Austro Engine IAE50R-AA User manual

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

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: Coversheet - 1

Revision no: 9

ENGINE MANUAL

IAE50R – 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 – Straße - 11

2700 Wiener Neustadt, Austria

Document number: E1.01.05 – E

Revision: 9

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 0-1

Revision no: 9

0 TABLE OF CONTENTS

0 TABLE OF CONTENTS ..................................................................................................................... 0-1

1 INTRODUCTION .............................................................................................................................. 0-1

1.1 Record of Revisions .......................................................................................................................... 1-2

1.2 List of Revisions ................................................................................................................................ 1-3

1.3 List of Valid Pages ............................................................................................................................ 1-5

1.4 List of Incorporated Temporary Revisions .................................................................................... 1-7

2 GENERAL INFORMATION .............................................................................................................. 2-1

3 SAFETY INFORMATION ................................................................................................................. 3-1

3.1 Safety Symbols ................................................................................................................................. 3-1

3.2 Model Designation Breakdown ....................................................................................................... 3-2

3.3 Replacement parts ........................................................................................................................... 3-2

4 RESERVED ......................................................................................................................................... 4-1

5 GENERAL ENGINE DATA ................................................................................................................ 5-1

5.1 Description ........................................................................................................................................ 5-1

5.2 Technical data ................................................................................................................................... 5-1

5.2.1

Design Responsibility

................................................................................................................... 5-1

5.2.2

Certification

................................................................................................................................... 5-1

5.2.3

Engine Overall Dimensions

......................................................................................................... 5-2

5.2.4

Engine Particulars

........................................................................................................................ 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

.................................................................................................................................... 5-5

5.2.12

Oil Specification

............................................................................................................................ 5-5

6 OPERATING DATA / LIMITATIONS ............................................................................................ 6-1

6.1 Maximum Take – off Rating ............................................................................................................ 6-1

6.2 Maximum Continuous Rating .......................................................................................................... 6-1

6.2.1

Power Curve

................................................................................................................................. 6-2

6.3 Operating Limitations....................................................................................................................... 6-2

6.3.1

Engine RPM

................................................................................................................................... 6-2

6.3.2

Ambient Temperature Limits

...................................................................................................... 6-2

6.3.3

Liquid Coolant Temperature Limits

........................................................................................... 6-3

6.3.4

Rotor Cooling Air Outlet Temperature Limits

........................................................................... 6-3

6.3.5

Exhaust Gas Temperature (EGT)

............................................................................................... 6-3

6.3.6

Fuel Pressure

................................................................................................................................ 6-3

6.3.7

Altitude

.......................................................................................................................................... 6-3

6.4 Manuals .............................................................................................................................................. 6-3

7 COMPONENTS .................................................................................................................................. 7-1

7.1 Description of Components ............................................................................................................. 7-2

7.1.1

Rear Assemblies

........................................................................................................................... 7-2

7.1.2

Front Assemblies

.......................................................................................................................... 7-2

7.1.3

Centre and Rotating Assembly

................................................................................................... 7-2

7.1.4

Rotor Sealing

................................................................................................................................ 7-2

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 0-2

Revision no: 9

8 DESCRIPTIONS OF SYSTEMS ....................................................................................................... 8-1

8.1 Fuel System ....................................................................................................................................... 8-1

8.1.1

Typical Schematic Fuel System (provided by engine installer)

............................................. 8-1

8.1.2

Throttle Valve Setting

.................................................................................................................. 8-1

8.2 Cooling System ................................................................................................................................. 8-2

8.2.1

Liquid Cooling System

................................................................................................................. 8-2

8.2.2

Water Pump

.................................................................................................................................. 8-2

8.2.3

Temperature Regulation

............................................................................................................. 8-2

8.2.4

Coolant

.......................................................................................................................................... 8-3

8.2.5

System Pressure

........................................................................................................................... 8-3

8.2.6

Air cooling system

........................................................................................................................ 8-3

8.2.7

Rotor Cooling Air Parts

................................................................................................................ 8-4

9 OPERATING THE ENGINE ............................................................................................................. 9-1

9.1 Starting Procedure and Warm–up ................................................................................................. 9-1

