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Austro Engine IAE50R-AA, Manual

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ENGINE MANUAL 

IAE50R – AA 

E1.01.05 – E 

 

 

Issue date: 25.Jan.2018 

Page: 0-3 

 

Revision no: 9

 

13.5.3

 

Air Filters

 ..................................................................................................................................... 13-7

 

13.5.4

 

Air Filter Cleaning Procedure

 .................................................................................................... 13-7

 

13.5.5

 

Rotor Cooling Air Fan Impeller

 ................................................................................................. 13-8

 

14

 

ENGINE INTERNAL INSPECTION

 .............................................................................................. 14-1

 

14.1

 

Spark Plug

 ....................................................................................................................................... 14-1

 

15

 

GROUND RUN

 ................................................................................................................................. 15-1

 

15.1

 

Pre–start Checks Outside Aircraft

 ................................................................................................ 15-1

 

15.2

 

Pre–start Checks Inside Aircraft

 ................................................................................................... 15-1

 

15.3

 

Ground Run

 ..................................................................................................................................... 15-1

 

15.4

 

Ground Run Check List (example)

 ............................................................................................... 15-2

 

16

 

MAINTENANCE AND OVERHAUL

 ............................................................................................... 16-1

 

17

 

TROUBLE SHOOTING

 ................................................................................................................... 17-1

 

17.1

 

General

 ............................................................................................................................................ 17-1

 

17.2

 

Rough Idle

 ....................................................................................................................................... 17-1

 

17.3

 

Engine Misfires on One Spark Plug

 .............................................................................................. 17-2

 

17.4

 

Engine Cannot Develop Full Power

 .............................................................................................. 17-2

 

17.5

 

Excessive Rotor Cooling Outlet Temperatures

 ........................................................................... 17-2

 

17.6

 

Liquid Coolant Overheats on Medium and High Power

 ............................................................ 17-2

 

17.7

 

ECU Error Warning Light Flashes

 ................................................................................................. 17-3

 

18

 

NOTES FOR INSTALLERS OF ENGINES

 .................................................................................... 18-1

 

18.1

 

General Notes

 ................................................................................................................................. 18-1

 

18.2

 

Notes for engine installers

 ............................................................................................................ 18-1

 

18.3

 

Fuel System

 ..................................................................................................................................... 18-2

 

18.3.1

 

Fuel Specification

 ....................................................................................................................... 18-2

 

18.3.2

 

Fuel delivery

 ............................................................................................................................... 18-2

 

18.3.3

 

Fuel filters

 ................................................................................................................................... 18-3

 

18.3.4

 

Pressure Regulator

 .................................................................................................................... 18-3

 

18.3.5

 

Water in Fuel

 .............................................................................................................................. 18-3

 

18.3.6

 

Fuel Lines

 .................................................................................................................................... 18-3

 

18.4

 

Oil System

 ....................................................................................................................................... 18-3

 

18.5

 

Engine mounting

 ............................................................................................................................ 18-4

 

18.6

 

Exhaust system

 ............................................................................................................................... 18-4

 

18.7

 

Air Filters

 ......................................................................................................................................... 18-4

 

18.8

 

Drive interface

 ................................................................................................................................ 18-4

 

19

 

ELECTRICAL SYSTEM

 ................................................................................................................... 19-1

 

19.1

 

Engine Control System

 .................................................................................................................. 19-2

 

19.1.1

 

Fuel injection

 .............................................................................................................................. 19-2

 

19.1.1.1

 

Injection Timing

 ................................................................................................................................ 19-2

 

19.1.1.2

 

Load Demand

..................................................................................................................................... 19-2

 

19.1.2

 

Ignition System

 .......................................................................................................................... 19-2

 

19.1.2.1

 

Ignition Triggering

 ............................................................................................................................ 19-2

 

19.1.2.2

 

Ignition

 ............................................................................................................................................... 19-2

 

19.1.3

 

Mechanical installation of the ECU

 .......................................................................................... 19-3

 

19.1.4

 

Electrical installation of the ECU

 .............................................................................................. 19-4

 

19.1.4.1

 

Harness Connector for ECU

 ............................................................................................................. 19-5

