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E-MAG LYCOMING 200-6XL Series, Installation And Operating Manual

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E-MAG LYCOMING 200-6XL Series Installation And Operating Manual Download Page 10

 

9 

 

 

Lycoming

™ styled engines: 

1)  Always - route Bank A to cylinders 1&2. 
2)  Most will route Bank B to 3&4, Bank C to 5&6 as shown.  
3)  In the event of a Left* (CCW) rotating engine, route Banks 

B to 5&6 and C to 3&4. 

  

Always verify proper firing with the Pull-Thru test.  

Tip:  Penetrating oil and heating the case area around the studs with a heat-gun can make stud 
removal and replacement much easier.  (Remove rubber cushions before using heat gun.) 

Plug Wires 

–

 Cylinder Assignments 

As with any wasted-spark ignition, E-MAGs fire spark plugs in pairs.  Cylinders 1&2, 3&4, 5&6 are 
pairs with plug leads connected to both ends of a double ended coil “Bank”.  See Appendix 5 for 
instructions on fabricating individual trim-to-fit plug wires. 
.   

 
 
 
 
 
 
  
 
 
 

 
Note 1: The Pull-Thru test [highly recommended] is the best way to verify the installation follows 
correct bank (cylinder pair) firing order. This test uses encoder data at the lowest possible 
resolution, i.e., pull-thru firing positions cannot be used to check tracking accuracy.  During 
normal operation, dynamic quadrature counters are used to increase tracking resolution and 
accuracy.  

 

Note 2: Ignition Bank firing sequence is A-B-C regardless of the direction of the engine/ignition drive 
interface.  
 
Note 3: * CW and CCW engine rotation reference 

– as viewed from back of engine looking to prop 

on the far side. 
 
Note 4:  If using strap (Adel) clamps to secure plug leads, make sure the clamps are properly sized.  
Reusing clamps for smaller size (previous 7mm aviation leads) wire may be too tight and 
crush/compromise the internal silicone insulation layer of our 8mm wire.   

Auto Plugs and Adapters  

Aircraft engines are typically tapped for 18mm spark plug threads.  To use 14mm automotive style 
plugs, E-MAG can provide auto plug adapters.  There are numerous auto spark plug styles and 
temperature ranges available through various outlets.  E-MAG has NOT studied the relative 
durability or performance of different plug brands and styles.  Customers need to monitor plug 
condition and evaluate and adjust as necessary.  The plugs listed in Appendix A and have a history 
of good service.  

Set plug gaps at 0.030” to 0.035”. 

Bank A  

Bank B  

Bank C  

1 

2 

3 

4 

5 

6 

 

Summary of Contents for LYCOMING 200-6XL Series

Page 1: ... Product Documentation Instruction Set for Lycoming Styled 6 Cylinder EXPERIMENTAL Engines Series 200 6XL Installation and Operating Guide V 200 6XL 041 LYCOMING Style ...

Page 2: ...d ignition operation Nothing stated by E MAG in this manual its employees owners agents representatives or affiliates should be construed as overriding or invalidating the engine manufacturer s instructions E MAG has NOT performed testing on the wide variety of engines in popular use and cannot offer specific advice as to proper suitable ignition configuration Notwithstanding engine manufacturer a...

Page 3: ...R ASSIGNMENTS 9 AUTO PLUGS AND ADAPTERS 9 MANIFOLD PRESSURE MAP 10 SETPOINTS 11 SET IGNITION TIMING 11 PULL THRU TEST 14 TUNING MAX 15 OPERATING NOTES 16 MAINTENANCE 18 WIRING DIAGRAM 20 APPENDIX 1 SPARK PLUGS ADAPTERS 22 APPENDIX 2 ENGINE TC LOCATOR 23 APPENDIX 3 TACH ELECTRICAL SPECIFICATIONS 24 APPENDIX 4 INSTALLATION CHECKLIST 25 APPENDIX 5 HARNESS FABRICATION LEADS 27 ...

Page 4: ...of cylinders 1 2 3 4 5 6 constitutes a separate high voltage loop ID Date Summary of Principal Changes V 200 6X 31 5 25 19 Initial Product Release disregard all previous materials Note This ignition version includes two operating modes fixed and variable firing Both modes share common position and processer based control logic elements Redundancy is provided by having two autonomous left right ign...

Page 5: ...esume normal LED signaling Most Lycoming styled engines will look for a White RED Color Burst clockwise rotation signal Prior to installation make sure you have the following items identified and on hand Suitable size ignition mounting studs and clamps see Engine Attachment and Appendix 4 Fittings needed to connect ignition manifold pressure to your induction system see Manifold Pressure MAP Ident...

