Rotax 915 iS A Installation Manual
Rotax 915 iS A is a cutting-edge aircraft engine renowned for its exceptional performance and reliability. This powerful engine is meticulously crafted to provide an unparalleled flying experience, boasting an impressive array of features that cater to the demands of pilots seeking both efficiency and exhilaration in their aerial adventures.
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INSTALLATION MANUAL FOR ROTAX ENGINE TYPE 915 i A / C24 SERIES REF NO.: IM-915 i A / C24 | PART NO.: 898871 Before starting with engine installation, please read the Installation Manual completely as it contains important safety relevant information. This Installation Manual for the ROTAX® aircraft engines should only be used as a general installation guide for the installation of ROTAX® engines into airframes. It should not be used as instruction for the installation of a ROTAX® aircraft engine in a specific type of airframe or airplane. BRP-Rotax GmbH & Co KG does not assume any warranty or liability in this context. In no event shall the Installation Manual be used without following the specific instructions and/or requirements of the manufacture of an airframe or airplane (“Manufacturer”). For verification and/or for release of the engine installation, the respective Manufacturer must be contacted. Any modifications or adaptations to the airframe or airplane shall be carried out and/or be verified and released by the Manufacturer only. Improper use of the Installation Manual and/or non compliance with the installation requirements of the Manufacturers can cause personal injury or property damage. BRP-Rotax GmbH & Co. KG disclaims any liability for any and all damage and/or injuries (including death) resulting from the improper use of Installation Manual and non compliance with the installation requirements of the Manufacturer. These technical data and the information embodied therein are the property of BRP-Rotax GmbH & CO KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRP-Rotax GmbH & Co KG, be disclosed in whole or in part to third parties. This legend shall be included on any reproduction of these data, in whole or in part. The Manual must remain with the engine/aircraft in case of sale. ROTAX® is a trademark of BRP-Rotax GmbH & Co KG. In the following document the short form of BRP-Rotax GmbH & Co KG = BRP-Rotax is used. Other product names in this documentation are used purely for ease of identification and may be trademarks of the respective company or owner. Copyright 2024 © - all rights reserved. Translation into other languages might be performed in the course of language localization but does not lie within ROTAX® scope of responsibility. In any case the original text in English language and themetric units are authoritative. BRP-Rotax INSTALLATION MANUAL Table of Content Chapter INTRO – GENERAL NOTE Chapter LEP – LIST OF EFFECTIVE PAGES Chapter TOA – TABLE OF AMENDMENTS Chapter 00–00–00 – GENERAL NOTE Chapter 10–10–00 – STORAGE AND INSTALLATION Chapter 24–00–00 – ELECTRICAL POWER Chapter 61–00–00 – PROPELLER DRIVE Chapter 72–00–00 – ENGINE Chapter 72–60–00 – AIR INTAKE SYSTEM Chapter 73–00–00 – ENGINE – FUEL AND CONTROL Chapter 75–00–00 – COOLING SYSTEM Chapter 76–00–00 – ENGINE CONTROLS Chapter 77–00–00 – ENGINE INDICATING Chapter 78–00–00 – EXHAUST SYSTEM Chapter 79–00–00 – LUBRICATION SYSTEM Chapter 80–00–00 – STARTING Chapter 92–00–00 – WIRING DIAGRAMS Chapter APPENDIX – OPERATIONAL AND INSTALLATION CONSIDERATIONS Effectivity: 915 i A / C24 Edition 0/Rev. 5 Content Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 2 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: INTRO GENERAL NOTE Foreword Before carrying out engine installation related work on the engine, read this Installation Manual carefully. The manual will provide you with basic information on correct engine installation for safe engine operation. If any passages of the manual are not clearly understood or if you have any questions, please contact a ROTAX® authorized distributor or their independent Service Center for ROTAX® aircraft engines. BRP-Rotax GmbH & Co KG (hereinafter “BRP-Rotax“) wishes you much pleasure and satisfaction flying your aircraft powered by this ROTAX® aircraft engine. The structure of the manual follows, whenever possible, the structure of the ATA (Air Transport Association) standards. The aim is the compatibility with the aircraft manufacturers documentation, which means they still must adapt or incorporate the documentation to their standard. Effectivity: 915 i A / C24 Edition 0/Rev. 5 INTRO Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 2 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: LEP LIST OF EFFECTIVE PAGES Each new revision to the Installation Manual will have a new List of Effective Pages. Page Chapter Date Title page INTRO LEP TOA 00-00-00 Page Chapter Date 13 February 01 2024 1 February 01 2024 14 February 01 2024 2 February 01 2024 15 February 01 2024 1 February 01 2024 16 February 01 2024 2 February 01 2024 17 February 01 2024 3 February 01 2024 18 February 01 2024 4 February 01 2024 19 February 01 2024 5 February 01 2024 20 February 01 2024 1 February 01 2024 1 February 01 2024 2 February 01 2024 2 February 01 2024 3 February 01 2024 3 February 01 2024 4 February 01 2024 4 February 01 2024 5 February 01 2024 5 February 01 2024 6 February 01 2024 6 February 01 2024 1 February 01 2024 7 February 01 2024 2 February 01 2024 8 February 01 2024 3 February 01 2024 1 February 01 2024 4 February 01 2024 2 February 01 2024 5 February 01 2024 3 February 01 2024 6 February 01 2024 4 February 01 2024 7 February 01 2024 5 February 01 2024 8 February 01 2024 6 February 01 2024 9 February 01 2024 7 February 01 2024 10 February 01 2024 8 February 01 2024 11 February 01 2024 9 February 01 2024 12 February 01 2024 10 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 10-10-00 24-00-00 LEP Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Page Chapter 61-00-00 72-00-00 Date Page Chapter Date 11 February 01 2024 3 February 01 2024 12 February 01 2024 4 February 01 2024 13 February 01 2024 5 February 01 2024 14 February 01 2024 6 February 01 2024 15 February 01 2024 7 February 01 2024 16 February 01 2024 8 February 01 2024 17 February 01 2024 9 February 01 2024 18 February 01 2024 10 February 01 2024 19 February 01 2024 11 February 01 2024 20 February 01 2024 12 February 01 2024 21 February 01 2024 13 February 01 2024 22 February 01 2024 14 February 01 2024 23 February 01 2024 1 February 01 2024 24 February 01 2024 2 February 01 2024 25 February 01 2024 3 February 01 2024 26 February 01 2024 4 February 01 2024 27 February 01 2024 5 February 01 2024 28 February 01 2024 6 February 01 2024 1 February 01 2024 7 February 01 2024 2 February 01 2024 8 February 01 2024 3 February 01 2024 9 February 01 2024 4 February 01 2024 10 February 01 2024 5 February 01 2024 11 February 01 2024 6 February 01 2024 12 February 01 2024 7 February 01 2024 1 February 01 2024 8 February 01 2024 2 February 01 2024 9 February 01 2024 3 February 01 2024 10 February 01 2024 4 February 01 2024 1 February 01 2024 5 February 01 2024 2 February 01 2024 6 February 01 2024 LEP Page 2 February 01 2024 72-60-00 73-00-00 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Page Chapter 75-00-00 76-00-00 Date Page Chapter Date 7 February 01 2024 9 February 01 2024 8 February 01 2024 10 February 01 2024 9 February 01 2024 11 February 01 2024 10 February 01 2024 12 February 01 2024 11 February 01 2024 13 February 01 2024 12 February 01 2024 14 February 01 2024 13 February 01 2024 15 February 01 2024 14 February 01 2024 16 February 01 2024 1 February 01 2024 17 February 01 2024 2 February 01 2024 18 February 01 2024 3 February 01 2024 19 February 01 2024 4 February 01 2024 20 February 01 2024 5 February 01 2024 1 February 01 2024 6 February 01 2024 2 February 01 2024 7 February 01 2024 3 February 01 2024 8 February 01 2024 4 February 01 2024 9 February 01 2024 5 February 01 2024 10 February 01 2024 6 February 01 2024 11 February 01 2024 7 February 01 2024 12 February 01 2024 8 February 01 2024 13 February 01 2024 9 February 01 2024 14 February 01 2024 10 February 01 2024 1 February 01 2024 11 February 01 2024 2 February 01 2024 12 February 01 2024 3 February 01 2024 13 February 01 2024 4 February 01 2024 14 February 01 2024 5 February 01 2024 15 February 01 2024 6 February 01 2024 16 February 01 2024 7 February 01 2024 17 February 01 2024 8 February 01 2024 18 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 77-00-00 LEP Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL Page Chapter 78-00-00 79-00-00 80-00-00 Date Page Chapter Date 19 February 01 2024 3 February 01 2024 20 February 01 2024 4 February 01 2024 1 February 01 2024 5 February 01 2024 2 February 01 2024 6 February 01 2024 3 February 01 2024 7 February 01 2024 4 February 01 2024 8 February 01 2024 5 February 01 2024 9 February 01 2024 6 February 01 2024 10 February 01 2024 1 February 01 2024 11 February 01 2024 2 February 01 2024 12 February 01 2024 3 February 01 2024 1 February 01 2024 4 February 01 2024 2 February 01 2024 5 February 01 2024 1 February 01 2024 6 February 01 2024 2 February 01 2024 7 February 01 2024 3 February 01 2024 8 February 01 2024 4 February 01 2024 9 February 01 2024 5 February 01 2024 10 February 01 2024 6 February 01 2024 11 February 01 2024 7 February 01 2024 12 February 01 2024 8 February 01 2024 13 February 01 2024 9 February 01 2024 14 February 01 2024 10 February 01 2024 15 February 01 2024 11 February 01 2024 16 February 01 2024 12 February 01 2024 17 February 01 2024 13 February 01 2024 18 February 01 2024 14 February 01 2024 19 February 01 2024 15 February 01 2024 20 February 01 2024 16 February 01 2024 1 February 01 2024 17 February 01 2024 2 February 01 2024 18 February 01 2024 LEP Page 4 February 01 2024 92–00–00 APPENDIX Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Chapter Page Index Effectivity: 915 i A / C24 Edition 0/Rev. 5 Date Chapter Page Date Rear page LEP Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 6 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: TOA TABLE OF AMENDMENTS Approval* The technical content of this document is approved. It is issued under the authority of the DOA ref. EASA. 21J.048. Edition 0/Rev. 0 December 01 2017 Revision 1 June 01 2019 Revision 2 Feb. 01 2020 Revision 3 Oct. 01 2020 Revision 4 July 01 2021 Revision 5 Feb. 01 2024 Rev. no. Obsolete with Revision 5, which is a complete re-revision Chapter Page 0 INTRO all December 01 2017 DOA* 0 LEP all December 01 2017 DOA* 0 TOA all December 01 2017 DOA* 0 00-00-00 all December 01 2017 DOA* 0 10-10-00 all December 01 2017 DOA* 0 24-00-00 all December 01 2017 DOA* 0 61-00-00 all December 01 2017 DOA* 0 72-00-00 all December 01 2017 DOA* 0 72-60-00 all December 01 2017 DOA* 0 73-00-00 all December 01 2017 DOA* 0 75-00-00 all December 01 2017 DOA* 0 76-00-00 all December 01 2017 DOA* 0 77-00-00 all December 01 2017 DOA* 0 78-00-00 all December 01 2017 DOA* 0 79-00-00 all December 01 2017 DOA* 0 80-00-00 all December 01 2017 DOA* Effectivity: 915 i A / C24 Edition 0/Rev. 5 Date of change Remark for approval Date of approval from authorities Date of inclusion Signature TOA Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Rev. no. Page Chapter Date of change Remark for approval 1 LEP all June 01 2019 DOA* 1 TOA all June 01 2019 DOA* 1 00-00-00 3, 4, 5,10,15,17 June 01 2019 DOA* 1 10-00-00 2,5 June 01 2019 DOA* 1 24–00–00 2,3,7,8,13 June 01 2019 DOA* 1 61-00-00 4,5,6,9 June 01 2019 DOA* 1 72-00-00 2,4 up to 7, 9, 10 June 01 2019 DOA* 1 72-60-00 3 up to 7 June 01 2019 DOA* 1 73-00-00 10 June 01 2019 DOA* 1 75-00-00 3,5,7,10,11 June 01 2019 DOA* 1 76-00-00 9,12 June 01 2019 DOA* 1 77-00-00 3,8 June 01 2019 DOA* 1 78-00-00 3,4 June 01 2019 DOA* 1 79-00-00 2,3,8,11,15 June 01 2019 DOA* 1 APPENDIX all June 01 2019 DOA* Rev. no. Page Chapter Date of change Remark for approval 2 LEP all Feb. 01 2020 DOA* 2 TOA all Feb. 01 2020 DOA* 2 61-00-00 6 Feb. 01 2020 DOA* 2 72-60-00 4, 5 Feb. 01 2020 DOA* 2 73-00-00 8 Feb. 01 2020 DOA* 2 79-00-00 4, 5 Feb. 01 2020 DOA* TOA Page 2 February 01 2024 Date of approval from authorities Date of inclusion Signature Date of approval from authorities Date of inclusion Signature Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Rev. no. Page Chapter Date of change Remark for approval 3 LEP all Oct. 01 2020 DOA* 3 TOA all Oct. 01 2020 DOA* 3 24-00-00 12 Oct. 01 2020 DOA* 3 61-00-00 3 Oct. 01 2020 DOA* 3 73-00-00 5,8 Oct. 01 2020 DOA* 3 76-00-00 4 Oct. 01 2020 DOA* 3 79-00-00 3,4,13 Oct. 01 2020 DOA* Rev. no. Page Chapter Date of change Remark for approval 4 LEP all July 01 2021 DOA* 4 TOA all July 01 2021 DOA* 4 00-00-00 3,18 July 01 2021 DOA* 4 10-00-00 4 July 01 2021 DOA* 4 24-00-00 3,5,12–29 July 01 2021 DOA* 4 72-00-00 9 July 01 2021 DOA* 4 72-60-00 3 July 01 2021 DOA* 4 73-00-00 5,6,7 July 01 2021 DOA* 4 76-00-00 3,4,1013,18,19 July 01 2021 DOA* 4 77-00-00 3,9-11,1619 July 01 2021 DOA* 4 79-00-00 3,4 July 01 2021 DOA* 4 80-00-00 4,5,7 July 01 2021 DOA* 4 92-00-00 1,2 July 01 2021 DOA* Effectivity: 915 i A / C24 Edition 0/Rev. 5 Date of approval from authorities Date of inclusion Signature Date of approval from authorities Date of inclusion Signature TOA Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL Rev. no. Page Chapter Date of change Remark for approval 5 LEP all Feb. 01 2024 DOA* 5 TOA all Feb. 01 2024 DOA* 5 00-00-00 20 Feb. 01 2024 DOA* 5 24-00-00 5 Feb. 01 2024 DOA* 5 61-00-00 3,6 Feb. 01 2024 DOA* 5 72-00-00 11 Feb. 01 2024 DOA* 5 72-60-00 9 Feb. 01 2024 DOA* 5 75-00-00 7–11 Feb. 01 2024 DOA* 5 78-00-00 3 Feb. 01 2024 DOA* 5 79-00-00 3,5,7 Feb. 01 2024 DOA* 5 80-00-00 9 Feb. 01 2024 DOA* TOA Page 4 February 01 2024 Date of approval from authorities Date of inclusion Signature Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Summary of amendments Summary of the relevant amendments in this context, but without any claim to completeness. Rev. no. Chapter Page Date of change Comment 1 1 1 1 1 1 1 1 1 1 1 1 00-00-00 24-00-00 61-00-00 72-00-00 72-60-00 75-00-00 76-00-00 77-00-00 78-00-00 79-00-00 APPENDIX 3 10 2,13 5,6 9, 10 3–7 5,7,10 9,12 8 3,4 2,3,8,11,15 all June 01 2019 June 01 2019 June 01 2019 June 01 2019 June 01 2019 June 01 2019 June 01 2019 June 01 2019 June 01 2019 June 01 2019 June 01 2019 June 01 2019 Configuration 2 added Wiring color codes New figure New figure Change of text Change of text, new figures Change of text Change of text, Update of figures Update of figures New figures Change of text, new figures Appendix added Rev. no. Chapter Page Date of change Comment 2 2 2 2 61-00-00 72-60-00 73-00-00 79-00-00 6 4,5 8 4,5 Feb. 01 2020 Feb. 01 2020 Feb. 01 2020 Feb. 01 2020 Change of text Change of text, Update of figures Change of text, Update of figures Change of text Rev. no. Chapter Page Date of change Comment 3 3 3 3 3 24-00-00 61-00-00 73-00-00 76-00-00 79-00-00 12 3 5,8 4 3,4,13 Oct. 01 2020 Oct.01.2020 Oct. 01 2020 Oct. 01 2020 Oct. 01 2020 Change of text New figures Update of figures Change of text Change of text Rev. no. Chapter Page Date of change Comment 4 4 4 4 4 4 4 4 4 00-00-00 24-00-00 72-00-00 73-00-00 76-00-00 77-00-00 79-00-00 80-00-00 92-00-00 3,19 3,5,12–19 9 5,7 3,10-13,18 3.9-11,16-18 3,4 4,5,7 1,2 July 01 2021 July 01 2021 July 01 2021 July 01 2021 July 01 2021 July 01 2021 July 01 2021 July 01 2021 July 01 2021 New engine type, Change of text New text New figures with torque New figures, New text New figures, New text Change of text, Update of figure New text, New figure New text New chapter Effectivity: 915 i A / C24 Edition 0/Rev. 5 TOA Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL Rev. no. Chapter Page Date of change Comment 5 5 5 5 5 5 5 5 5 00-00-00 24-00-00 61-00-00 72-00-00 72-60-00 75-00-00 78-00-00 79-00-00 80-00-00 20 5 3,6 11 9 7-11 3 3,5,7 9 Feb. 01 2024 Feb. 01 2024 Feb. 01 2024 Feb. 01 2024 Feb. 01 2024 Feb. 01 2024 Feb. 01 2024 Feb. 01 2024 Feb. 01 2024 Change of text New figure New text, New figures New text New figures New text, New figure Change of text, Update of figure, New text New section TOA Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Chapter: 00–00–00 GENERAL NOTE TOPICS IN THIS CHAPTER General....................................................................................................................................................2 Type description......................................................................................................................................3 Scope of supply.......................................................................................................................................4 Auxiliary equipment (optional) ................................................................................................................5 Abbreviations and terms (depending on respective engine type)............................................................6 Wiring color codes ............................................................................................................................... 