 

19.1.4.2

 

ECU Pin Assignment

 .......................................................................................................................... 19-6

 

19.1.4.3

 

CAN Bus

 .............................................................................................................................................. 19-8

 

19.1.4.4

 

Option: Installation of ECU according D0160 section 16 CAT Z

 ................................................. 19-9

 

19.1.4.5

 

Error Codes

 ...................................................................................................................................... 19-10

 

19.1.4.6

 

Error Code Table

 ............................................................................................................................. 19-11

 

Summary of Contents for IAE50R-AA

Page 1: ...ENGINE MANUAL IAE50R AA E1 01 05 E Issue date 05 Dec 2014 Page Intro 1 Revision No 8 Engine Manual Operation Maintenance Installation IAE50R AA Doc No E1 01 05 E...

Page 2: ...ENGINE MANUAL IAE50R AA E1 01 05 E Issue date 25 Jan 2018 Page Coversheet 1 Revision no 9...

Page 3: ...AA E1 01 05 E Issue date 25 Jan 2018 Page Coversheet 2 Revision no 9 Date Wiener Neustadt 25 Jan 2018 Author Austro Engine GmbH Rudolf Diesel Stra e 11 2700 Wiener Neustadt Austria Document number E1...

Page 4: ...rticulars 5 3 5 2 5 Out put Drive 5 3 5 2 6 Net Dry Weight 5 3 5 2 7 Cooling 5 4 5 2 8 Fuel Specification 5 4 5 2 9 Fuel Consumption Curve 5 4 5 2 10 Pressure to Fuel Injector 5 5 5 2 11 Lubrication 5...

Page 5: ...o 90 Days 9 4 9 5 2 Storage beyond 90 Days 9 4 9 5 3 Returning to Service from Storage 9 5 10 ENGINE EMERGENCY PROCEDURES 10 1 10 1 Fan Belt Failure 10 1 10 1 1 Low Oil in the Tank 10 1 10 1 2 Low Fue...

Page 6: ...8 NOTES FOR INSTALLERS OF ENGINES 18 1 18 1 General Notes 18 1 18 2 Notes for engine installers 18 1 18 3 Fuel System 18 2 18 3 1 Fuel Specification 18 2 18 3 2 Fuel delivery 18 2 18 3 3 Fuel filters...

Page 7: ...ector 19 20 19 3 7 Coolant Temperature Sensor for instruments 19 21 19 4 Generator regulator and Generator wiring 19 22 19 4 1 Mechanical installation of the Generator Regulator 19 22 19 4 2 Electrica...

Page 8: ...ons of the Engine described in this manual These technical data and the information contained therein are the property of Austro Engine GmbH and may not be reproduced either in full or in part or pass...

Page 9: ...r your particular serial number modification level of the engine Equipment Inventory etc then this information must be transferred to the new pages in hand writing Temporary revisions if applicable ar...

Page 10: ...8 2 4 8 6 4 9 4 9 5 1 12 2 13 3 13 5 5 14 1 17 2 19 1 19 2 19 4 20 0 1 4 1 5 8 1 8 5 9 3 12 2 13 1 13 4 13 5 14 1 14 2 17 1 19 2 19 3 19 4 20 2 Maintenance Interval 12 1 12 1 3 New spark plug implemen...

Page 11: ...no 9 8 MDC E1 154 All All 18 Dec 2014 9 MDC E1 186 1 5 2 4 6 3 3 6 3 4 9 5 2 8 1 8 2 5 9 1 12 1 13 2 13 3 19 3 2 1 1 5 3 6 3 6 3 9 4 8 1 8 3 9 1 12 1 13 4 13 4 19 14 25 Jan 2018 The technical content...

Page 12: ...18 3 9 25 Jan 2018 7 1 9 25 Jan 2018 2 9 25 Jan 2018 3 9 25 Jan 2018 8 1 9 25 Jan 2018 2 9 25 Jan 2018 3 9 25 Jan 2018 4 9 25 Jan 2018 9 1 9 25 Jan 2018 2 9 25 Jan 2018 3 9 25 Jan 2018 4 9 25 Jan 2018...