Page 6: ... WHITE only Installation and Operation Cockpit Controls 1 Circuit breaker or fuse one per ignition 2 Ignition kill switch p lead can be either a Rotary switch OFF R L Both Start b Toggle switch UP ON and DOWN OFF 3 Ignition power test switch Note 1 is for testing ignition internal alternator see Ignition Checks a Ramp Checks a basic ignition alternator check a Cut Out test a stress test for igniti...

Page 7: ...ad with the switch To turn ignition ON un ground the p lead Switch 22 AWG e Pin F Pig Tail blue wire connects to tach instrument 3 pulses per rev 22 AWG Mode Switch optional Ignitions can work with a cockpit switch to select either Fixed Mode or Variable Mode operation The switch circuit adds a 1K bias signal to the existing kill wire pin E to enable Fixed Mode operation The switch E MAG offers is...

Page 8: ...move MIN MAX setpoints or change ignition DIR 2 Mode Switch optional Fixed Mode or Variable Mode can be selected by a single cockpit Mode Switch that directs both left and right Series 200 ignitions Fixed Mode is enabled when the Mode Switch applies a 1K bias resistance to the kill p lead circuit s The Mode Switch can serve one or two Series 200 ignitions The Mode Switch is required for all booste...

Page 9: ...ones will sound at a The stored ignition TC position with YELLOW LED b Ignition 20 and 25 degree positions Tones are for the sole purpose of helping installers locate their chosen MIN and MAX setpoints After setting TC these tones will flag the 20 and 25 degree positions see Fig A Other positions 18 22 35 etc if needed can be interpolated from these fixed reference locations YELLOW is a composite ...

Page 10: ...acking accuracy During normal operation dynamic quadrature counters are used to increase tracking resolution and accuracy Note 2 Ignition Bank firing sequence is A B C regardless of the direction of the engine ignition drive interface Note 3 CW and CCW engine rotation reference as viewed from back of engine looking to prop on the far side Note 4 If using strap Adel clamps to secure plug leads make...

Page 11: ...ailures are not covered under warranty Use anti seize sparingly on the outer engine side of adapters Auto plug manufacturers do not recommend anti seize on their plugs Manifold Pressure MAP The ignition comes with 3 of 1 8 x1 4 silicone tubing and a 1 8 barbed nipple to 1 8 NPT brass fitting packed separately for use in connecting manifold pressure You could also use the female 1 8 NPT in the igni...

Page 12: ...set anywhere between 6 and 9 degrees before MIN 4 DIR not a setpoint per se The ignition s current operating direction DIR is displayed by various means throughout the installation process i e if it s wrong the system will catch it later Note 1 Anytime you move a TC MIN or MAX setpoint reconfirm the stored setpoint positions of all three Some changes will restore the original factory default overr...

Page 13: ...tomatically re start in normal mode The LED will settle at steady YELLOW with tone indicating the ignition is setting at the newly stored TC position Proceed to Step 4 b TC Locator method If preferred installers can use TC Locator to locate and store TC see Appendix 2 4 MIN BLUE and MAX WHITE setpoints a Check setpoints by positioning prop engine to the MIN and then the MAX positions Approaching s...

Page 14: ...press hold Button for 10 seconds until the LED turns WHITE release Button Ignition will store the change and re start with a color burst WHITE then RED or GREEN that signals the new DIR setting Changing DIR will restore factory default MIN MAX and TC settings Turn bus power OFF and return to Setup Step 3 Note 2 Make sure Kill Switch stays OFF until all high voltage connections plugs plug wires coi...

Page 15: ...oltage drops below a certain level while cranking a safety circuit may prohibit the ignition from firing The starter motor pulls the largest load on the electrical bus Keeping non essential loads turned OFF while cranking will help Note We have no definitive guidance but there is some indication light weight lithium batteries may contribute to greater ignition voltage dips during startup Pull Thru...

Page 16: ...default MAX setting is thought to be a relatively conservative setting especially when a Mode Switch installed and the operator can change to Fixed Mode at any time Operators can monitor VAR mode cruise conditions RPM above 2400 and MAP 22 or below where spark advance is greatest and be mindful of the engine manufacturer s temperature recommendations and red lines It should be understood that impr...

Page 17: ...itching to Fixed Mode Mode Switch FIX and return to your previously established fixed firing baseline The Mode Switch can be operated at any time other than startup when Variable Mode is required Note 2 Alternative auto Fuels CAUTION Notwithstanding engine manufacturer approval of some engines to burn auto alternative fuels such approvals almost certainly presume operation with fixed magneto firin...