11 Conversion table .................................................................................................................................12 Safety notice .........................................................................................................................................13 Safety information ...............................................................................................................................14 Instruction...........................................................................................................................................16 Technical documentation ......................................................................................................................17 Approval of electric and electronic components (Equipment Qualification according to RTCA/DO160) .......................................................................................................................................................19 Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL GENERAL Purpose The purpose of this Manual is to provide aircraft manufacturers with technical requirements (e.g. interface descriptions and limitations) that must be adhered to when installing this type of engine into an aircraft or certifying aircraft powered by this engine type. Furthermore it should allow independent ROTAX® Maintenance Technicians (iRMT) to install this engine into an airframe in compliance with the relevant installation and safety instructions provided by the engine manufacturer. For detailed information related to aircraft and aircraft/engine installation, maintenance, safety or flight operation, consult the documentation provided by the aircraft manufacturer and/or its dealer. For additional information on engines, its maintenance or parts, you can also contact your nearest ROTAX® authorized Aircraft Engine Distributor or their independent Service Center. ROTAX Distributors For ROTAX® Authorized Distributors for aircraft engines see latest Operators Manual or the official website www.FLYROTAX.com. Engine serial number When making inquiries or ordering parts, always indicate the engine serial number. Due to continuous product improvement, engines of the same engine type might require different support and spare parts. The engine serial number is on top of the crankcase, behind the propeller gearbox. Figure 1.1: Engine serial number 1 00–00–00 Page 2 February 01 2024 Engine serial number Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL TYPE DESCRIPTION The type description consists of the following parts: e. g. ROTAX 915 iSc 2 A type certification configuration additional designation Designation Designation Type 915 4-cylinder horizontally opposed, turbocharged engine. Certification iSc Certified to EASA CS-E (TC No.EASA.E.121) iS Approved to according ASTM F2339. 2 Propeller shaft with flange for fixed pitch propeller. 3 Propeller shaft with flange for constant speed propeller and drive for hydraulic governor for constant speed propeller. A 12 Volt air-frame bus version C24 24 Volt air-frame bus version Configuration Additional designation Options Description Available options (optional equipment) for the engine type mentioned above: external alternator governor exhaust system for configuration 2 YES NO YES for configuration 3 YES YES YES NOTE Conversion of the configuration 2 to configuration 3 and vice versa may be accomplished by BRP-Rotax Authorized Distributors or their independent Service Centers. Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL SCOPE OF SUPPLY Basic • 4- stroke-, 4 cylinder horizontally opposed-, spark ignition engine, single central camshaft push rods —OHV (Over Head Valve) • Liquid cooled cylinder heads • Ram air cooled cylinders • Dry sump forced lubrication • Fully redundant electronic engine management system (EMS) for controlling fuel injection, ignition, etc. • Propeller drive via gearbox with integrated torsional vibration absorber and overload clutch • Oi tank • Electric starter • Turbocharger • Electronic/pneumatic control of boost pressure • Exhaust system Optional • Accessory drive for hydraulic propeller governor (configuration 3 only) • Cooling air baffle 00–00–00 Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL AUXILIARY EQUIPMENT (OPTIONAL) Any equipment not included as part of the standard engine version and thus not a fixed component of the engine is not in the volume of supply. Components especially developed and tested for this engine are readily available at BRPRotax. Auxiliary equipment certified The following auxiliary equipment has been developed and tested for this engine. • See relevant Illustrated Parts Catalog (IPC) Auxiliary equipThe following auxiliary equipment has been developed and tested, but NOT certified for ment not certified this engine. Certification of auxiliary equipment is the responsibility of the aircraft manufacturer. • See relevant Illustrated Parts Catalog (IPC) The representation of components that are not within scope of the delivery is purely symbolic. It does not constitute the specification of the engine version and shall therefore only be seen functionally. The actual interpretation/selection of corresponding regulations is the aircraft manufacturer’s responsibility. Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL ABBREVIATIONS AND TERMS (DEPENDING ON RESPECTIVE ENGINE TYPE) Abbreviations Description * Reference to another section @ center of gravity The drop symbol indicates use of sealing agents, adhesives or lubricants (only in the Maintenance Manual Heavy) 00–00–00 Page 6 February 01 2024 °C Degrees Celsius (Centigrade) °F Degrees Fahrenheit rpm Revolutions per minute A Ampere AAPTS Ambient Air Pressure Temperature Sensor AC alternating current AD Airworthiness Directives Ah Ampere hour A/C Aircraft AC-DC EMS Modul voltage converter AR as required assy. assembly ASB Alert Service Bulletin ACG Austro Control GmbH ACL Anti Collision Light API American Petrol Institute ASTM American Society for Testing and Materials ATA Air Transport Association AWG American Wire Gauge CAN Controller Area Network CCS Camshaft position sensor Coil 1–4 Ignition coils 1–4 CPS 1+2 Crankshaft Position Sensor 1+2 CSA Constant Speed Actuator CTS Cooling Temperature Sensor Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Abbreviations Description CW clockwise CCW counter-clockwise CGSB Canadian General Standards Board DCDI Dual Capacitor Discharge Ignition DC direct current DOA Design Organisation Approval DOT Department of Transport EASA European Aviation Safety Agency IM Installation Manual ECU Engine Control Unit EGT Exhaust Gas Temperature INTRO Introduction EMS Engine Management System EMS GND Engine system internal ground reference which is intended to be disconnected from aircraft common ground during flight EMC Electromagnetic compatibility EN European Standard ETFE Ethylene Tetrafluoroethylene FAA Federal Aviation Administration FAR Federal Aviation Regulations FOD Foreign object damage FL Flight Level Fuse box Power conditioning and distribution for the Engine Management System hr. hours HIC A Harness Interface Connector A HIC B Harness Interface Connector B IAT Indicated Air Temperature ICA Instructions for Continued Airworthiness IFR Instrument Flight Rules IFSD In-flight-shutdown INJ 1–8 Injector 1–8 Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL 00–00–00 Page 8 February 01 2024 Abbreviations Description IPC Illustrated Parts Catalog ips inch per second iRMT independent ROTAX Maintenance Technician ISA International Standard Atmosphere kg Kilograms KNOCK Knock sensor Lane A System A of Engine Management System Lane B System B of Engine Management System LOPC Loss of power control MAPS 1 & 2 Manifold Air Pressure Sensor 1 & 2 MATS 1 & 2 Manifold Air Temperature Sensor 1 & 2 MCON 1.2 Sealed electrical connector MON Motor Octane Number MAG Magneto Side N Newton n.a. not available NDT Non Destructive Testing NEW Part must be replaced against NEW (mentioned in figures) Nm Newtonmeter NVFR Night Visual Flight Rules OAT Outside Air Temperature OHM Overhaul Manual OHV Over Head Valve OM Operators Manual OPS Oil Pressure Sensor OTS Oil Temperature Sensor PCD Pitch Circle Diameters PCV Pressure Control Valve PMA Permanent magnet alternator POA Production Organization Approval PS Power supply Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Abbreviations Description PTFE Polytetrafluoroethylene (Teflon) PTO Power Take Off Rev. Revision ROTAX® is a trademark of BRP-Rotax GmbH & Co KG RON Research Octane Number RON 424 ROTAX® Standard 424 s.v. still valid (only Illustrated Parts Catalog) S/N Serial Number SAE Society of Automotive Engineers SEP Single Engine Piston SB Service Bulletin SI Service Instruction SI-PAC Service Instruction Parts and Accessories SPST Single pole single throw STP Shielded twisted pair wire SL Service Letter SMD Surface Mounted Devices TBO Time Between Overhaul TC Type certificate part no. part number TOA Table Of Amendments TOC Table Of Contents TPS Throttle Position Sensor TSN Time Since New TSNP Time Since New Part TSO Time Since Overhaul V Volt VFR Visual Flight Rules LEP List of Effective Pages MM Maintenance Manual MEP Multi Engine Piston Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL 00–00–00 Page 10 February 01 2024 Abbreviations Description X3 Connector on Engine Management System wiring harness which serves as an interface for power supply XXXX shows the component serial number Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL WIRING COLOR CODES Figure 1.2 Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL CONVERSION TABLE Units of length: 1 mm = 0.03937 in 1 in = 25.4 mm 1 ft = 12 in = 0.3048 m Units of area: 1 cm² = 0.155 sq. in (in²) 1 sq. in (in²) = 6.4516 cm² Units of volume: 1 cm³ = 0.06102 cu in (in³) 1 cu in (in³) = 16.3871 cm³ 1 dm³ = 1 l 1 dm³ = 0.21997 gal (UK) 1 gal (UK) = 4.5461 dm³ 1 dm³ = 0.26417 gal (US) 1 gal (US) = 3.7854 dm³ Units of mass: 1 kg = 2.2046 lbs. 1 lb. = 0.45359 kg Density: Units of force: 1 N = 0.224809 lbf 1 lbf = 4.4482 N Units of pressure: 1 Pa = 1 N/m² 1 bar = 100 000 Pa / 1000 hPa / 100 kPa 1 bar = 14.503 lbf/in² (psi) 1 in Hg = 33.8638 hPa Page 12 February 01 2024 1 kW = 1.341 hp 1 hp = 0.7457 kW 1 kW = 1.3596 PS 1 PS = 0.7355 kW Units of temperature: K = °C – 273,15 °C = (°F – 32) / 1,8 °F = (°C x 1.8) +32 Units of velocity: 1 m/s = 3.6 km/h 1 ft/min = 0.3048 m/min = 0.00508 m/sec 1 m/s = 196.85 ft/min 1 kt = 1.852 km/h 1 km/h = 0.53996 kn spec. fuel consumption: 1 g/kWh = 0.001644 lb/hph 1 lb/hph = 608.277 g/kWh Units of torque: 1 g/cm³ = 0.016018 lb/ft³ 1 lb/ft³ = 62.43 g/cm³ 00–00–00 Units of power: 1 Nm = 0.737 ft lb = 8.848 in lb 1 ft lb = 1.356 Nm 1 in lb = 0.113 Nm Cable cross-section: Conversion tableWire Gauge: AWG-mm² AWG —> mm² 4 —> 21 6 —> 13 8 —> 8.4 10 —> 5.3 12 —> 3.3 14 —> 2.1 16 —> 1.3 18 —>0.8 20—> 0.52 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SAFETY NOTICE Although reading such information does not eliminate any hazards, it promotes understanding, and applying of the information will promote correct use of the engine. Always apply common workshop safety rules. The information and descriptions of components and systems contained in this Manual are correct at the time of publication. BRP-Rotax maintains a policy of continuous improvement of its products without imposing upon itself any obligation to retrofit products previously manufactured. Revisions BRP-Rotax reserves the right to remove, replace or discontinue any design, specification, feature or other at any time, and without incurring obligation. Measurement Specifications are given in the SI metric system with the imperial- and US customary measurement system equivalents in parenthesis. Symbols used This Manual uses the following symbols to emphasize particular information. This information is important and must be observed. m WARNING Identifies an instruction which, if not followed, may cause serious injury or even fatal injury. m CAUTION Identifies an instruction which, if not followed, may cause minor or moderate injury. NOTICE Identifies an instruction which, if not followed, may severely damage the engine or could void any warranty. NOTE Indicates supplementary information which may be needed to fully complete or understand an instruction. ENVIRONMENTAL NOTE Environmental notes give you tips on environmental protection. A revision bar outside the page margin indicates a change to text or graphic. Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL SAFETY INFORMATION Use for intended purpose m WARNING Non-compliance can result in serious injuries or death! The user has to assume all risks possibly arising from utilizing auxiliary equipment. m WARNING Non-compliance can result in serious injuries or death! Never fly the aircraft equipped with this engine at locations, air speeds, altitudes or in other situations which do not allow a successful no-power landing after sudden engine stoppage. • This engine is not suitable for aerobatics (inverted flight, etc.). Flight attitudes outside the permissible limits are not allowed • This engine has exclusively been developed and tested for fixed wing, gyrocopter, pusher and tractor applications. In case of any other usage, the OEM is responsible for testing and the correct function of the engine • It should be clearly understood that the choice, selection and use of this particular engine on any aircraft is at the sole discretion and responsibility of the aircraft manufacturer, assembler or owner/user • Due to the varying designs, equipment and types of aircraft, BRP-Rotax grants no warranty on the suitability of its engines use on any particular aircraft. Further, BRP-Rotax grants no warranty on this engines suitability with any other part, component or system which may be selected by the aircraft manufacturer, assembler or user for aircraft application m WARNING Non-compliance can result in serious injuries or death! For each use of DAY VFR, NIGHT VFR or IFR in an aircraft the applicable legal requirements and other existing regulations must be adhered to. • In addition to observing the instructions in our Manual, general safety and accident precautions, legal regulations and regulations of any aeronautical authority must be observed • Where differences exist between this Manual and regulations provided by any authority, the more stringent regulation shall be applied • For continued airworthiness see Maintenance Manual Line (MML) • Unauthorized modifications of engine or aircraft will automatically exclude any liability of the engine manufacturer for consequential damage 00–00–00 Page 14 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Engine operation • The engine must always be operated according to the content of the latest Operators Manual (OM) • To eliminate the risk of injury or damage, ensure any loose equipment or tools are properly secured before starting the engine • The use of propellers and their fastenings which exceed the specified values of moment of inertia and imbalance is not allowed and releases the engine manufacturer from any liability • Improper engine installation, use of unsuitable piping for fuel, cooling and lubrication system and use of unsuitable wiring for electric and engine management system releases the engine manufacturer from any liability Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 15 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTRUCTION Engines require instructions regarding their installation, application, use, operation, maintenance and repair. Technical documentation and regulations are useful and necessary complementary elements for trainings, but can by no means substitute for theoretical and practical instructions. These instructions should cover explanation of the technical context, advice for operation, maintenance, installation, use and operational safety of the engine. Safety notice In this technical Manual passages concerning safety are especially marked. Pass on safety warnings to other users! Accessories This engine must only be operated with accessories supplied, recommended and released by BRP-Rotax. Modifications are only allowed after consent of the engine manufacturer. Spare parts See Illustrated Parts Catalog (IPC), latest issue for the respective engine type. NOTICE Only use GENUINE ROTAX® spare parts. Spare parts must meet the requirements defined by the engine manufacturer. This can only be guaranteed when using spare parts and/or accessories. Spare parts are available at Authorized Distributors and their independent Service Centers. Any warranty by will become void if spare parts and/ or accessories other than spare parts and/or accessories are used (see latest Warranty Conditions). See relevant Service Letter on www.flyrotax.com. Standard tools / Special tools NOTICE Only use tools and appliances which are suitable for the relevant task according to the latest Manuals. State of delivery m WARNING Engine and gearbox are delivered in “dry“ conditions (without fuel, oil and coolant). Before putting the engine into operation it must be filled with oil and cooling liquid. Use only oil and coolant as specified. See latest Operators Manual (OM) and Service Instruction SI-915 i-001 “Selection of suitable operating fluids“, current issue. 