9.2 Engine Start down to approximately -10 °C ................................................................................. 9-2

9.3 Ground Tests..................................................................................................................................... 9-2

9.3.1

Full Power Check

.......................................................................................................................... 9-2

9.3.2

Idle Check

..................................................................................................................................... 9-3

9.3.3

Stopping the Engine

.................................................................................................................... 9-3

9.4 Power Loss at Altitude ..................................................................................................................... 9-3

9.5 Storage .............................................................................................................................................. 9-4

9.5.1

Storage up to 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 Fuel Pressure

...................................................................................................................... 10-1

10.1.3

Rotor Cooling Air Temperature

................................................................................................ 10-1

10.1.4

Coolant Temperature

................................................................................................................. 10-1

11 MAINTENANCE NOTES ................................................................................................................. 11-1

11.1 Austro Engine GmbH Available Consumables ............................................................................ 11-1

11.2 General Torque Settings................................................................................................................ 11-1

11.2.1

Specific Torque Settings

........................................................................................................... 11-1

11.2.2

MAP Hoses

.................................................................................................................................. 11-2

11.2.3

Checking & Setting Fan Belt Tension

...................................................................................... 11-2

11.2.4

Adjusting engine idle speed

..................................................................................................... 11-2

12 SCHEDULED MAINTENANCE ...................................................................................................... 12-1

12.1 Maintenance Schedule ................................................................................................................... 12-1

12.2 Typical 50 Hours Check ................................................................................................................. 12-2

12.3 Mandatory Life Limitation.............................................................................................................. 12-3

13 COOLING SYSTEM ......................................................................................................................... 13-4

13.1 Liquid Cooling System ................................................................................................................... 13-4

13.2 Coolant leak check ......................................................................................................................... 13-4

13.3 Coolant System Filling and Bleeding ........................................................................................... 13-4

13.4 Coolant System Pressure Test ...................................................................................................... 13-5

13.5 Air Cooling System ......................................................................................................................... 13-6

13.5.1

Fan Belt

....................................................................................................................................... 13-6

13.5.2

Fan Belt Replacement

............................................................................................................... 13-6

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

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 0-4

Revision no: 9

19.2 GND Concept IAE50R .................................................................................................................. 19-12

19.3 Sensors and actuators ................................................................................................................. 19-13

19.3.1

Air Temperature sensor

.......................................................................................................... 19-13

19.3.2

Rotor cooling air out temperature sensor

............................................................................ 19-14

19.3.3

Map Sensors

............................................................................................................................. 19-16

19.3.4

Speed Sensors

.......................................................................................................................... 19-17

19.3.5

Ignition Coils

............................................................................................................................. 19-18

19.3.5.1 H.T. Leads ........................................................................................................................................ 19-19

19.3.5.2 Spark plugs ...................................................................................................................................... 19-19

19.3.6

Injector

...................................................................................................................................... 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

Electrical installation of the Regulator

.................................................................................. 19-23

19.5 Starter ............................................................................................................................................ 19-24

19.5.1

Mechanical installation

............................................................................................................ 19-24

19.5.2

Electrical connection of starter

.............................................................................................. 19-24

19.6 Electronic Components Capability .............................................................................................. 19-25

19.6.1

Electrical tests

........................................................................................................................... 19-25

19.6.2

Environmental tests

................................................................................................................. 19-26

19.6.3

Control System Reliability

....................................................................................................... 19-27

19.6.3.1 Control system reliability objective. .............................................................................................. 19-27

19.6.3.2 Software Quality level ..................................................................................................................... 19-27

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 1-1

Revision no: 9

1 INTRODUCTION

This engine may only be operated in accordance with the procedures and operating limitations

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 passed on to a third

party without written consent from Austro Engine GmbH.

This text must be included in any full or partial reproduction of this documentation.

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 1-2

Revision no: 9

1.1 Record of Revisions

All revisions of this manual must be recorded in chapter 1.2. Revisions of chapter

“6 OPERATING DATA / LIMITATIONS” requires approval by EASA.

All incorporated Temporary Revisions must be recorded in chapter 1.4.