Page 13: ...018 9 9 25 Jan 2018 10 9 25 Jan 2018 11 9 25 Jan 2018 12 9 25 Jan 2018 13 9 25 Jan 2018 14 9 25 Jan 2018 15 9 25 Jan 2018 16 9 25 Jan 2018 17 9 25 Jan 2018 18 9 25 Jan 2018 19 9 25 Jan 2018 20 9 25 Ja...

Page 14: ...05 E Issue date 25 Jan 2018 Page 1 7 Revision no 9 1 4 List of Incorporated Temporary Revisions Temporary Revision Number Title of Temporary Revision E10105 EM TR MDC E1 163 Rotor Cooling Air Outlet T...

Page 15: ...sonable effort has been made to ensure that the information contained in this publication is correct when going to print However as Austro Engine GmbH policy is one of continuous improvement the infor...

Page 16: ...ual service problems All queries to Austro Engine GmbH should be accompanied by details of the engine model and serial number hours operated and any other relevant information 3 1 Safety Symbols The f...

Page 17: ...only genuine quality assured replacement spare parts are used when carrying out maintenance operations on this engine The use of parts not approved by Austro Engine GmbH may significantly affect the...

Page 18: ...ENGINE MANUAL IAE50R AA E1 01 05 E Issue date 25 Jan 2018 Page 4 1 Revision no 9 4 RESERVED...

Page 19: ...ankel type rotary single rotor dual spark ignition liquid cooled rotor housing forced air cooled rotor ECU normal aspirated 5 2 Technical data 5 2 1 Design Responsibility Austro Engine GmbH Rudolf Die...

Page 20: ...ENGINE MANUAL IAE50R AA E1 01 05 E Issue date 25 Jan 2018 Page 5 2 Revision no 9 5 2 3 Engine Overall Dimensions Fig 1 Engine overall dimensions...

Page 21: ...n optional oil separator assembly supplied by the installer mounted directly onto the outlet casting Eccentric Shaft Hardened and ground alloy steel The complete rotating assembly is in full dynamic b...

Page 22: ...ater Ethylene Glycol mix Silkolene PRO COOL or equivalent 5 2 8 Fuel Specification AVGAS 100LL EUROSUPER ROZ 95 in accordance with EN228 or equivalents 5 2 9 Fuel Consumption Curve Fig 2 Fuel consumpt...

Page 23: ...tering unit driven off the water pump The flow rate of the metering unit is calibrated and must not be adjusted Use only approved engines oils Oil Separator An optional oil separator is recommended Th...

Page 24: ...pipe fitted with filter Power measured at eccentric shaft output Approved fuels Test bed exhaust used 6 1 Maximum Take off Rating Max T O Power minimum 37 3 kW 50 BHP Value quoted includes losses ass...

Page 25: ...g 3 Typical power curve 6 3 Operating Limitations 6 3 1 Engine RPM Maximum for take off for 3 mins 7 750 RPM Maximum Continuous 7 100 RPM Maximum Overspeed 20 sec limit 8 000 RPM Idle Minimum 2 500 RP...

Page 26: ...ion defined by Austro Engine GmbH For detailed information refer to chapter 19 3 2 For an installation of a RCAO temperature sensor different from the sensor position defined by Austro Engine contact...

Page 27: ...ENGINE MANUAL IAE50R AA E1 01 05 E Issue date 25 Jan 2018 Page 7 1 Revision no 9 7 COMPONENTS Fig 4 Location of components Fig 5 Location of components...

Page 28: ...cooled end plate temperature transmitter 7 1 3 Centre and Rotating Assembly The centre assembly comprises a rotor housing with passageways for liquid cooling Externally is the throttle body with fuel...

Page 29: ...heat from the injector and reduces the risk of vapor locking 8 1 1 Typical Schematic Fuel System provided by engine installer Provided by AE as part of the engine Fig 7 Typical schematic of fuel syst...

Page 30: ...Pump A water pump impeller driven from the eccentric shaft via a tufnol drive coupling a shear point is mounted at the rear of the engine and circulates coolant through the engine casting and radiato...