00–00–00 Page 16 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL TECHNICAL DOCUMENTATION These documents form the instructions ensuring continued airworthiness of ROTAX® aircraft engines. The information contained herein is based on data and experience that are considered applicable for authorized mechanics (iRMT, see MML, Chapter 05–00–00 section “Authorized Personnel”) under normal conditions for engine removal and installation. Concerning design of engine installation in depth knowledge of aircraft design is required. Due to the fast technical progress and fulfillment of particular specifications of the customers it may occur that existing laws, safety prescriptions, constructional and operational regulations may not be sufficient or cannot be transferred completely to the object bought, in particular for special constructions. Documentation • Installation Manual (IM) • Operators Manual (OM) • Maintenance Manual Line (MML) • Maintenance Manual Heavy (MMH) • Overhaul Manual (OHM) • Illustrated Parts Catalog (IPC) • Alert Service Bulletin (ASB) • Service Bulletin (SB) • Service Instruction / Service Instruction-Parts and Accessories (SI-PAC) • Service Letter (SL) Status The status of the Manuals can be determined by checking the table of amendments. The first column of this table indicates the revision status, which should be compared with the revision provided on the ROTAX®-Website: www.FLYROTAX.com Amendments and current versions can be downloaded free of charge. Replacement pages Furthermore the Manual is constructed in such a way that single pages can be replaced instead of the complete document. The list of affected pages is given in the chapter LEP. The particular edition and revision number is given on the footer of each page. Reference This Manual is only part of the technical documentation and will be supplemented by the respective Operators Manual (OM), Maintenance Manuals and Illustrated Parts Catalog (IPC). NOTICE Pay attention to references to other documentation, found in various parts of this Manual. If not stated otherwise, any reference to a document refers to the latest edition issued by BRP-Rotax. Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 17 February 01 2024 BRP-Rotax INSTALLATION MANUAL This symbol informs you of additional references (data sheets, Manuals, etc.) associated with the given subject. Illustrations The illustrations in this Manual are merely sketches and show typical arrangements. They may not represent full detail or the exact shape of the parts but should outline the same or similar function. Therefore deriving dimensions or other details from illustrations is not permitted. TYPICAL indicates a general view which may not represent exact details. NOTE The Illustrations in this Manual are stored in a graphic database system and are provided with a consecutive, irrelevant, number. This number (e.g. AE 5iS001) is of no significance for the content. Some measurements are given in the drawings, these are manufacturing dimensions and are subject to corresponding tolerances. Installation drawings Installation drawings and a “digital mock-up (DMU) model” for (virtual) installation analysis are available from the ROTAX® Authorized Distributors or their independent Service Centers on special request and relevant non disclosure and copyright regulations. The illustrations in this Manual show a possible installation variant including non certified parts. 00–00–00 Page 18 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL APPROVAL OF ELECTRIC AND ELECTRONIC COMPONENTS (EQUIPMENT QUALIFICATION ACCORDING TO RTCA/DO-160) RTCA/DO-160 defines a series of minimum standard environmental test conditions and applicable test procedures for airborne equipment. The purpose of these tests is to provide a laboratory means of determining the performance characteristics of airborne equipment in environmental conditions representative of those which may be encountered in airborne operation of the equipment. Electric and Electronic components (incl. wiring harness, ECU, Fuse Box, PMA, Sensors and Actuators) of the 915 i A Series are considered as part of the equipment and have been tested and qualified according to the following table: DO-160G, Section 4 — Temperature and Altitude Cat. B3V1 DO-160G, Section 5— Temperature Variation Cat. B DO-160G, Section 6— Humidity Cat. B DO-160G, Section 7— Operational Shocks and Crash Safety Cat. BD DO-160G, Section 8 — Vibration Cat. S (L) DO-160G, Section 9— Explosion Proofness Test not performed DO-160G, Section 10 — Water Proofness Cat. S DO-160G, Section 11 — Fluids Susceptibility Cat. F DO-160G, Section 12 — Sand and Dust Cat. D DO-160G, Section 13 — Fungus Resistance Test not performed DO-160G, Section 14 — Salt Spray Cat. S DO-160G, Section 15 — Magnetic Effect Cat. A DO-160G, Section 16 — Power Input Cat. BXX DO-160G, Section 17 — Voltage Spike Cat. A DO-160G, Section 18 — AF Cond. Susceptibility Cat. Z DO-160G, Section 19 — Induced Signal Susceptibility Cat. ZCX DO-160G, Section 20 — RF Susceptibility Conducted DO-160G, Section 20 — RF Susceptibility Radiated Cat. M Cat. D DO-160G, Section 21 — Emission RF Energy Conducted DO-160G, Section 21 — Emission RF Energy Radiated Cat. B Cat. B DO-160G, Section 22 — Lightning Induced Trans. Suspectibility Cat. B3H3L3 DO-160G, Section 23 — Lightning Direct Effects Test not performed 1. Components were tested at „operating low temperature“ of - 40 °C (- 40 °F) instead of - 45 °C (- 49 °F). Effectivity: 915 i A / C24 Edition 0/Rev. 5 00–00–00 Page 19 February 01 2024 BRP-Rotax INSTALLATION MANUAL Component surface temperature limits 00–00–00 Page 20 February 01 2024 DO-160G, Section 24 — Icing Test not performed DO-160G, Section 25 — Electrostatic Discharge Cat. A System Limit Min. Max. ECU - 40 °C (- 40 °F) 80 °C (176 °F) EGT Sensors (electronic box) - 40 °C (- 40 °F) 80 °C (176 °F) Fusebox - 40 °C (- 40 °F) 80 °C (176 °F) AC-DC Converter assy. - 40 °C (- 40 °F) 80 °C (140 °F) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Chapter: 10–10–00 STORAGE AND INSTALLATION TOPICS IN THIS CHAPTER Special tools............................................................................................................................................3 General....................................................................................................................................................4 Engine storage......................................................................................................................................4 Unpacking the engine ............................................................................................................................5 Engine handling ....................................................................................................................................7 Effectivity: 915 i A / C24 Edition 0/Rev. 5 10–10–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 2.1: 915 iS engine TYPICAL 10–10–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SPECIAL TOOLS Description Part number Engine lift set 876040 Effectivity: 915 i A / C24 Edition 0/Rev. 5 10–10–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL GENERAL NOTICE Risk of consequential damage to engine and aircraft as a result of corrosion and damage. Under no circumstances is a corroded or damaged engine to be installed in an aircraft! ENGINE STORAGE The engine is preserved at BRP-Rotax thus guaranteeing proper protection against corrosion damage for at least 12 months after the date of delivery from BRP-Rotax. This warranty is subject to the following conditions: • The engine must be stored in the GENUINE-ROTAX®-packing as supplied by BRPRotax. • The covers on various openings must not be removed • The engine must be stored in a suitable place (at min. -40 °C/-40 °F and max. +80 °C/ 176 °F) • The bag (blue) surrounding the engine must not be damaged or removed, as it protects the engine from corrosion and oxidation If the engine is stored for a period longer than 12 months (or it is not stored in the GENUINE-ROTAX®-packing) then maintenance tasks must be carried out every 3 months as per the currently valid Maintenance Manual Line. General note All general inspection, maintenance and repair has to be carried out in accordance with Advisory Circular AC 43.13 from FAA. Advisory Circular This Manual "Advisory Circular" AC describes maintenance methods, techniques and practice. These are recognized and authorized for inspection and repairs in non-pressurized areas for which there are no separate maintenance and repair instructions. Corrosion Environmental corrosion (on the external surfaces) is a naturally occurring process which can inevitably affect the continued airworthiness of the engine, engine mounted components and accessories. Susceptibility to corrosion is influenced by a number of factors, including but not limited to, geographical location, season and usage. All general preventive (technical) measures, identification, control and treatment of corrosive attack on aircraft structures and engine materials has to be carried out in accordance with Advisory Circular AC 43-4B from FAA and also in accordance with the information of the aircraft manufacturers Instruction for Continued Airworthiness. Furthermore the preservation procedures for stored and inactive aircraft (engines) provides an effective means for combating and minimizing the corrosion condition and should be adhered to. Advisory Circular AC 43-4B This advisory circular (AC) is a summary of the current available data regarding identification and treatment of corrosive attack on aircraft structures and engine materials. Corrosion inspection frequency, corrosion identification, and especially corrosion treatment continues to be the responsibility of the operator. These inspections should be accomplished per this AC, the manufacturer’s recommendations, or the operator’s own maintenance program. The procedures in this AC are an acceptable 10–10–00 Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL means, but not the only acceptable means, of corrosion treatment. The information in this AC is applicable to aircraft for which the manufacturer has not published corrosion control information. UNPACKING THE ENGINE NOTICE The attachment screws are only for transport and must not be used in the aircraft. NOTICE During engine installation take into account the total engine weight and ensure careful handling. Unpacking the engine When the engine is delivered, check for damage of the packaging. If the package is damaged, contact a ROTAX® Authorized Distributor or their independent Service Center for ROTAX® aircraft engines. To unpack a new engine and for checking the state of delivery, proceed as follows: 1. Remove the wooden cover. 2. Remove the bag and protective wrapping around the engine. 3. Check that the serial number and engine type on the type plate are identical to those shown on the delivery note. If the serial number or the engine type is deviating from the delivery contact a ROTAX® Authorized Distributor- or their independent Service Center for ROTAX® aircraft engines. 4. Check the engine for damage or corrosion. If the engine is damaged or corroded, contact a ROTAX® Authorized Distributor- or their independent Service Center for ROTAX® aircraft engines. 5. Screw off the transport bracket screws from wooden bottom of the box. 6. Remove transport brackets from engine. Protective coverings NOTICE Protective coverings are only for use during transport and engine installation. They must be removed completely (including sealing materials) before the engine is operated. All openings are protected against ingress of contamination and dampness. It is recommended to leave the protective plugs in place until installation of the specific feed line. The protective coverings can be found at following locations: Effectivity: 915 i A / C24 Edition 0/Rev. 5 10–10–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL Pos. Installation location 1 Exhaust pipe (tail pipe) 2 Fuel rail (outlet) / fuel pressure regulator 3 Fuel rail (inlet) 4 Oil inlet/outlet and oil return turbo (oil pump) 5 Coolant inlet/outlet 6 Throttle body socket assy. 7 Air intake socket on turbocharger 8 Wastegate 9 Propeller shaft 10 Cover plate hydraulic governor (if configuration 3) 11 Oil return turbo (governor flange) Amount Figure 2.2: Protective covering positions 10–10–00 Page 6 February 01 2024 1 Exhaust pipe 2 Fuel (outlet) /fuel pressure regulator 3 Fuel rail (inlet) 4 Oil inlet/outlet and oil return turbo 5 Coolant inlet/outlet 6 Throttle body socket assy. 7 Air intake socket on turbocharger 8 Wastegate 9 Propeller shaft 10 Cover plate governor (if configuration 3) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL ENGINE HANDLING NOTICE Do not use the fuel lines or the wiring harness for lifting the engine! Attachment points The engine may only be lifted on the dedicated attachment points by using the GENUINEROTAX®- engine lift set and a spreader bar with 350 mm (13.78 in) distance between lifting points. Make sure that lifting device does not bend the attachment lugs by relevant force distribution. Figure 2.3: Attachment points Effectivity: 915 i A / C24 Edition 0/Rev. 5 10–10–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 8 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: 24–00–00 ELECTRICAL POWER TOPICS IN THIS CHAPTER System description .................................................................................................................................4 System limitations .................................................................................................................................4 Interface description– 915 I Type A..........................................................................................................6 Interface overview .................................................................................................................................6 Electrical interfaces ...............................................................................................................................6 Mechanical interfaces .......................................................................................................................... 11 Interface description– 915 I Type C24 ...................................................................................................12 Interface overview.– 915 I Type C24 .....................................................................................................12 Electrical interfaces – 915 I Type C24 ...................................................................................................12 Mechanical interfaces – 915 I Type C24 ................................................................................................18 Installation notes...................................................................................................................................20 Installation overview ............................................................................................................................20 Grounding cables ................................................................................................................................20 Battery................................................................................................................................................21 Control elements .................................................................................................................................22 Validation of installation ........................................................................................................................26 Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL 915 i TYPE A Figure 3.1: Internal power supply 24–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 915 i TYPE C24 Figure 3.2: Internal power supply Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed system description refer to the latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS NOTICE Consumer cables must NOT be routed alongside the ignition cables. There is a risk of electromagnetic interference. Valid installation positions The Fusebox must not be installed in the cockpit. Installation is only allowed in the engine compartment. Component temperatures limitation Limitations see Chapter 00-00-00 Approval of electric and electronic components. The Regulator temperature must be measured as shown within the following figure: 915 i TYPE A Figure 3.3: Regulator temperature measurement area TYPICAL 1 24–00–00 Page 4 February 01 2024 Rectifier regulator 2 Component temperature measurement area Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 915 i TYPE C 24 Figure 3.4: Regulator temperature measurement area 1 28 V AC-DC Converter assy. 2 Component temperature measurement area Separation of A connection between regulator plate A (EMS ground) and airframe ground should only EMS and Airframe be done during supply of the EMS System by an external power source (e.g. during encircuit gine start). Although it would have no impact on the redundancy of the EMS, the fault tolerance of the system will be degraded if the EMS ground is connected permanently with the airframe ground. Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION– 915 I TYPE A INTERFACE OVERVIEW Figure 3.5: Fusebox connections 1 X1 Connector (electrical interface) 2 X2 Connector (electrical interface) 3 X3 Connector (electrical. interface) 4 Regulator Plate A (electrical interface) 5 Regulator Plate B (electrical interface) 6 Fusebox mounting points (mechanical interface) ELECTRICAL INTERFACES The seals supplied with the Fusebox must be inserted into the X1,X2 and X3 Connector (Fusebox side) to enable a good connection between plug and socket and thus avoid unnecessary vibrations and misalignment of connector pins. Fusebox –X1, X2 Connector The X1 and X2 ensure the power distribution to the EMS System. Both plugs must be connected with mating sockets on the (engine-) wiring harness. The connectors are not interchangeable and are marked on the wiring harness side. Fusebox–X3 Connector For information on the X3 Connector, see the relevant SI-PAC-012. 