Page 18: ...can be blended into your routine left right Ramp Check but the alternator has an additional test Cut Out test that is done on a less frequent schedule 1 Ramp Checks roughly 1700 RPM a Internal Alternator E MAG internal alternator operates in parallel with power supplied by the aircraft bus The ignition automatically transitions between aircraft power and internal alternator power as needed Aircraf...

Page 19: ...power or activating the other ignition at the last moment to keep the engine running may not restore full operation and is unlike the power boundary event we are probing Maintenance Condition Inspection annual 1 Confirm Setup reference positions TC MIN MAX prior to removal Look for discrepancies if any from prior settings 2 Check E MAG web site for the most recent Manual www emagair com downloads ...

Page 20: ...fy proper operation including a Perform Ignition Checks on each ignition see Ignition Check section for guidelines i Basic internal alternator Ramp Check ii Internal alternator Cut Out test record results in logbook for L R Both Mode Switch Check if installed ...

Page 21: ...t used Cockpit Circuit Breaker Alternator Test Switch Can Be Combined A F B D E C Bus 14v to 28v A F B D E C Second ignition Control plug cable end left Solder cup pins on back of standard control plug Pin orientation matches the schematic above and is marked on the inner face of the plug itself When assembling the Std connector remember to pre position wires thru the strain clamp plug shell and s...

Page 22: ...test switch can be configured several ways and is largely a matter of installer operator preference 1 If using switchable circuit breakers vs fuses the breaker itself can be used as a power test switch one breaker per ignition 2 A dedicated power test switch can also be used One such implementation to consider is a momentary push button switch non latching normally closed push to open one switch p...

Page 23: ...sert the combined plug adapter assembly in the engine and tighten to 18 ft lb standard auto plug torque through the spark plug ONLY Do NOT torque the adapter itself If you torque the adapters directly stress will be focused underneath the adapter head and it can fail during installation Such failures are not covered under warranty Use anti seize sparingly on the outer engine side of adapters Opera...

Page 24: ...e following processes are enabled a Slowly rotate the prop either direction until the piston gently contacts the stop first stop Quick press the Button and the LED will switch to GREEN with a periodic BLUE pulse b Slowly rotate prop in the other direction until the piston gently contacts the stop second stop Quick press the Button and the LED will switch to steady GREEN indicating the ignition has...

Page 25: ... or 48 volt systems a Minimum 10 volts b Maximum 58 volts c Current draw from bus i less than 0 5 amp normal operating conditions ii less than 1 0 amp maximum draw with no op internal alternator 2 Tach circular connector pin F blue 66 33 0 volts 10 12 volts 2 2K ohm pull up resistor built in ...

Page 26: ...arb can be used with the 1 8 ID tubing provided or it can be removed to access i 10 32 female thread fitting that can be removed to access ii 1 8 NPT female thread in the ignition case b 36 silicone MAP tube 1 8 ID x 1 4 OD c 3 each nylon tube clamps for OD MAP tube 2 Ignition gasket 3 Mounting Studs Two 31C 13 studs specify when ordering will replace the longer studs used with magneto mounting sp...

Page 27: ...egrated color coded wiring Mode Switch is optional for normally aspirated engines but is REQUIRED for boosted engines Installation supplies and tools needed 1 Silicone spray used when fabricating trim to fit harness 2 Ohm meter recommended but not required to test spark plug wires after assembly 3 Solder iron and rosin core solder for control wires not needed if ordering pre wired Control Plug 4 H...

Page 28: ... ignition firing all the upper plugs and the other ignition firing all the lower plugs Organizing leads Because plugs in each Bank fire simultaneously the coil attachments within each Bank are interchangeable Example Plug wires for cylinders 1 2 can attach to either coil tower of Bank A This flexibility can reduce congestion and wiring cross over at the back of the ignition when attachments favor ...

Page 29: ... crimping tool Position so you have at least 1 8 of plug wire past the terminal ears Final Crimp Crimp the terminal using the W Crimp Station on the Tool Position the ears so they feed toward the side with the W point The ears will roll back toward each other and imbed themselves in the outer jacket as the Final Crimp is formed Push not pull the terminal to final position inside the boot Coil term...

Page 30: ...be provided by E MAG If not properly secured the leads can come lose which risks interrupting ignition operation and can damage the ignition coil NEVER operate the ignition fire plugs without ALL high voltage loops coil to wires to plugs to engine to plug to wire to coil secured in place Note1 After plug wires are connected verify the boot sleeve is fully inserted over the spark plug and coil towe...

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