harness will be made and provided to you that meet the dimensions that you provide. Please make sure that the measurements you provide are correct, as you will be charged for any changes that need to be made. Ensure that all wires are long enough to be routed in a manner that allows adequate support and sufficient flexibility to account for any movement between the engine and the airframe. The minimum allowable bend radius for harnesses is 2 inches. 3.1 ECU to Fuel Injectors Measure the distance from the face of the fuel injector plug on the ECU to the end of the connector on each individual injector. Record these four values on the Wire Harness Order Form. Part of the ECU Fuel Injector harness are two courtesy output wires for RPM and Fuel Flow that go to customer supplied gauges or engine monitor if used. Measure from the ECU to the engine monitor or gauges; record these two values on the Wire Harness Order Form. 3.2 ECU to Sensors Measure the distance from the face of the right sensor plug on the ECU to each of the components/locations listed. Repeat for the left side. Record these values on the form. - Speed Sensor connector face - Fuel Pressure Sensor connector end (on Distribution Block) - Cylinder Head Temperature (CHT) Probe at top of threaded hole in cylinders 3 (right side) and 4 (left side) - Inlet Air Temperature (IAT) at face of body adjacent to IAT sensor hole - Pilot s mixture knob at center of mounting hole (left only) 3.3 ECU to Ignition Coils Measure the distance from the face of the right ignition coil plug on the ECU to the face of the right ignition coil adjacent to the wire thru hole. Repeat for the left side. Record these values on the form _C.DOCX

17 3.4 Ignition Coils to Spark Plugs Measure the distance from the end of the spark plug tower on the ignition coil to the end of the corresponding spark plug. Repeat for each spark plug. Select the appropriate spark plug wire from the available lengths. If the measured length is between lengths order the next longer length. Record these selections on the form. 3.5 ECU to Power/Communications Measure the distance from the face of the PMU plug on the ECU to each of the components/locations listed. Record these values on the form. - Right Breaker attachment - Left Breaker attachment - ECU ground location - Left Comm connector - Right Comm connector - Annunciator Panel 3.6 PMU to Aircraft Power/Eagle Battery Measure the distance from the face of the plug on the PMU to each of the components/locations listed. Record these values on the form. - Aircraft Bus + - Right Breaker - Left Breaker - ECU Ground location - Key Switch - Eagle Battery + - Annunciator Panel 4.0 HARNESS INSTALLATION Install the wire harness components provided using good wire routing and clamping procedures. Take care to protect the wires from chafing and damage. NOTE: All EMS connections should be completed before connecting to the Eagle Battery and aircraft power bus. 4.1 ECU to Fuel Injectors Connect the wires to the ECU and injectors, route and clamp. At the injector connector, the wires shall be secured to the fuel line with cable ties on both sides of the connector to ensure that the connector is firmly secured. 4.2 Fuel Flow and Tachometer Outputs Fuel Flow and Tachometer outputs go to existing gages on the instrument panel, if the plane is so equipped. The ECU is capable of changing its Fuel Flow and RPM signal to match different instrumentation. For wiring questions see the Eagle wiring diagram located at the end of this document _C.DOCX

18 4.3 ECU to Sensors Install the CHT adapters into the cylinder heads. Torque to in-lbs. Install the CHT probes in the adapters. Install the IAT probes into the throttle body and tighten the pipe thread fitting to in-lbs. Adjust so that the probe extends to roughly the center of the throttle bore. Tighten the compression fitting to securely retain the sensor. Install the Mixture knob in the cockpit. Connect the wires to the ECU, Speed Sensors, and Fuel Pressure Sensors. NOTE: On early throttle bodies the upper IAT probe hole is close enough to allow the probe to contact the butterfly. The IAT probe has a compression fitting that can be tightened and adjusted for clearance between the probe and butterfly. Ensure there is a full range of motion on the butterfly before tightening the compression fitting because once tightened there is no readjustment. 4.4 ECU to Ignition Coils Connect the left ignition coil to the left side ECU connector. Connect the right ignition coil to the right ECU connector. The coil assemblies are identical therefore they are interchangeable for troubleshooting. The ignition wires should be connected, routed, and dressed the same as they would be for magnetos. 4.5 Ignition Coils to Spark Plugs Connect the Ignition Coils to the corresponding spark plug. It is recommended that the coils be wired to the cross fire configuration. An example of the cross fire configuration is the right coil is set to fire the top spark plugs in the #1 and #3 cylinders and the bottom spark plugs are set to fire in the #2 and #4 cylinders. The left coil would then fire the bottom spark plugs in the #1 and #3 cylinders and the top spark plugs in the #2 and #4 cylinders. Torque compression nuts per the manufacturer s requirements. 4.6 ECU to Power/Communications Connect the wires to the PMU and to the components indicated on the wire labels. 4.7 PMU to Aircraft Power/Eagle Battery Connect the wires to the PMU and to the components indicated on the wire labels _C.DOCX

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20 DB9 and Mixture Control Cut Out Dimensions NOT to Scale _C.DOCX

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