24–00–00 Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 1 2 3 AE 5iS_0372 Figure 3.6: X3-Connector: Fusebox side 1 Terminal 1 3 Terminal 3 2 Terminal 2 Terminal 1 enables the EMS to be supplied with an external power source (e.g. in case the internal power supply fails supplying the EMS). Terminal 2 enables powering the EMS during engine start (until the engine speed is high enough that the internal generator is able to supply the EMS). Terminal 3 can be used for supplying the Airframe with electrical energy after generator A has taken over powering the EMS. Terminal 1 Interface Parameter Input voltage: Min. 9 V2 Input load: 2 Input: voltage: Output voltage: Output capacity: Nominal 14.5 V 12 V 230 W DC cont. 290 W DC peak 9V Input load: 3 Max. 14.5 V 12 V 230 W DC cont. 290 W DC peak 13.9 V 14.5 V 14.2 V max. 420 W DC (at 20°) (68 °F) see section performance diagram 2. This limit must also be considered when the starter motor is actuated Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL NOTICE In failure conditions the output voltage can exceed the specified limits. The following measurement is taken at an oil temperature of 135 °C (275 °F). Figure 3.7: Characteristic curve of internal generators 24–00–00 Page 8 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Fusebox Regulator A The regulator plate A needs to be connected with the EMS Ground (ring terminals on the (engine-) wiring harness). The stud has M4 threads suitable for ring terminals according to DIN 46225 or MS25036– 149 (size #8) (tightening torque: 1.2 Nm / 11 in lb). The ring terminals need to be evenly spread onto the three available studs. Figure 3.8: Fusebox -Regulator A 1 Regulator 3 Ground studs 2 Regulator plate A NOTICE A connection between regulator plate A and airframe ground should only be done during supply of the EMS System by an external power source (e.g. during engine start). Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL Fusebox Regulator B The Regulator B needs to be connected with the Airframe Ground. The stud has M6 threads suitable for ring terminals according to DIN 46225 or MS25036 (1/4” PIDG) (tightening torque: 5.9 Nm / 52 in lb). Figure 3.9: Fusebox -Regulator B – TYPICAL 1 Regulator 3 Ground terminals 2 Regulator plate B Figure 3.10: Fusebox – Regulator B with Amphenol connector 1 24–00–00 Page 10 February 01 2024 Connector Regulator A 2 Amphenol connector Regulator B Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL MECHANICAL INTERFACES Fusebox mounting points Figure 3.11: Fusebox –Connections and dimensions – TYPICAL Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION– 915 I TYPE C24 INTERFACE OVERVIEW.– 915 I TYPE C24 915 i TYPE C 24 Figure 3.12: Fusebox connections 1 X1 Connector (electrical interface) 2 X2 Connector (electrical interface) 3 X3 Connector (electrical. interface) 4 Regulator Plate A (electrical interface) 5 Connector to 28 V AC-DC Converter assy. 6 Mounting points ELECTRICAL INTERFACES – 915 I TYPE C24 915 i TYPE C24 The seals supplied with the Fusebox must be inserted into the X1,X2 and X3 Connector (Fusebox side) to enable a good connection between plug and socket and thus avoid unnecessary vibrations and misalignment of connector pins. Fusebox –X1, X2 Connector The X1 and X2 ensure the power distribution to the EMS System. Both plugs must be connected with mating sockets on the (engine-) wiring harness. The connectors are not interchangeable and are marked on the wiring harness side. Fusebox – X3 Connector Terminal 1 enables the EMS to be supplied with an external power source (e.g. in case the internal power supply fails supplying the EMS). 24–00–00 Page 12 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Terminal 1 Interface Parameter Input voltage: Min. 9 V3 Input load: Max. 14.5 V Nominal 12 V 230 W DC cont. 290 W DC peak 2 Pluged, do not pierce the plug seal. 3 Pluged, do not pierce the plug seal. NOTICE In failure conditions the output voltage can exceed the specified limits. 3. This limit must also be considered when the starter motor is actuated Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL Fusebox Regulator A The regulator plate A needs to be connected with the EMS Ground (ring terminals on the (engine-) wiring harness). The stud has M4 threads suitable for ring terminals according to DIN 46225 or MS25036– 149 (size #8) (tightening torque: 1.2 Nm / 11 in lb). The ring terminals need to be evenly spread onto the three available studs. 915 i TYPE C24 Figure 3.13: Fusebox -Regulator A 1 Regulator 3 Ground studs 2 Regulator plate A NOTICE A connection between regulator plate A and airframe ground should only be done during supply of the EMS System by an external power source (e.g. during engine start). 24–00–00 Page 14 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Fusebox The Fusebox needs to connected with the 28 V AC-DC Converter assy.. 915 i TYPE C24 Figure 3.14 1 Effectivity: 915 i A / C24 Edition 0/Rev. 5 Fusebox 2 Connector to 28 V AC-DC Converter assy. 24–00–00 Page 15 February 01 2024 BRP-Rotax INSTALLATION MANUAL 28 V AC-DC CONVERTER ASSY. 915 i TYPE C24 Figure 3.15: 28 V AC-DC Converter assy. 1 Firewall 3 Orientation of the heat sink to the firewall 2 Orientation of the heat sink NOT to the firewall Figure 3.16: 28 V AC-DC Converter assy. 24–00–00 Page 16 February 01 2024 X1 Generator B (stator cable from ignition housing) X2 Aircraft 28 V Bus / Battery 24 V X3 Generator B ( connector from Fusebox) X4 Cockpit Airframe side X5 See Chapter 77–00–00 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Generator B (stator cable from ignition housing) Aircraft 28 V Bus / Battery 24 V Generator B ( connector from Fusebox) Cockpit Airframe side Connector X1 PIN A Phase 1 of Generator Input B Phase 2 of Generator Input C Phase 3 of Generator Input Connector X2 PIN 28 V (output for Aircraft) Output B 28 V GND (output for Aircraft) Output C +24 V (Aircraft Battery Plus Pol) Input PIN X5 Effectivity: 915 i A / C24 Edition 0/Rev. 5 Type Function A 14 V (for EMS, connected at Fusebox B Minus Pol) Output B 14 V GND (for EMS, connected at Fusebox B Minus Pol) Output Connector X4 Type Function A Connector X3 Type Function PIN Function Type A 14 V (for EMS, Battery Backup) Output B 14 V GND (for EMS, Battery Backup) Output C 14 V (for Fuel Pump 2 / Aux.) Output D 14 V GND (for Fuel Pump 2 / Aux) Output See Chapter 77-00-00. 24–00–00 Page 17 February 01 2024 BRP-Rotax INSTALLATION MANUAL MECHANICAL INTERFACES – 915 I TYPE C24 Fusebox and Converter assy. mounting points 915 i TYPE C 24 Figure 3.17: Fusebox –Connections and dimensions 24–00–00 Page 18 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 915 i TYPE C 24 Figure 3.18: 28 V Converter: Connections and dimensions NOTE 28 V AC-DC converter need to be installed with connector facing down. Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 19 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES General The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). INSTALLATION OVERVIEW Wiring diagrams 915 i TYPE A For improved clarity, see diagrams in Chapter 92-00-00 “Wiring diagrams”. 915 i TYPE C24 For improved clarity, see diagrams in Chapter 92-00-00 “Wiring diagrams”. GROUNDING CABLES The wiring of the grounding cables is an essential point when conducting engine electronics. Following two circuits must be distinguished: • Airframe circuit • Engine management system circuit (EMS circuit) During engine start (dynamic condition, transient), the two circuits are connected to each other. When the engine is running or when the engine is turned off ( and the Fusebox is not supplied with external power), the EMS circuit is electrically isolated from the rest of the aircraft. Therefore, the following components need to be installed without any contact to the airframe ground: • ECU • Regulator A (mounted on Fusebox) • Starter relay The engine block must be connected to the airframe using a properly sized ground strap (minimum the same cable cross section as the starter supply but at least 10 mm2), for carrying the starter current and to avoid static electricity between the engine and the airframe. To gain full lighting strike compliance the rubber shock mounts must be bridged by using ground straps (min. 10 mm2). 24–00–00 Page 20 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL BATTERY NOTICE The use of rechargeable batteries with lithium–ion technology should only be used in combination with a suitable battery management system. If such an battery is used, the responsibility is up to the aircraft manufacturer. The approval of the relevant aeronautical authority may be necessary. For installation of lithiumion batteries refer e.g. to FAA AC No: 20-184 The specification of the battery must ensure that during each operating state and also during the transition between two operation states a sufficient supply of the avionics is guaranteed (e.g. during engine start). Depending on the applicable regulations avionics need to be supplied for at least 30 minutes with energy after a failure of the primary power supply in case they are required for safe operation of the aircraft. If the aircraft is regularly started at temperatures below - 5 °C (23 °F) (ambient- and oil/ coolant temperature are below this temperature) it is recommended to provide a connection for an external power supply and a possibility for adequate engine pre-heating. NOTICE If all consumers are active, take care not to discharge the battery deeply. Following battery specifications are recommended: Interface Parameter Min. Max. Nominal Input Voltage Internal resistance 915 Type A Nominal 915 Type C24 Nominal 12 V 28 V Maximum 10 mΩ at -18 °C (-0.4 °F) Cold Cranking Ampere 350 A at -18 °C (-0.4 °F) (SAE J537) Capacity 16 Ah The usage of a battery with lower capacity may have a negative impact on the starting behavior of the engine. Additional electrical loads, which are in some cases required by law, may affect the battery performance during the starting process,(e.g. ACL (Anti Collision Light), Navigation Light, Avionics). Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 21 February 01 2024 BRP-Rotax INSTALLATION MANUAL CONTROL ELEMENTS START POWER CONTROL Parameter Value Contact type Momentary (must not be active after engine start) Nominal voltage 28 V DC Nominal current 20 A BATTERY BACKUP CONTROL Parameter Value Contact type Toggle (must not be active during normal operation) Nominal voltage 28 V DC Nominal current 20 A 915 i TYPE C24 The 28 V output of the AC-DC Converter is able to supply a maximum current of 27.9 A. If this current flow is exceeded, the 28 V output is switched off because an overload has been detected. The so-called hiccup mode now performs a cyclic activation of the output and queries the elimination of the overload. This is done in intervals of about three seconds. If an accumulator is connected to the 28 V output and its charge state is very low, it can happen that the charge current exceeds the 27.9 A mentioned above. A switch-off of the 28 V output is the consequence and an overload is permanently detected by the hiccup mode. Charging the accumulator is therefore not possible. Figure 3.19: Schematic AC-DC Converter 24–00–00 Page 22 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Concept for limiting the charging current: In order to limit the charging current, a series resistor can be used. In following Figure this resistor is called R_I. R_L1 and R_L2 are symbolically shown as load (L= Load) of the 28 V output and define the current flow I_Load. Figure 3.20: Simple Charging Circuit Formula 1 The voltage drop U_R_I is the difference of U_28 V and U_BAT: U_R_I = U_28 V – U_BAT Formula 2 The current flow I_BAT can be calculated as follows: Example 1 – Calculate series resistance U_28 V = 28.9 V, U_BAT = 20 V, I_BAT = 10 A The accumulator is discharged, and the State of Charge is 0%. For U_BAT in this case 20 V is assumed. The AC-DC converter supplies a voltage of 28.9 V. The maximum charge current is set to 10 A. U_R_I is therefore 8.9 V. Formula 2 is transformed to R_I and from the division U_R_I to I_BAT a resistance value of 0.89 Ω results. The following figures show the relationship between resistance R_I and current I_BAT and the resulting power dissipation once for U_R_I = 9 V and U_R_I = 5 V. Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 23 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 3.21: U_R_I = 9 V Figure 3.22: U_R_I = 5 V 24–00–00 Page 24 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Formula 3 The sum of the currents from I_BAT and I_Load results in I_28 V and must not exceed 27.9 A: I_BAT + I_Lad < 27.9 A Formula 4 I_BAT + I_Load = I_28 V If I_28 V is greater than 27.9 A, the 28 V output is switched off, as already mentioned at the beginning. Therefore, the condition from formula 3 must always be fulfilled. The expected load current I_BAT and the load current I_Load must be calculated by the installer. Formula 5 Special attention must be paid to the dimensioning of the resistor with regard to the power dissipation: P = I2 *R Once the battery is charged, the current flow is reduced to a minimum and thus also the power loss, which is converted into heat. Example 2 – Calculate power dissipation: I = 10 A, R_I = 0.89 Ω From formula 5, the worst-case power dissipation is 89 Watts. To supply the aircraft with voltage when the AC-DC converter is not active, the accumulator is used. Therefore, it must also be connected to the loads R_L1 and R_L2. Without the diode D1, the resistor R_I would be bypassed, and a current limitation would no longer exist. The choice and dimensioning of the diode must be adapted to the individual requirements of the aircraft. Parameters like voltage drop, current and cooling must be considered. Summary: By using a series resistor R_I the charging current to the accumulator can be limited. Feeding the aircraft via the accumulator gate is made possible by a diode which prevents bridging of the series resistor R_I. Special attention must be paid to the component dimensioning in order to achieve the desired reliability at these relatively high currents. Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 25 February 01 2024 BRP-Rotax INSTALLATION MANUAL VALIDATION OF INSTALLATION General The validation procedures described in this chapter do not claim to be complete. The correct execution and compliance with all given system limitations and interface descriptions as well as with standards and norms given by authorities must be proven by the aircraft manufacturer. External Power Supply If an engine is installed in a specific aircraft type for the first time, it is required to measure the voltage on three positions: • Battery Voltage (separate Voltmeter) • Voltage on Electric Starter (separate Voltmeter) • ECU Bus Voltage (displayed in BUDS Aircraft diagnostic tool) Depending on the geographical location where the engine should be used, this measurement must be done at the lowest reachable ambient temperature. In case the measured voltages drop below 9 V especially during engine start, the installation is insufficient. In this case specification of the external power source, the execution of the wiring as well as the total consumption of all electrical loads needs to be checked. Separation of 915 i TYPE A EMS and Airframe Test to ensure there is no continuity between Fusebox Regulator A and Fusebox Regulacircuit tor B in static condition (Fusebox is not supplied with power by an external power source). To determine the ECU BUS voltage at the transient moment of the engine start an oscilloscope must be used and also the total consumption of all electrical loads needs to be checked. Figure 3.23: Validation of EMS and Airframe Circuit separation 1 Multimeter 2 Rectifier regulator A (black connector) 3 Rectifier regulator B (grey connector) 4 Ground connections regulator A 5 Ground connections regulator B In case of continuity the installation is not sufficient and the wiring concept needs to be revised. 24–00–00 Page 26 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Separation of 915 i TYPE C24 EMS and Airframe Test to ensure there is no continuity between Fusebox Regulator A and Fusebox Regulacircuit tor B in static condition (Fusebox is not supplied with power by an external power source). To determine the ECU BUS voltage at the transient moment of the engine start an oscilloscope must be used and also the total consumption of all electrical loads needs to be checked. Figure 3.24: Validation of EMS and Airframe Circuit separation 1 Multimeter 2 Rectifier regulator A (black connector) 3 Ground connections regulator A 4 Airframe ground In case of continuity the installation is not sufficient and the wiring concept needs to be revised. Effectivity: 915 i A / C24 Edition 0/Rev. 5 24–00–00 Page 27 February 01 2024 BRP-Rotax INSTALLATION MANUAL EMS and Airframe 915 i TYPE C24 circuit test for Test to ensure there is no warning or caution lamp indication between AC-DC Converter AC-DC Converter and any known airframe (aircraft) ground when EMS system is powered (EMS system is powered on, engine need to run for this test - please follow the procedures mentioned in the current Operators Manual. The engine must run on an engine speed at 3000 1/min for at least 2 minutes.) Figure 3.25: Airframe circuit test for AC-DC Converter 1 Ground connections regulator A 2 Airframe ground • Connect a cable between ground connections regulator A to any airframe ground point • Check all safety regulations, because EMS system now gets powered ON and the engine will be started • Run the engine for 2 minutes at 3000 1/min (follow the procedures mentioned in the current Operators Manual). Check for warning and/or caution lamp indication 915 i TYPE C24 Check that warning lamps and caution lamps stay OFF at an engine speed of 3000 1/min and for 2 minutes engine run. If not, there is a connection between EMS ground and airframe ground which need to be detected and removed before engine and aircraft can be released. 