Page 31: ...gth or the heat transfer properties of the coolant 8 2 5 System Pressure The cooling system is a closed loop system designed for a working pressure of 0 9 bar 13 psi overpressure 8 2 6 Air cooling sys...

Page 32: ...ENGINE MANUAL IAE50R AA E1 01 05 E Issue date 25 Jan 2018 Page 8 4 Revision no 9 8 2 7 Rotor Cooling Air Parts Fig 9 Rotor cooling air parts...

Page 33: ...ter ON 4 Set throttle slightly off the idle stop 5 Switch on battery and alternator 6 Switch on ignition verify that all gauges alarms are correct 7 Switch on both fuel pumps verify that all gauges al...

Page 34: ...ely 10 C The engine will start equally well with either permitted fuels 9 3 Ground Tests See chapter 15 9 3 1 Full Power Check Set WOT and note RPM achieved in relation to the minimum acceptable value...

Page 35: ...sual to idle the engine for 2 to 3 minutes before stopping to dissipate internal heat prior to shut down see aircraft manufacturers operating manual Switching off either the ECU power or ignition swit...

Page 36: ...may require that the engine is removed from the aircraft see aircraft manufacturer s instructions Never rotate the engine with the oil can nozzle still in the spark plug or exhaust inlet ports 1 To p...

Page 37: ...UST BAN 395 of ESSO It is also ESSENTIAL that the fuel system be drained Items 1 to 3 should be carried out every 90 days 9 5 3 Returning to Service from Storage 1 Restore the engine to operation acco...

Page 38: ...l of 10 minutes at this reduced power Flying under such conditions may cause damage to the engine 10 3 Low Fuel Pressure If low fuel pressure is indicated the engine may stop or operate at reduced pow...

Page 39: ...Loctite 595 Sealing silicone R1A 09 000 801 Spark Plug NGK K N Filter Oil Air Filter Oil R1A 30 000 801 Injector For further part replacement contact Austro Engine GmbH 11 2 General Torque Settings Bo...

Page 40: ...ce during the test 1 Slacken the three attachments numbered 1 2 and 3 above 2 Attach a loop of suitable material around the fan outlet duct 3 Using a suitable spring balance apply a force to the loop...

Page 41: ...fasteners X X Aircraft Manual Check fan belt condition tension X X 13 5 1 Check cooling system condition and security X X 13 Inspect clean replace spark plugs X X 14 1 Full engine ground run X X 15 C...

Page 42: ...de Nuts bolts 20 Fuel Rail Injector Pressure Regulator Leaks Cracks Cable Connection 21 Linkage Throttle Stops 22 Ram pipe Check temperature sensor connection 23 Induction Air Filter Cleanliness and d...

Page 43: ...bris Level 32 Oil Separator Hoses Leakage 33 Rotate Propeller by Hand Check 6 x compression on prop Carry out engine ground run according to check list 12 3 Mandatory Life Limitation There is no life...

Page 44: ...d mating surfaces for leaks Check water pump bleeding hole and engine bay for any coolant residue If any residue is found check engine until leak is found and contact Austro Engine GmbH 13 3 Coolant S...

Page 45: ...oolant temperature rises rapidly shut down the engine and bleed the system again Risk of scalding do not remove the pressure cap from the radiator until the engine and radiator have cooled 13 4 Coolan...

Page 46: ...r Stator Assembly and check the water pump bearings for play Care should be taken in withdrawing the assemblies due to the loose internal tufnol drive coupling 5 Fit the new Fan Belt using Austro Engi...

Page 47: ...n 3 Ensure that the contaminated solution does not come in contact with the inside surfaced of the filter 4 Rinse off the filter from the inside with clean low pressure water from a tap or a similar s...

Page 48: ...e on the engine Either or both filters should be replaced if their condition is suspect 13 5 5 Rotor Cooling Air Fan Impeller 1 At the intervals stated in 12 1 the fan impeller should be inspected The...

Page 49: ...centre line of the engine where the cooling medium is air This can only be achieved through the inlet port 3 If there is any doubt about the acceptability of the faces or the seals then access should...

Page 50: ...or use abrasive materials If due to local conditions the plug connections become corroded then the corrosion may be removed from the plug nipple with a wire brush and the inside of the plug cap clean...