The new or amended text is indicated by a vertical line at the left hand side of the revised

page, with the revision number and data appearing at the bottom of the page.

If pages are revised which contain information valid for 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, are inserted behind the cover page of this manual.

Temporary revisions are used to provide information on systems or equipment until the next

‘permanent’ revision of the Engine Manual. When a ‘permanent’ revision covers a Mandatory

or Optional Design Change (MDC or ODC), then the corresponding temporary revision is

superseded.

It is the responsibility of the operator to ensure that this manual is maintained to a current

status.

If the address or the ownership of the engine/aircraft changes, an address card has to be sent

to Austro Engine GmbH.

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 1-3

Revision no: 9

1.2 List of Revisions

Rev.

No.

Reason

Chapter

Page(s)

Date of

Revision

Approval

Date of

Approval

Date

In-

serted

Signature

1

Editorial

changes.

Part No

Correction

5.2.3

5.2.4

11.1

5

6

26

15.Feb.

2006

*)

2

Page

numbering

all

10.March

2006

*)

Editorial

Changes

1.2

1.3

8.2.1

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

implemented

1.1

1.2

11.1

1-3

1-4

11-1

22.Nov.

2006

*)

4

No. changed

MDC-E1-072

1.1

1.2

8.4

11.1

1-3

1-4

8-2

11-1

10.Nov.

2008

*)

5

Editorial

change

MDC-E1-083

1.1

1.2

8.4

11.1

1-3,1-4

1-5

8-1

11-1

08.July

2009

*)

6

All Diamond

Logos

changed to

Austro

Engine Logo.

Oil

specification

changed

MDC-E1-116

all

10.Narch

2011

*)

7

MDC-E1-148

1.1

5

11

2,3,4,5

3

2

16.Oct.

2013

*)

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 1-4

Revision no: 9

8

MDC-E1-154

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

9-4

8-1

8-3

9-1

12-1

13-4

19-14

25.Jan.

2018

*)

*) The technical content of this document is approved under the authority of DOA ref. EASA.21J.0399.

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 1-5

Revision no: 9

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ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 1-6

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ENGINE MANUAL

IAE50R – AA

E1.01.05 – 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 Temperature

Measuring Position

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 2-1

Revision no: 9

2 GENERAL INFORMATION

Every reasonable 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 information

given here may be superseded over a period of time by manual revisions or temporary by

Service Bulletins.

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 3-1

Revision no: 9

3 SAFETY INFORMATION

The instructions in this manual have been compiled to assist pilots and personnel responsible

for maintenance in the correct operation of the engines produced by Austro Engine GmbH.

Only correct operation and maintenance can ensure optimum availability throughout engine

life.

No recommendation in this manual absolves operators from compliance with any official

directive that may be issued by the controlling aviation authority of any country concerned, or

with any relevant Austro Engine GmbH Service Bulletins.

Austro Engine GmbH personnel are always happy to answer queries or give advice on

individual 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 following symbols and warning signs are used in this manual to point out important

instruction. They must be observed strictly to prevent personal injury and material damage, to

insure operational safety of the aircraft and to avoid any damage to the aircraft as a result of

incorrect handling.

Disregarding these safety rules can cause personal injury or even death.

Disregarding these special instruction and safety measures can damage the

engine or other components.

The maintenance intervals must be strictly observed. When the service is not executed in

accordance to this manual Austro Engine GmbH will reject any warranty claims.

Additional note or instruction for better understanding of an instruction.

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 3-2

Revision no: 9

3.2 Model Designation Breakdown

3.3 Replacement parts

It is strongly recommended that 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 performance, reliability and life of

the engine and may hazard the operator.

The use of parts not approved by Austro Engine GmbH may

invalidate the Engine Certification.

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 4-1

Revision no: 9

4 RESERVED

ENGINE MANUAL

IAE50R – AA

E1.01.05 – E

Issue date: 25.Jan.2018

Page: 5-1

Revision no: 9

5 GENERAL ENGINE DATA

5.1 Description

Wankel 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 – Diesel – Straße 11

2700 Wiener Neustadt

Austria

5.2.2 Certification

Refer to Engine Type Certificate Data Sheet No EASA.E.085.

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

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