24–00–00 Page 28 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Chapter: 61–00–00 PROPELLER DRIVE TOPICS IN THIS CHAPTER System description .................................................................................................................................3 System limitations .................................................................................................................................3 Interface description ...............................................................................................................................4 Interface overview .................................................................................................................................4 Mechanical interfaces ............................................................................................................................6 Hydraulic governor for constant speed propeller ......................................................................................8 Effectivity: 915 i A / C24 Edition 0/Rev. 5 61–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 4.1: Propeller drive – TYPICAL 61–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed System description refer to the latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual (OM). Moment of inertia System Limit Min. Max. Moment of inertia on propeller 1500 kg cm2 (3.559 lb ft2) 7500 kg cm2 (17.798 lb ft2). Out of balance Dynamic balancing of the propeller as specified by the propeller manufacturer must be carried out. Propeller shaft System Limit Min. Max. Extension of the propeller shaft - Maximum 70 mm (2.75 in.) System Limit Min. Max. Power consumption of governor - 600 W Operating pressure of governor - 10 bar (145 psi) peak pressure: 30 bar (435 psi) Figure 4.2 Hydraulic governor flange/drive/ oil supply Effectivity: 915 i A / C24 Edition 0/Rev. 5 61–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW Figure 4.3: Interface (configuration 3) 1 Propeller shaft (mechanical. Interface) 3 Cover plate 2 Governor flange (hydraulic. Interface) NOTE The cover used for delivery needs to be removed before engine operation. The cover may not be used in operational condition. 61–00–00 Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 4.4: Interface (configuration 2) 1 Effectivity: 915 i A / C24 Edition 0/Rev. 5 Propeller shaft (mechanical. Interface) 61–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL MECHANICAL INTERFACES Propeller shaft flange The propeller in tractor or pusher arrangement must be fitted on the propeller flange in accordance with applicable regulations. As required utilize one of three possible pitch circle diameters (P.C.D.) on the flange. NOTICE Modification of the propeller shaft is not permitted. Figure 4.5: Propeller shaft flange NOTICE Propeller hub has to be centered on diameter 47 mm (1.85 in.). 61–00–00 Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Interface Parameter Value Pitch circle diameter 75 mm (2.95 in.) 6x through holes 8 mm (0.31 in.) Pitch circle diameter 80 mm (3.15 in.) 6x through holes 11.5 mm (0.45 in.) Pitch circle diameter 101.6 mm (4 in.) 6x through holes 13mm (0.51 in.) Hub diameter 47 mm (1.85 in.) Gear transmission i=2.54. Propeller shaft turns with 0.395 times engine speed. Figure 4.6: Direction of rotation Effectivity: 915 i A / C24 Edition 0/Rev. 5 61–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL HYDRAULIC GOVERNOR FOR CONSTANT SPEED PROPELLER Figure 4.7: Governor flange (configuration 3 only) 61–00–00 Page 8 February 01 2024 1 Governor flange 2 Pressure oil line assy. 3 Oil inlet 4 Oil outlet Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Drive Drive via propeller gearbox. Position of the propeller connection on the governor flange: x-axis [mm/in] y-axis [mm/in] z-axis [mm/in] -206.3 (-8.12) 0 51.5 (2.03) Connection NOTICE Obey the manufacturers instructions! Technical Data Gear ratio from crankshaft to hydraulic governor is 1.932, i.e. the propeller governor runs at 0.759 times engine speed. Mounting pad AND20010 Thread size M8 Thread length max. 14 mm (0.55 in) Toothing Internal spline 20/40 SMS 1834 NA 14x1,27x30x12 Power input max. 600 W Operating pressure max. 30 bar (435 psi) Effectivity: 915 i A / C24 Edition 0/Rev. 5 61–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 10 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: 72–00–00 ENGINE TOPICS IN THIS CHAPTER System description .................................................................................................................................3 System limitations .................................................................................................................................6 Interface description ...............................................................................................................................9 Interface overview .................................................................................................................................9 Mechanical interfaces ............................................................................................................................9 Installation notes...................................................................................................................................13 Engine suspension ..............................................................................................................................13 Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 5.1: Engine – TYPICAL 72–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed System description refer to the latest issue of the Operators Manual. Figure 5.2: Engine side view Effectivity: 915 i A / C24 Edition 0/Rev. 5 1 Engine number 2 Propeller flange 3 Propeller gearbox 4 Connection for return line, both sides mandatory 5 Connection for return line A Attachment points (for engine lifting) Z Center of gravity (Z) P Reference coordinate system (X, Y, Z) 72–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 5.3: Engine Front view 72–00–00 Page 4 February 01 2024 6 Oil filter 7 Oil pump 8 Exhaust flange 9 Muffler assy. 10 Fuel line assy. 11 Crankshaft locking screw position 12 Connection for Turbo oil line return 13 Wastegate regulator assy. 14 Wastegate rod end Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 5.4: Top view Effectivity: 915 i A / C24 Edition 0/Rev. 5 15 Throttle valve support assy. 16 Airbox 17 Dual ignition coils 18 Expansion tank assy. 19 Fuel rail (right, left) 20 POP OFF valve 21 Inter cooler 22 Connection for fuel feed line 23 Connection for fuel return line A Attachment points (for engine lifting) 72–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 5.5: Rear view 24 Ignition housing 25 Electric starter 26 Water pump housing 27 Engine suspension frame (ring mount) 28 Turbocharger assy. 29 Pressure control valve (PCV) 30 Fuel pressure regulator SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual (OM). Installation position The oil system, fuel system and the cooling system are unsuitable for upside-down / inverted installation of the engine. System Limit Static roll angle ß Min. Max. 40° The oil level should be in the upper half (between the “50%” and the “Max.” mark) and should never fall below the “Min.” mark. For the oil level measuring procedure refer to the latest version of the respective Operators Manual (OM). 72–00–00 Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 5.6: Bank angle Attachment points Angle/force Description É‘ Bank or rotation F1 Gravity For mounting the engine on the engine suspension, R2, R3, L3 and L2 of attachment points must be used. Attachment bolts/screws must not protrude into engine components. Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 5.7: Propeller and vertical axis Propeller axis The y1-axis must be perpendicular to the longitudinal axis of the aircraft. 72–00–00 Page 8 February 01 2024 System Limit Min. Max. Permissible deviation from perpendicular (α) - 10° + 10° Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW Figure 5.8: Attachment points MECHANICAL INTERFACES Attachment points Interface Parameter Value Attachment points L1 x-axis (in) - 253.5 mm (9.98 in.) y-axis (in) - 71 mm (-2.8 in.) z-axis (in) - 211 mm (-8.31 in.) Effectivity: 915 i A / C24 Edition 0/Rev. 5 R1 L2 R2 - 615 mm (24.21 in.) 105 mm (4.13 in.) - 105 mm (-4.13 in.) - 277 mm (-10.91 in.) 72–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL Interface Parameter Attachment points Value L1 R1 Thread Max. usable Thread length R2 — M10 25 mm (0.98 in.) Interface Parameter Value Attachment points L3 x-axis (in) - 615 mm (24.21 in.) y-axis (in) L2 R3 105 mm (4.13 in.) L4 R4 - 181 mm (7.13 in.) -105 mm (-4.13 in.) -90 mm (-3.54 in.) 90 mm (3.54 in.) z-axis (in) -7 mm (-0.28 in.) 12.2 mm (0.48 in.) Thread — M10 Max. usable Thread length 16 mm (0.63 in.) Interface Parameter Value Attachment points L5 R5 L6 R6 x-axis (in) - 51 mm (1.97 in.) - 71 mm (2.79 in.) - 51 mm (1.97 in.) - 71 mm (2.79 in.) y-axis (in) 48 mm (1.89 in.) -64.5 mm (-2.54 in.) 48 mm (1.89 in.) -64.5 mm (-2.54 in.) z-axis (in) 25.4 mm (1.00 in.) 39 mm (1.53 in.) -25.4 mm (-1.00 in.) -39 mm (-1.53 in.) Thread Max. usable Thread length M8 M8 20 mm (0.79 in.) 20 mm (0.79 in.) m WARNING Non-compliance can result in serious injuries or death! The aircraft or fuselage manufacturer must design the engine suspension so that it can safely carry the maximum occurring operational loads without exceeding the max. allowable forces and bending moments on the engine housing and attachment points. Tighten all engine suspension screws as specified by the aircraft manufacturer. 72–00–00 Page 10 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Weight Engine component Weight Base engine with gearbox: 74.23 kg (163.65 lb) Governor drive add on weight version 3 0.60 kg (1.32 lb) Cooling air baffle 0.38 kg (0.838 lb) PCV 0.35 kg (0.771 lb) Oil tank 1.50 kg (3.31 lb) Intercooler 1.65 kg (3.65 lb) ECU 1.13 kg (2.49 lb) Fusebox 915 i A Series 2.02 kg (4.45 lb) Fusebox 915 i C24 Series 1.64 kg (3.62 lb) Ambient sensors 0.06 kg (0.132 lb) Wiring harness 915 i A Series 2.50 kg (5.51 lb) Wiring harness 915 i C24 Series 1.84 kg (4.06 lb) Intermediate flange with overboost valve, air hose and clamps 0.78 kg (1.72 lb) AC-DC Converter assy. 1.68 kg (3.70 lb) Total 915 iSc 3 A Series with governor drive 85.2 kg (187.8 lb) Total 915 iSc 3 C24 Series with governor drive 85.9 kg (189.4 lb) 0.14 kg (0.308 lb) Starter Relay Centre of gravity of engine The position information of the center of gravity does only consider the engine itself. Parts without an specific installation position in relation to the reference coordinate system are not considered. NOTE All distances are given in relation to the reference coordinate system (P). Center of gravity Axis X-axis - 376 mm (14.80 in.) Y-axis -15.9 mm (-0.63 in.) Z-axis -115.9 mm (-4.56 in.) Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL Moments of inertia (relative to COG) Axis 72–00–00 Page 12 February 01 2024 Moment of intertia X-axis 2.0020282*106 kg*mm2 Y-axis 2.5397901*106 kg*mm2 Z-axis 2.9713711*106 kg*mm2 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES General The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). ENGINE SUSPENSION NOTICE During engine installation take into account the total engine weight and ensure careful handling. The rubber mounts for neutralizing vibrations and other engine suspension components are not in the scope of delivery. Those components must be designed, selected and tested on vibration behavior during ground runs and flight testing at specified loads. NOTICE The engine suspension must be designed to prevent excessive engine movement and to minimize noise emission and vibration on the airframe. The engine suspension is determined essentially by the aircraft design. Four attachment points are provided on the engine suspension frame assy. The engine will be supplied with a well tried and certified suspension frame for attachment on the fireproof bulkhead. The exhaust system and the turbo charger are supported on this frame, too. The installation into the aircraft is as generally practised by captive rubber mounts which ensure also to reduce vibrations and sound transmission from engine to aircraft frame. Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–00–00 Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL m WARNING The hex. screws M10x60 on the attachment points R2 and L2 are only used for transport securing but must never be utilized for engine suspension. See interface overview. Therefore, use the ROTAX engine suspension frame and the 4 stated attachment points R2, L2, R3, L3. Figure 5.9: Damping element engine suspension Standard aircraft industry damping elements (e.g. Lord) are suitable and need to be choosen according to the aircraft specific design requirements. Check with the relevant equipment manufacturer. The vibration and acoustic insulation factor depends on the airframe. 72–00–00 Page 14 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Chapter: 72–60–00 AIR INTAKE SYSTEM TOPICS IN THIS CHAPTER System description .................................................................................................................................3 System limitations .................................................................................................................................3 Interface description ...............................................................................................................................6 Interface overview .................................................................................................................................6 Mechanical interfaces ............................................................................................................................7 Pneumatic interfaces .............................................................................................................................8 Electrical interfaces .............................................................................................................................10 Installation notes................................................................................................................................... 11 Installation overview ............................................................................................................................ 11 Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–60–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 6.1: Air intake system 72–60–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed System description refer to the latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS Induction air intake Following requirements may be used: System Limit Flow rate Min. Max. 400 kg/h Pressure loss (between ambient pressure and altitude pressure 975 mbar / 14.14 psi at ISA conditions) 10 mbar (0.14 psi) Icing in the area of the air intake needs to be avoided. The prevention of icing lies within the aircraft manufacturer’s responsibility. Airbox reference pressure The reference pressure of the fuel system is the airbox pressure. Induction air intake ducting System Limit PCV ducting Min. Max. Intake pressure loss (Engine Speed: 5500 ±50 rpm; Airflow: 360-366 kg/h) 85 mbar (1.23 psi) Intake pressure loss (Engine Speed: 5800 ±50 rpm; Airflow: 384-396 kg/h) 90 mbar (1.30 psi) All pneumatic hoses leading from and to the Pressure Control Valve (PCV) may not be changed. Changes in length and diameter of the hoses will have an significant effect on the wastegate control. Depending on the installation heat protection must be provided. System Limit Bending radius on tube centerline Min. Max. 60 mm Valid installation positions The intercooler as well as the PCV must be installed vibration-decoupled from the engine. Compressor housing The turbo compressor housing must not be rotated. The wastegate functionality would be affected. Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–60–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL Throttle lever Adjust Bowden cable such that throttle valve can be fully opened and closed. Step 1 Procedure Push to “full throttle”, then adjust Bowden cable so that it has 1 mm (0.04 in.) clearance (no tensioning), thereby ensured that throttle valve is completely open. NOTE Spring pulls the throttle valve to full throttle position. 