Page 51: ...ecks Inside Aircraft 1 Close and lock canopy if appropriate 2 Record outside air temperature Minimum limit 10 C for normal starts 3 Battery master ON 4 Check note all indicators and alarms as indicate...

Page 52: ...Pressure Alarm Engine Coolant Charge System Fail Alarm OAT ECU Error Warning EGT 1 optional Fuel Flow Oil Low Alarm Record data after 1 minute steady running at each condition after warm up Engine Co...

Page 53: ...AE50R AA E1 01 05 E Issue date 25 Jan 2018 Page 16 1 Revision no 9 16 MAINTENANCE AND OVERHAUL For maintenance of particular system or for overhauling the engine please contact Austro Engine GmbH or e...

Page 54: ...d if disturbed If during troubleshooting any foreign object fall into the engine internals through the spark plug holes the inlet or exhaust ports or the rotor air cooling inlet and exit passages they...

Page 55: ...ilter Replace clean filter Low fuel pressure Investigate fuel system replace fuel filter 17 5 Excessive Rotor Cooling Outlet Temperatures Excessive back pressure in outlet duct Rectify before continui...

Page 56: ...ENGINE MANUAL IAE50R AA E1 01 05 E Issue date 25 Jan 2018 Page 17 3 Revision no 9 17 7 ECU Error Warning Light Flashes See chapter 19 1 4 6...

Page 57: ...efore attempting to operate the engine for the first time or if they are subsequently disturbed in any way 18 2 Notes for engine installers COOLING SYSTEM Arrangement must be made by the engine instal...

Page 58: ...100 C Heat rejection rate approximately 25 kW of heat is rejected to the coolant when the engine is operated at max continuous power 50 BHP An integral water pump is provided with the engine This pro...

Page 59: ...must be routed away and protected from hot engine and exhaust components Fuel line should be of sufficient quality and appropriate to the pressures transmitted Fuel hose end connections must be of th...

Page 60: ...anufacturer Contact Austro Engine GmbH for installation details 18 6 Exhaust system Exhaust design and fitting remains the responsibility of the aircraft manufacturer engine installer Limitations must...

Page 61: ...st chafing at hot parts or sharp edges No engine harness is provided by Austro Engine GmbH The wiring harness is not included and must be provided by the installer The necessary information can be fou...

Page 62: ...spacer block with tapping points for oil feeds and MAP sensors The correct fuel injection timing is provided by the same speed sensors and the appropriate amount of fuel is delivered by controlling th...

Page 63: ...ble via 4 elongated holes M4 screws with washers on the side of the ECU housing are suggested The ECU must be grounded using two independent wires of 16AWG minimum The mounting bolts can be used to fi...

Page 64: ...r Low side switch 1 A C Meter Low side switch 5 V P Meter Low side switch 1 A P Meter Low side switch 5 V F Meter Low side switch 1 A F Meter Low side switch 5 V Tacho Low side switch Pull up 2k2 to U...

Page 65: ...table for engine harness manufacturing The connector and accessories described in this section are not part of Austro Engine delivery Fig 14 ECU harness connector Description Manufacturer Part Number...

Page 66: ...11 Ins Drive 1 Low Side Switch Coolant Signal Out No AWG18 A12 Injector 1 Low Side Switch Injector 1 No AWG 20 B1 TX Low Side Switch 2k2 Pull Up to UBAT Error Lamp Out No AWG 20 C5 RX Serial Input inc...

Page 67: ...E50R AA C7 CAN 3 not used for IAE50R AA C8 Rotor Air Out Temp Signal Input Signal Sensor Signal No AWG 20 C9 Pickup 1 GND GND Sensor GND Yes AWG 20 C10 Pickup 1 Signal Input Signal Sensor Signal Yes A...

Page 68: ...termination is required at the physical end of the BUS CAN termination resistors 60R 2x 120R in parallel 120R in EECU included CAN Bus according ISO 11898 For Example CAN Termination in Installation 1...

Page 69: ...commended Installation of ECU Supply Bus to fulfill Do160 Sec 16 CAT Z Fig 16 Cat Z To meet category Z as tested in certification progress you have to ensure that the ECU is supplied directly from alt...

Page 70: ...n of the failure Error warning display is continuously lit during engine operation When the engine is stopped and there are errors the ECU output B1 TX will flash with a coded message to indicate whic...

Page 71: ...ensor Sensor short circuit or sensor low None Investigate after landing 1 4 Rotor Cooling Air Sensor Sensor open circuit or reading high None Investigate after landing 2 1 Supply Voltage Supply volts...

Page 72: ...shall be included Engine housing 12V Battery Capacitor Generator Regulator Aircraft GND ECU Starter Fig 17 GND concept Possible GND connection Points Regulator see Chapter Generator Regulator Engine...

Page 73: ...robe in the induction airflow Type of Air Temp Sensor s Part Number QTY per engine E4A 40 000 804 1 Pin Assignment Air Temp Sensor s Fig 19 Pin Description 1 GND 2 Signal Mating Connector for Air Temp...

Page 74: ...te 25 Jan 2018 Page 19 14 Revision no 9 19 3 2 Rotor cooling air out temperature sensor The sensor should be mounted as defined in the following figures Fig 20 approx 10 mm approx 5 3 mm approx 27 mm...

Page 75: ...engine E4A 40 000 804 1 Pin Assignment of Rotor Cooling Air out Temp Sensor s Fig 21 Pin Description 1 Signal 2 GND Mating Connector for of Rotor Cooling Air out Temp Sensor Description Manufacturer P...

Page 76: ...The flexible pipe Inner Diameter 6mm must be at least oil resistant fuel engine oil and does not change the inner diameter at inlet pressures of 20kPa VCC VOUT GND Fig 22 Type of MAP Sensor s Part Nu...

Page 77: ...r Sensor is supplied with open wires It is recommended to use dust and water protected connectors for engine harness adaption An adequate connector type can be found in the following tables Possible S...

Page 78: ...rovide independent switches to interrupt the power supply for each ignition coil separately if required Type of Ignition Coil Part Number QTY per engine R1A 09 000 804 2 Mechanical and electrical conn...

Page 79: ...g R1A 09 000 501 Connection to Spark Plug 19 3 5 1 H T Leads The inductive H T coils are connected to the spark plugs by copper cored cable and resistive plug caps The cable is provided by AE Part Num...

Page 80: ...e 25 Jan 2018 Page 19 20 Revision no 9 19 3 6 Injector One injector is used for the IAE50R AA Engine Type of Injector Part Number QTY per engine R1A 30 000 801 1 Pin Assignment Injector Fig 25 Pin Des...

Page 81: ...0 000 803 is fitted to the engine in the front plate for connecting to a temperature gauge or an external instrumentation panel This sensor is a provision for the installer It is not connected to the...

Page 82: ...Power supply Current 18 A 19 4 1 Mechanical installation of the Generator Regulator Mounting of the Regulator is possible via M8 screws on both sides of the Regulator Install the regulator on a well v...

Page 83: ...Connected to Yellow Yellow Cable Generator Yellow Yellow cable Generator Red Power 12V Red Power 12V White 12V Lamp Not requested Black Power 12V Switchable ON OFF 10 1 2 Charge Circuit Fail Alarm Th...

Page 84: ...tery 12 5V 18Ah 80 A Voltage of Battery drops down during cranking Inrush current can reach up to 350A for some milliseconds 19 5 1 Mechanical installation The starter is mounted on the engine Two M8...

Page 85: ...ltage Spike Test DO 160C Section 17 Cat A Audio Frequency Conducted Susceptibility DO 160C Section 18 Cat Z Induced Signal Susceptibility Test DO 160C Section 19 Cat Z Conducted RF Susceptibility Test...

Page 86: ...sts DO 160C Sections 4 5 1 4 5 2 4 5 3 and 4 6 1 Cat B2 Temperature Variation Test DO 160C Section 5 Cat B2 Fluids Susceptibility DO 160D Section 11 The ECU and associated equipment is compatible with...

Page 87: ...d dedicated to the ECU DO 160D Section 11 was tested during the basic certification from Midwest Company 19 6 3 Control System Reliability 19 6 3 1 Control system reliability objective Certification r...

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