2 Push to "idle". Set the spring-loaded screw that the throttle lever hits the stop screw with the black cap (maximum setting for lowest idle). 3 If the idling speed is too low, then open throttle lever with the spring-loaded screw until the required idling speed is reached 4 Mark adjustments with locking varnish. NOTE It is not recommended to install a throttle limiter. With the installation of a throttle limiter, the engine can not reach its nominal power. 72–60–00 Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 6.2: Figure shows idle position 1 Bowden cable 2 Spring-loaded screw (idle speed adjustment) 3 Screw with black cap (maximum setting for lowest idle speed) 4 Locking varnish m WARNING Non-compliance can result in serious injuries or death! With throttle lever not connected the throttle valve will remain fully open. The starting position of the throttle valve is therefore full throttle! Therefore never start the engine without connecting the throttle lever first. m WARNING Non-compliance can result in serious injuries or death! The cable actuations being used must not be affected at all by vibrations emanating from the engine or the airframe. Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–60–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW Interface overview Figure 6.3: Air intake: Interface overview and components 72–60–00 Page 6 February 01 2024 1 Turbocharger inlet (pneumatic Interface) 2 Air intake hose (POP OFF valve to throttle body) 3 Turbocharger 4 Intercooler 5 POP OFF valve 6 Throttle body (mechanical interface) 7 Pressure Control Valve (PCV) (electrical interface) 8 Wastegate (boost pressure valve) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL MECHANICAL INTERFACES Pressure control valve (PCV) Interface Parameter Min. Max. Tightening torque – 1 Nm (9 in. lb) Figure 6.4: PCV: Connection and dimensions Throttle body Interface Parameter Min. Max. Tightening torque 4 Nm (35 in. lb) (suitable for flexible cable), 1.5 mm (0.06 in.) steel rope or single-strand wire — Cable travel 65 mm (2.56 in.) — Actuating force 7.5 N (1.69 lbs.) 20 N (4.5 lbs) Max. permissible actuating force — 20 N (4.5 lbs) Connection: Set screw M6x12 mm Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–60–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL Intercooler Figure 6.5: Intercooler: Connection and dimensions To attach the intercooler within the airframe design four suitable fixation points are available and M6 screws must be used. NOTICE Make sure proper dampening of the 4 fixation points and assure stress free installation on these 4 fixation points. PNEUMATIC INTERFACES Airfilter connection See figure Connection on turbocharger 72–60–00 Page 8 February 01 2024 Interface Parameter Min. Max. Slip-on length 30 mm (1.18 in.) - Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL NOTE Use only filter elements which will not tend to restrict the flow when in contact with water. Turbocharger to intercooler Connection on turbocharger: Interface Parameter Min. Max. Slip-on length 30 mm (1.18 in.) - Figure 6.6: Connection on turbocharger, TYPICAL Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–60–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL Connection on intercooler: Interface Parameter Min. Max. Slip-on length 32 mm (1.26 in.) - See Figure 6.5: Intercooler: Connection and dimensions Intercooler to POP OFF valve Interface Parameter Min. Slip-on length 18 mm (0.71 in.) Max. Figure 6.7: POP OFF valve Connection on throttle body: Install the delivered hose (scope of supply) to the correct side of the POP OFF valve, recheck if it fits. ELECTRICAL INTERFACES PCV sockets The appropriate connectors on the wiring harness as well as the corresponding sockets on the PCV are color coded. To avoid inappropriate behavior of the wastegate the correct linkage needs to be ensured. 72–60–00 Page 10 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES General The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). INSTALLATION OVERVIEW Pneumatic diagram Figure 6.8: Pneumatic diagram Connection between compressor outlet and intercooler Temperature-resistant hoses must be used. Effectivity: 915 i A / C24 Edition 0/Rev. 5 72–60–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 12 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: 73–00–00 ENGINE – FUEL AND CONTROL TOPICS IN THIS CHAPTER System Description .................................................................................................................................3 System limitations .................................................................................................................................3 Interface description ...............................................................................................................................4 Interface overview .................................................................................................................................4 Hydraulic interfaces ...............................................................................................................................6 Electrical interfaces – 916 I Type A .........................................................................................................6 Electrical interfaces – 915 I Type C24 .....................................................................................................7 Mechanical interfaces ............................................................................................................................7 Installation notes.....................................................................................................................................8 Installation overview ..............................................................................................................................9 Fuel lines ............................................................................................................................................10 Inlet line..............................................................................................................................................10 Return line ..........................................................................................................................................10 Bypass line .........................................................................................................................................10 Coarse filter ........................................................................................................................................ 11 Water trap, gascolator.......................................................................................................................... 11 Fine filter............................................................................................................................................. 11 Fuel pump ..........................................................................................................................................12 Fuel pressure sensor ...........................................................................................................................12 Fuel pressure regulator ........................................................................................................................12 Fuel tank.............................................................................................................................................12 Fuel shut off valve ...............................................................................................................................13 Effectivity: 915 i A / C24 Edition 0/Rev. 5 73–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 7.1: Fuel System 73–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed System description refer to the latest issue of the Operators Manual. SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual (OM). Effectivity: 915 i A / C24 Edition 0/Rev. 5 73–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW 915 i TYPE A Figure 7.2: Fuel System: Interface overview and components 73–00–00 Page 4 February 01 2024 1 Fuel rail 2/4 outlet line (hydraulic Interface) 2 Fuel rail 1/3 feed line (hydraulic Interface) 3 Fuel rail 4 Fuel line assy. 5 Injection valves 6 Fuel pump connectors (electrical interface) 7 Banjo bolt Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 915 i TYPE C24 Figure 7.3: Fuel System: Interface overview and components Effectivity: 915 i A / C24 Edition 0/Rev. 5 1 Fuel rail 2/4 outlet line (hydraulic Interface) 2 Fuel rail 1/3 feed line (hydraulic Interface) 3 Fuel rail 4 Fuel line assy. 5 Injection valves 6 Fuel pump connectors (electrical interface) 7 Banjo bolt 73–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL HYDRAULIC INTERFACES NOTICE Independent from the ambient conditions (e.g. fuel pressure and temperature) and independent from the fuel used the design of the fuel system must prevent vapour lock conditions. Vapour lock may result in engine stoppage. Fuel inlet Interface Parameter Min. Max. Fuel pressure (relative to MAP) 2.9 bar (42 psi) 3.2 bar (46 psi) Acceptable Fuel pressure exceedance (max. 3 sec.) 2.5 bar (36 psi) 3.5 bar (51 psi) NOTE Fuel pressure exceedance only allowed after power setting change Fine filter quality Fuel pressure oscillation (min. sample rate 20 kHz) - 1.0 bar (14.5 psi), peak-to-peak Fuel flow 56 I/h (14.8 gal/h) 150 I/h (39.6 gal/h) Fuel quality EN 228 - NOTE Nominal rating 8 – 12 μm, minimum 82 % capture efficiency according to ISO 19438 (edition 11/2003), dirt particles > 35 μm are not permissible. Connection: M14x1.5 or AN-6 (9/16-18 UNF). Fuel outlet Interface Parameter Min. Max. Fuel pressure (relative to Fuel Tank pressure) - 0.5 bar (7.3 psi) Connection: M14x1.5 or AN-6 (9/16-18 UNF). ELECTRICAL INTERFACES – 916 I TYPE A Fuel pump connectors Interface Parameter Min. Max. Nominal Output Voltage (V) 12 V 14.5 V 13.8 V Output Current (A) Fuel pump assy. (both pumps): 7A Output Current (A) Page 6 February 01 2024 – 7.5 A – Single pump: 4.5 A 73–00–00 10.5 A Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL ELECTRICAL INTERFACES – 915 I TYPE C24 Fuel pump connectors 915 i TYPE C 24 Interface Parameter Min. Max. Nominal Output Voltage (V) 12 V 14.5 V 13.8 V Fuel pump assy. (both pumps): @ 12 V = 9.1 A [+/- 2 A] Output Current (A) Single pump: @ 12 V = 5 A [+ 2.5 A / - 0.5 A] Cockpit Airframe side Connector X4 PIN Type Function A 14 V (for EMS, Battery Backup) Output B 14 V GND (for EMS, Battery Backup) Output C 14 V (for Fuel Pump 2 / Aux.) Output D 14 V GND (for Fuel Pump 2 / Aux) Output MECHANICAL INTERFACES Adapter for fuel pressure Standard banjo bolt can be replaced by an optional Sensor adapter for connectivity directly on the fuel inlet of the fuel pressure regulator. See SI-PAC–024. Interface Parameter Min. Max. Tightening torque 23 Nm (17 ft. lb) 27 Nm (20 ft.lb) Component mass (adapter with sensor) - 80 g Connection: M12 x 1.5 Effectivity: 915 i A / C24 Edition 0/Rev. 5 73–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES General The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). 73–00–00 Page 8 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL INSTALLATION OVERVIEW Figure 7.4: Fuel system Effectivity: 915 i A / C24 Edition 0/Rev. 5 1 Fuel tank 2 Fuel pump 1 3 Fuel pump 2 4 Fine filter 5 Fuel pressure regulator 6 Coarse filter/water trap 73–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL FUEL LINES To prevent problems with vapour lock, all the fuel lines should be insulated against heat in the engine compartment. It is recommended to route the fuel lines in an appropriate distance from hot engine components and avoid sharp bends. For a better heat dissipation it is recommended to use fuel lines made of metal whenever practicable (except for flex hoses to/ from engine). Fuel lines should be installed by using suitable screw clamps or by ferrules. Non drainable low points in feed, return and vent lines should be avoided. Any low points should allow for drainage of water and other contaminants. m WARNING Non-compliance can result in serious injuries or death! At the low points, accumulations of water can freeze and cut off the fuel flow. INLET LINE The inlet line should have an inner diameter of at least 7.5 mm (0.3 in). (AN-6 or 3/8’’). NOTICE Fuel lines smaller than this diameter may have a significant impact on the proper functionality of this engine. RETURN LINE The return line should have a inner diameter of at least 7.5 mm (0.3 in). (AN-6 or 3/8’’). NOTICE Fuel lines smaller than this diameter may have a significant impact on the proper functionality of this engine. Vapour locks in the return line should be efficiently vented out of the fuel system to the atmosphere. Adequate fuel tank venting system design is imperative. Large vent lines with (most) direct routing avoiding low points are desired. BYPASS LINE To allow venting of the fuel system and better fuel pump engagement after a potential inclusion of air, there could be installed a restricted bypass line between the inlet (pressure side of the fuel pump module) and the return line. In this bypass line a restricted orifice should be installed so that there is an ideal balance between short venting time and minimum fuel flow rate. The positioning and dimensioning of the orifice is up to the aircraft manufacturer. If no bypass line is installed, the pressure release in the fuel lines is very slow. This should be noted accordingly in the manuals of the aircraft manufacturer (fuel lines are possibly under full operating pressure even after engine stop). 73–00–00 Page 10 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL NOTE The switching between several fuel tanks at power loss due to fuel shortage should be given within a defined period of time and without falling below the minimum performance limit and must be ensured by the aircraft manufacturer. Refer to the latest requirements such as FAR or EASA. COARSE FILTER The coarse filter should be installed at an easily accessible position to allow a periodic inspection. Following fuel filter could be used to ensure that the engine is supplied with fuel of an adequate quality: Interface Parameter Min. Max. Filter mesh size 50 micron (0.0019 in.) 70 micron (0.0027 in.) Filter surface (total) 64.4 cm² (10 in²) - Passing area 18.4 cm² (2.85 in²) - The filter should be installed in the supply line between the tank and the fuel pumps and should be of sufficient capacity to prevent complete blockage between maintenance intervals. NOTICE An installation without coarse filter may have a significant impact on the proper functionality of this engine. WATER TRAP, GASCOLATOR A suitable water trap must be installed. Certification according to the latest regulations, such as FAR or EASA, must be conducted by the aircraft or fuselage manufacturer. FINE FILTER The fine filter should be installed at an easy accessible position to allow a periodic inspection. To ensure that the engine is supplied with fuel of an adequate quality, a fine filter with following specifications should be installed between the fuel pumps (module) and the injection rail (Cylinder 1/3): Interface Parameter Min. Max. Filter mesh size 8 micron 12 micron Fuel flow rate 90 l/h (23.8 gal/h) - Differential pressure Effectivity: 915 i A / C24 Edition 0/Rev. 5 0.02 bar (0.29 psi) 73–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL NOTICE An installation without fine filter may have a significant impact on the proper functionality of this engine. FUEL PUMP For reducing the risk of vapor lock, the fuel pump should be placed in a well–ventilated area. A recommended installation position would be near the fuel tank in order to ensure a safe fuel supply. FUEL PRESSURE SENSOR The operating limit of the fuel pressure should be observed at the inlet of the fuel pressure regulator. See the relevant SI-PAC-024 “Optional fuel pressure adapter”, current issue. An additional fuel pressure sensor could be placed before the fine filter, so the filter load can be checked. An increase of fuel pressure over the allowed limit could mean that the fine filter is becoming contaminated. The fine filter should be checked and replaced if necessary. FUEL PRESSURE REGULATOR Fuel pressure regulators have very precise tolerances and are generally reliable. Mostly pressure fluctuations are not caused by the pressure regulator, they might be found in other sections (filter clogged, pulsation of lines, kinks in the hoses etc.) of the fuel system. FUEL TANK In case of supply problems of the fuel pump, the fuel tank should be emptied and filled with AVGAS. If the problem does not occur at the next test (with AVGAS), then this is a sign of formation of vapour locks when using MOGAS (or auto fuel). Following points may have a positive impact on the proper functionality of this engine: • Single tank (large volume of fuel in the tank, just a few fuel lines) • Catch tanks in the wing tanks. This provides the fuel supply in every flight situation/ position • Header tank (the following reference values should be considered): 73–00–00 Page 12 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Interface Parameter Specification Venting line The venting line from header tank to wing tank should generally be on an incline to avoid trapping bubbles. The venting line must have an inner diameter of at least 12 mm (0.50 in). Feed lines Fuel feed lines from the wing tanks to the header tank should be on a steady decline. Following points may have a negative impact on the proper functionality of the engine: • A header tank design that enables the re-entry of vapour bubbles in the suction line • Multi tank system without catch-, header tank FUEL SHUT OFF VALVE The fuel shut off valve position on the pressure side of the fuel system (after the fuel pump module) can have an unfavorable impact on the installation of the engine. Effectivity: 915 i A / C24 Edition 0/Rev. 5 73–00–00 Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 14 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: 75–00–00 COOLING SYSTEM TOPICS IN THIS CHAPTER System Description .................................................................................................................................3 System limitations .................................................................................................................................3 Interface description ...............................................................................................................................4 Interface overview .................................................................................................................................4 Hydraulic interfaces ...............................................................................................................................5 Air Cooling interfaces.............................................................................................................................7 Installation notes...................................................................................................................................10 Installation overview ............................................................................................................................10 Water inlet elbow ................................................................................................................................. 11 Expansion tank ................................................................................................................................... 11 Coolant hoses ..................................................................................................................................... 11 Coolant...............................................................................................................................................12 Validation of installation ........................................................................................................................13 Effectivity: 915 i A / C24 Edition 0/Rev. 5 75–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 8.1: Cooling System 75–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed System description refer to the latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual (OM). m WARNING Non-compliance can result in serious injuries or death! The cooling system must be designed so that operating temperatures will not exceed the maximum values. Coolant types It is important that the coolant circuit is designed so that the coolant does not reach boiling point under any conditions. If the temperature exceeds the boiling point, the engine can quickly overheat due loss of coolant. The boiling point of the coolant is mainly influenced by: • the type of coolant • mixture ratio (percentage water rate) • the system pressure (opening pressure of radiator cap) For permissible coolant types see SI-915i-001, latest issue. System pressure Hose connecting expansion tank to overflow bottle System Limit Min. Max. Coolant system pressure – 1.2 bar (18 psi) System Limit Min. Max. Able to withstand heat and vacuum without collapsing-able 125 °C (257 °F) – A soft walled hose is not suitable as it can collapse and cause cooling system failure. Expansion tank To ensure proper operation of the cooling system, the expansion tank with pressure cap in the main operating systems must be installed on the highest point of the cooling circuit. Effectivity: 915 i A / C24 Edition 0/Rev. 5 75–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW Figure 8.2: Cooling System – Interfaces 75–00–00 Page 4 February 01 2024 1 Coolant hose 2 Water pump housing 3 Expansion tank 4 Pressure cap 5 Expansion tank to overflow bottle connection (hydraulic Interface) 6 Water inlet elbow (hydraulic Interface) 7 Water outlet (hydraulic Interface) 8 Coolant temperature sensor 9 Cooling air baffle Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL HYDRAULIC INTERFACES Water inlet elbow Interface Parameter Min. Max. Cooling system pressure (relative) 1.6 bar (23 psi) - Coolant temperature - 20 °C (- 4 °F) 125 °C (257 °F) Coolant flow (at 5800 rpm) 70 l/min (18.49 USgal/ min) - Slip on length 19 mm (0.75 in) Figure 8.3: Water inlet elbow Connection: Outer diameter 27 mm (1.07 in). Water outlet Interface Parameter Min. Max. Cooling system pressure (relative) 1.6 bar (23 psi) - Coolant temperature - 20 °C (- 4 °F) 130 °C (266 °F) Coolant flow (at 5800 rpm) 70 l/min (18.49 USgal/ min) - Effectivity: 915 i A / C24 Edition 0/Rev. 5 75–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL Connection: Inner diameter 25 mm (0.98 in). Overflow bottle connection Interface Parameter Min. Slip on length 18 mm Max. Figure 8.4: Overflow bottle connection 75–00–00 Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL AIR COOLING INTERFACES Cooling air baffle Figure 8.5: Cooling air baffle position Position x-axis y-axis z-axis P1 - 142 mm (- 5.59 in.) - 101 mm (- 3.98 in.) - 106 mm (- 4.17 in.) General information NOTE Cylinder wall temperature Max. permitted cylinder wall temperature on hottest cylinder is 200 °C (392 °F). See the following figure. The cylinder wall temperature can be measured using a thermocouple. In some special cases a separate cold air supply to the air baffle should be provided. NOTE If this temperature is exceeded, appropriate measures (e.g. cooling air ducts, modifications to cowling, etc.) must be taken to bring it within limits again. Effectivity: 915 i A / C24 Edition 0/Rev. 5 75–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL Measuring point Figure 8.6: Measuring point TYPICAL Following recommendations should assist the aircraft or fuselage manufacturer in selecting suitable cooling air ducts: 75–00–00 Page 8 February 01 2024 Specification Description Cooling capacity The cooling air baffle must be designed so, that it transfers thermal energy of approx. 6 kW (5.7 BTU/s) at take-off performance. Cross section of air baffle Cross section of the air baffle min. 100 cm² (15.50 in2). Material Glass fibre reinforced plastic or heat and fire resistant material. Attachment options Form-fitting on engine block and mounting above the cylinder and the crankcase. Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 8.7: Cooling air baffle for tractor Effectivity: 915 i A / C24 Edition 0/Rev. 5 75–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). INSTALLATION OVERVIEW Radiator In an installation as depicted with the radiator in a higher position than the standard supplied expansion tank, a water accumulator has to be fitted instead of the expansion tank. Additionally a suitable expansion tank has to be installed at the highest point of the cooling circuit In order to support the deployment of the radiator's full capacity, the radiator should be connected with the upper connection to the suction side in direction to the water pump. Otherwise, air bubbles may accumulate, resulting in reduced cooling capacity (see setup depicted in Cooling system schematic). 6 2 1 5 4 3 AE_5iS_0884 Figure 8.8: Cooling system schematic 75–00–00 Page 10 February 01 2024 1 Expansion tank 2 Pressure cap 3 Radiator 4 Water pump 5 Overflow bottle 6 Vent Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL WATER INLET ELBOW NOTICE The hoses should be fixed with appropriate clips to prevent loss e.g. with spring type hose clips, such as those used for the coolant hoses between the water pump and cylinder. Figure 8.9: Water inlet elbow 1 Water pump housing 2 Water inlet elbow Use two M6x20 Allen screws lock washers to attach the water inlet elbow. Tighten screws to 10 Nm (90 in lb.) NOTICE The total slip-on length of the water inlet elbow and expansion tank should be used. EXPANSION TANK The aircraft manufacturer should give the possibility to the pilots to check the coolant level in the expansion tank. It is also necessary to inform the pilots about the daily inspection of the coolant level in the aircraft manufacturers Operators Manual. To allow this inspection, e.g. a flap or panel on the cowling or a warning instrument in the cockpit for low coolant level should be foreseen. COOLANT HOSES NOTE For proper operation keep hoses as short as possible. Effectivity: 915 i A / C24 Edition 0/Rev. 5 75–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL Aluminium tubes with an inner diameter of 25 mm (0.98 in) can be used instead of longer hoses. These should have a bulge (1) in order to prevent coolant hoses working loose. Note as well that this will double the number of hose clamps required. The material of the hoses must be resistant against glycol, coolant and ozone. Interface Parameter Min. Temperature resistance 125 °C (257 °F) Pressure durability 5 bar (72 psi) Inner diameter 25 mm (1”) Bending radius 175 mm (6.89 in) Max. 1 09158 Figure 8.10: Aluminium tube 1 Bead m WARNING Risk of fire during operation. Because of the high temperatures, provide suitable protection against accidental contact. Install heat shields in required areas (fuel, oil, coolant hoses or tubes) and/or on the electronic components. Hoses Hoses exposed to direct heat radiation from exhaust system must be suitably protected with e.g. heat resistant protection tubes. The hose between the overflow bottle and the expansion tank should be as short as possible and have a resistance to collapsing under temperature and vacuum. COOLANT NOTICE Use only coolant as recommended in the current Operators Manual (OM) and SI915 i-001 “Selection of suitable operation fluids“, current issue. 75–00–00 Page 12 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL VALIDATION OF INSTALLATION General The validation procedures described in this chapter do not claim to be complete. The correct execution and compliance with all given system limitations and interface descriptions as well as with standards and norms given by authorities must be proven by the aircraft manufacturer. Coolant temperature The maximum coolant temperature must be determined in order to check the efficiency of the cooling system. Figure 8.11: Coolant Temperature Sensor (CTS), TYPICAL 1 Coolant temperature sensor The coolant temperature is measured using a temperature sensor (1), which is installed on cylinder 4. NOTICE It is possible to record a false measurement when measuring fluid temperatures. If fluid volume is lost and sensor is not fully submerged in the liquid, the indicating instrument could incorrectly display a lower temperature, by measuring the air temperature instead of the coolant temperature. Pressure test To ensure the System has no leakage, remove the pressure cap from the expansion tank. Then attach the pressure tester and pump the system until the pressure manometer shows 1.2 bar (18 psi). After min. 1 minute, there should be still 1.2 bar (18 psi) pressure in the system. • Check the efficiency of the coolant radiator and its proper sealing between cowling and radiator. • Check the proper flow between expansion tank and overflow bottle. • Ensure that no ram-air is induced onto the overflow bottle vent line. • Check efficiency of air duct and proper air flow through the duct and around cylinders. Effectivity: 915 i A / C24 Edition 0/Rev. 5 75–00–00 Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL • Consider cold (winter) and hot (summer) conditions in ground and flight testing. • Check proper dampening of the water radiator and stressfree installation and proper sealing. 75–00–00 Page 14 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Chapter: 76–00–00 ENGINE CONTROLS TOPICS IN THIS CHAPTER Special tools............................................................................................................................................4 System description .................................................................................................................................5 System limitations .................................................................................................................................5 Interface description ...............................................................................................................................6 Interface overview .................................................................................................................................6 Electrical interfaces ...............................................................................................................................7 Interface overview — 915 I Type C24 ....................................................................................................10 Electrical interfaces – 915 I Type C24 ................................................................................................... 11 Mechanical interfaces ..........................................................................................................................14 Installation notes...................................................................................................................................16 Installation overview ............................................................................................................................16 Installation overview – 915 I Type C24 ..................................................................................................18 LANE Select Switches .........................................................................................................................20 Fuel pump switches .............................................................................................................................20 Start Switch ........................................................................................................................................20 Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL 915 i TYPE A Figure 9.1: Engine management system (EMS) 76–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 915 i TYPE C24 Figure 9.2: Engine management system (EMS) Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL SPECIAL TOOLS Description Part number Crimping pliers MOLEX 64016-0035/63811-4400 n.a. Disassembly tool MOLEX 63813-1500 n.a. Crimp tool ROTAX® ACDC 28 V X1/X2 and 14 V X1 - SKU: 10–3064 n.a. Crimp tool ROTAX® ACDC 28 V X3/X4 - SKU: 10–3094 n.a. Crimp tool ROTAX® ACDC 28 V X5 and 14 V X3 - SKU: 10–3114 n.a. 4. can be ordered under www.rs-flightsystems.com 76–00–00 Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed System description refer to the latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual (OM). Valid installation positions The ECU may be installed either in the engine compartment or in the cockpit. To prevent the ingress of liquids (moisture), the ECU must be mounted in a way that the connectors are facing downward. The two Ambient Air Pressure and Temperature Sensors (AAPTS) are all-in-one sensors for engine ambient temperature and engine ambient pressure. In cowled engine installations they have to be mounted in the engine compartment in a ram air free area and close to the air inlet. The sensors must measure the correct air inlet temperature and the air pressure right before the air filter. The AAPTS sensors must not be mounted in the air intake system between the air filter and turbocharger inlet. The AAPTS need to be mounted isolated from vibrations (e.g. caused by the engine). The casing of the ECU must not be connected to the airframe ground. The rubber vibration damping (insulation material) must not be removed. If the rubber dampers were removed, the engine ground and the aircraft ground would be short-circuited. Component temperatures limitation Limitation see Chapter 00-00-00 Approval of electric and electronic components. Connections When connecting the wiring harness with the ECU take into account the labeling on the wiring harness and the ECU. Although the connectors are mechanically coded (i.e. wiring harness connector A1 can only be connected to ECU A1 socket), excessive force or incorrect positioning can result in bent pins and the ECU would then need to be replaced. Unplug the ECU connector from the wiring harness only if absolutely necessary. Connector plugs (ECU) are suitable for up to 20 plug-in operations. The number of plugging operations must be entered into the logbook. If this limit has been exceeded the ECU needs to be replaced. Wiring harness The wiring harness must NOT be shortened or modified. Do not bend, kink, pinch or otherwise improperly stress the wiring harness. The bending radius of the wiring harness must not be less than 50 mm (1.97 in). To avoid excessive tension on the ECU connectors, a strain relief must be installed in a distance of ~ 100 mm (3.94 in) from the ECU. NOTICE Do not bend, kink, pinch or otherwise improperly stress the wiring harness. Use proper routing, clamping and strain relief on wiring harnesses. Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW 915 i TYPE A Figure 9.3: Engine Management System (EMS)– Interfaces 76–00–00 Page 6 February 01 2024 1 Harness Interface Connector A (HIC A) (electrical Interface) 2 Harness Interface Connector B (HIC B) (electrical Interface) 3 X1 Connector (electrical Interface) 4 X2 Connector (electrical Interface) 5 Regulator A (electrical Interface) 6 ECU (electrical, mechanical Interface) 7 AAPTS (electrical, mechanical Interface) 8 Wiring harness 9 Starter relay connectors (electrical Interface) 10 Fuel pump connectors (electrical Interfaces) 11 Wiring harness grounding Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL ELECTRICAL INTERFACES Harness interface The HIC A connector allows powering ECU Lane A and Fuel Pump A. interfaces to Indicaconnector A tion elements are described in Chapter 77-00-00. Figure 9.4: HIC A Connector In case the EMS is powered by an external power source or by one of the internal generators: • A connection between Terminal 1 and Terminal 7 will power ECU Lane A • A connection between Terminal 3 and Terminal 9 will power Fuel pump 1 Figure 9.5: HIC A connector –Engine controls Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL Terminal (Supply) Terminal (Ground) Interface Parameter 1 LANE_SEL_ SW_A_1 7 LANE_SEL_SW_ A_2 Nominal Voltage Nominal Current 3 SIG_FUEL_ PUMP_1 9 GND_FUEL_ PUMP_1 Min. Max. 12 V 7.5 A Nominal Voltage Nominal Current Nominal 12 V 10 A Harness Interface Connector B AE 5iS_0187 Figure 9.6: HIC B connector In case the EMS is powered by an external power source or by one of the internal generators: • A connection between Terminal 1 and Terminal 9 will power ECU Lane B • A connection between Terminal 3 and Terminal 11 will power Fuel Pump 2 • A connection between Terminal 4 and Terminal 12 will actuate the Starter Relay 76–00–00 Page 8 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 9.7: HIC B Connector – Engine controls Terminal (Supply) 1 LANE_SEL_ SW_B_1 Terminal (Ground) 9 LANE_SEL_SW_ B_2 Interface Parameter Min. Nominal Voltage SIG_FUEL_ PUMP_2 11 GND_FUEL_ PUMP_2 7.5 A Nominal Voltage 12 V Nominal Current 12 SUPP_START_ SWITCH 4 CONN_STARTER_REL_SW Nominal 12 V Nominal Current 3 Max. 10 A Nominal Voltage 12 V Nominal Current 5A The HIC B connector allows powering ECU Lane B. Interfaces to indication elements are described in Chapter 77-00-00. X1, X2 Connector See Chapter 24-00-00 section Interface Description. Regulator A See Chapter 24-00-00 section 24–00–00 section Interface Description. Starter Relay See Chapter 80-00-00 section Interface Description Wiring harness grounding The grounding cable must be attached to Fusebox Regulator A. See Chapter 24-00-00 section Fusebox Regulator A Fuel pump See Chapter 73–00–00 section Interface Description Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE OVERVIEW — 915 I TYPE C24 915 i TYPE C24 Figure 9.8: Engine Management System (EMS)– Interfaces 76–00–00 Page 10 February 01 2024 1 Harness Interface Connector A (HIC A) (electrical Interface) 2 Harness Interface Connector B (HIC B) (electrical Interface) 3 X1 Connector (electrical Interface) 4 X2 Connector (electrical Interface) 5 Regulator A (electrical Interface) 6 ECU (electrical, mechanical Interface) 7 AAPTS (electrical, mechanical Interface) 8 Wiring harness 9 Starter relay connectors (electrical Interface) 10 Fuel pump connectors (electrical Interfaces) 11 Wiring harness grounding Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL ELECTRICAL INTERFACES – 915 I TYPE C24 915 i TYPE C24 Harness interface connector A The HIC A connector allows powering ECU Lane A and Fuel Pump A. interfaces to Indication elements are described in Chapter 77-00-00. Figure 9.9: HIC A Connector In case the EMS is powered by an external power source or by one of the internal generators: • A connection between Terminal N and Terminal P will power ECU Lane A Figure 9.10: HIC A connector –Engine controls Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL Terminal (Supply) Terminal (Ground) Interface Parameter N LANE_SEL_ SW_A_1 P LANE_SEL_SW_ A_2 Nominal Voltage Nominal Current F SIG_FUEL_ PUMP_1 E GND_FUEL_ PUMP_1 Max. Nominal 12 V 7.5 A Nominal Voltage Nominal Current Harness Interface Connector B Min. 12 V 10 A 915 i TYPE C24 Figure 9.11: HIC B connector In case the EMS is powered by an external power source or by one of the internal generators: • A connection between Terminal N and Terminal P will power ECU Lane B 76–00–00 Page 12 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 9.12: HIC B Connector – Engine controls Terminal (Supply) P LANE_SEL_ SW_B_1 Terminal (Ground) N LANE_SEL_SW_ B_2 Interface Parameter Min. Nominal Voltage SUPP_START_ SWITCH E CONN_STARTER_REL_SW 7.5 A Nominal Voltage 12 V Nominal Current c SIG_FUEL_ PUMP_2 D GND_FUEL_ PUMP_2 Nominal 12 V Nominal Current F Max. 5A Nominal Voltage 12 V Nominal Current 10 A The HIC B connector allows powering ECU Lane B. Interfaces to indication elements are described in Chapter 77-00-00. X1, X2 Connector See Chapter 24-00-00 section Interface Description. Regulator A See Chapter 24-00-00 section 24–00–00 section Interface Description. Wiring harness grounding The grounding cable must be attached to Fusebox Regulator A. See Chapter 24-00-00 section Fusebox Regulator A Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL MECHANICAL INTERFACES Engine Control Unit (ECU) Figure 9.13: ECU –mounting points 76–00–00 Page 14 February 01 2024 1 Connector socket A1 2 Connector socket A2 3 Connector socket B 4 Rubber sleeve Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Sensors Ambient Air Pressure and Temperature Sensors (AAPTS 1, 2) Figure 9.14: AAPTS – mounting points Maximum diameter of fastener in the interior of the mounting hole: 6 mm (0.24 in). Only mount sensor with a washer (Ø 10 mm (0.39 in) or with an adequate fastener head diameter. The maximum permissible pressure at the mounting flange may not exceed 20 N/mm2 (0.0029 psi). Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 15 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES General The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). INSTALLATION OVERVIEW 915 i TYPE A Figure 9.15: Harness Interface Connector A-Schematic 76–00–00 Page 16 February 01 2024 Part Function 1 Harness Interface Connector A 2 Lane Select Switch A (-S4) 3 Fuel Pump Switch A (-S7) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 9.16: Harness Interface Connector B-Schematic Part Function 4 Harness Interface Connector B 5 Lane Select Switch B (-S5) 6 Start Switch (-S6) 7 Fuel Pump Switch A (-S8) Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 17 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTALLATION OVERVIEW – 915 I TYPE C24 915 i TYPE C24 Figure 9.17: Harness Interface Connector A-Schematic 76–00–00 Page 18 February 01 2024 Part Function 1 Harness Interface Connector A 2 Lane Select Switch A (-S4) 3 Fuel Pump Switch 1 (-S7) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 9.18: Harness Interface Connector B-Schematic Part Function 4 Harness Interface Connector B 5 Lane Select Switch B (-S5) 6 Start Switch (-S6) Effectivity: 915 i A / C24 Edition 0/Rev. 5 76–00–00 Page 19 February 01 2024 BRP-Rotax INSTALLATION MANUAL LANE SELECT SWITCHES Lane Select Switch A (-S4) Lane Select Switch B (-S5) Interface Parameter Value Switch type Toggle (normally open) Nominal voltage 28 V Nominal current 7.5 A Number of poles 1-pole Interface Parameter Value Switch type Toggle (normally open) Nominal voltage 28 V Nominal current 7.5 A Number of poles 1-pole FUEL PUMP SWITCHES Fuel pump Switch 1 (-S7) Fuel Pump Switch 2 (-S7) Interface Parameter Value Switch type Toggle (normally open) Nominal voltage 28 V Nominal current 10 A Number of poles 1-pole Interface Parameter Value Switch type Toggle (normally open) Nominal voltage 28 V Nominal current 10 A Number of poles 1-pole Interface Parameter Value Switch type Button (normally open, non-locking) Nominal voltage 28 V Nominal current 5A Number of poles 1–pole START SWITCH Start Switch (-S6) 76–00–00 Page 20 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Chapter: 77–00–00 ENGINE INDICATING TOPICS IN THIS CHAPTER System description .................................................................................................................................4 System limitations .................................................................................................................................4 Interface description ...............................................................................................................................5 Interface overview .................................................................................................................................5 Electrical interfaces ...............................................................................................................................5 Interface overview – 915 I Type C24 .......................................................................................................9 Electrical interfaces – 915 I Type C24 ...................................................................................................10 Installation notes...................................................................................................................................13 Installation overview ............................................................................................................................13 Warning lamps ....................................................................................................................................15 CAN interfaces....................................................................................................................................15 Installation overview – 915 I Type C24 ..................................................................................................16 Warning lamps – 915 I Type C24 ..........................................................................................................19 CAN interfaces – 915 I Type C24 ..........................................................................................................19 Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL 915 i TYPE A Figure 10.1: Engine indication, TYPICAL 77–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 915 i TYPE C 24 Figure 10.2: Engine indication Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION The complete system is volume of supply and is certified together with the engine. For a detailed system description refer to latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS Maintenance CAN The Maintenance CAN must only be used in combination with a B.U.D.S. Aircraft USB-toCAN converter and B.U.D.S. Aircraft Software. It is not possible to use the Maintenance CAN for other displaying or data logging purposes. CAN wiring For the Display- and the Maintenance CAN twisted and shielded cables (3 pins: CAN_H, CAN_L, CAN_GND) must be used for the CAN-connections to ensure a high electromagnetic compatibility in data transmission. 77–00–00 Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW 915 i TYPE A Figure 10.3: Engine Management System (EMS) – Interfaces, TYPICAL 1 Harness Interface Connector A (HIC A) 3 Electromagnetic shielding of CAN Bus 2 Harness Interface Connector B (HIC B) ELECTRICAL INTERFACES Harness Interface The HIC Connector A is equipped with a Maintenance CAN interface, a Display CAN interConnector A face and terminals which can be used to actuate a warning lamp indicating the current status of the ECU Lane A. Interfaces to control elements are described in Chapter 76-00-00. Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 10.4: HIC A Connector Warning Lamp Terminal (Supply) Terminal (Ground) Interface Parameter 2 SUPP_WARN_ LAMP_A 8 WARN_LAMP_A Nominal voltage Min. Max. Nominal 12 V Nominal current 120 mA CAN Interfaces Terminal Specification 4 CAN_GND_1_A 5 CAN_LOW_1_A 6 CAN_HIGH_1_A 10 CAN_GND_2_A 11 CAN_LOW_2_A 12 CAN_HIGH_2_A Display CAN Lane A Maintenance CAN Lane A Connector: HIC Connector A (included in the engines scope of delivery). The HIC Connectors must be mounted according to the procedure prescribed in Chapter 76-00-00. The Display CAN is based on the CAN Aerospace protocol. For detailed interface description contact an authorized ROTAX® Distributor or its independent Service Center. Harness Interface The HIC Connector B is equipped with a Maintenance CAN interface, a Display CAN interConnector B face and terminals which can be used to actuate a warning lamp indicating the current status of the ECU Lane B. Interfaces to control elements are described in Chapter 76-00-00. 77–00–00 Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL AE 5iS_0187 Figure 10.5: HIC B connector Warning Lamp Terminal (Supply) Terminal (Ground) Interface Parameter SUPP_WARN_ LAMP_B 10 WARN_LAMP_B Nominal voltage 2 Min. Max. Nominal 12 V Nominal current 120 mA CAN Interfaces Terminal Specification 6 CAN_GND_1_B 7 CAN_LOW_1_B 8 CAN_HIGH_1_B 14 CAN_GND_2_B 15 CAN_LOW_2_B 16 CAN_HIGH_2_B Terminal (Supply) 2 SUPP_WARN_ LAMP_B Display CAN Lane B Maintenance CAN Lane B Terminal (Ground) 10 WARN_LAMP_B Interface Parameter Min. Max. Nominal voltage Nominal current Nominal 12 V 120 mA Connector: HIC Connector B (included in the engine’s scope of delivery). The HIC Connectors must be mounted according to the procedure prescribed in Chapter 76-00-00. Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL The Display CAN is based on the CAN Aerospace protocol. For detailed interface description contact an authorized ROTAX® Distributor or its independent Service Center. Electromagnetic shielding of CAN Bus The electromagnetic CAN Bus shielding ring terminals need to be connected with the Airframe Ground. Connector: Ring Terminal M6 77–00–00 Page 8 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL INTERFACE OVERVIEW – 915 I TYPE C24 915 i TYPE C 24 Figure 10.6: Engine Management System (EMS) – Interfaces Effectivity: 915 i A / C24 Edition 0/Rev. 5 1 Harness Interface Connector A (HIC A) 3 Electromagnetic shielding of CAN Bus 2 Harness Interface Connector B (HIC B) 77–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL ELECTRICAL INTERFACES – 915 I TYPE C24 Harness Interface The HIC Connector A is equipped with a Maintenance CAN interface, a Display CAN interConnector A face and terminals which can be used to actuate a warning lamp indicating the current status of the ECU Lane A. Interfaces to control elements are described in Chapter 76-00-00. 915 i TYPE C 24 Figure 10.7: HIC A connector Warning lamp Terminal (Ground) Terminal (Supply) A SUPP_WARN_ LAMP_A D WARN_ LAMP_A Interface Parameter Min. Max. Nominal voltage Nominal 12 V Nominal current 120 mA CAN Interfaces: Terminal Specification C CAN_GND_1_A L CAN_LOW_1_A M CAN_HIGH_1_A B CAN_GND_2_A J CAN_LOW_2_A K CAN_HIGH_2_A Display CAN Lane A Maintenance CAN Lane A Connector: HIC Connector A (included in the engines scope of delivery). The HIC Connectors must be mounted according to the procedure prescribed in Chapter 76-00-00. 77–00–00 Page 10 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL The Display CAN is based on the CAN Aerospace protocol. For detailed interface description contact an authorized ROTAX® Distributor or its independent Service Center. Harness Interface The HIC Connector B is equipped with a Maintenance CAN interface, a Display CAN interConnector B face and terminals which can be used to actuate a warning lamp indicating the current status of the ECU Lane B. Interfaces to control elements are described in Chapter 76-00-00. 915 i TYPE C 24 Figure 10.8: HIC B Connector Warning lamp Terminal (Supply) A SUPP_WARN_ LAMPE_B D Terminal (Ground) Interface Parameter WARN_LAMP_B Nominal voltage Min. Nominal current Max. Nominal 12 V 120 mA CAN Interfaces Terminal Specification C CAN_GND_1_B L CAN_LOW_1_B M CAN_HIGH_1_B B CAN_GND_2_B J CAN_LOW_2_B K CAN_HIGH_2_B Display CAN Lane B Maintenance CAN Lane B Connector: HIC Connector B (included in the engine’s scope of delivery). The HIC Connectors must be mounted according to the procedure prescribed in Chapter 76-00-00. Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL The Display CAN is based on the CAN Aerospace protocol. For detailed interface description contact an authorized ROTAX® Distributor or its independent Service Center. Electromagnetic shielding of CAN Bus The electromagnetic CAN Bus shielding ring terminals need to be connected with the Airframe Ground. Connector: Ring Terminal M6 77–00–00 Page 12 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES General The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). INSTALLATION OVERVIEW 915 i TYPE A Figure 10.9: Harness Interface Connector A-Schematic Part Function 1 Harness Interface Connector A 2 Warning Lamp A (-H1) Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL Part Function 3 Warning Lamp A (LED) (-H1 V2) 4 Resistor 1.5 kΩ (-R6) 5 Resistor 1 kΩ (-R7) 6 Display CAN A 7 Maintenance CAN A Figure 10.10: Harness Interface Connector B-Schematic 77–00–00 Page 14 February 01 2024 Part Function 8 Harness Interface Connector B 9 Warning Lamp B (-H2) 10 Warning Lamp B (LED) (-H2 V2) 11 Resistor 1.5 kΩ (-R8) 12 Resistor 1 kΩ (-R9) 13 Display CAN B 14 Maintenance CAN B Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL WARNING LAMPS Warning Lamp A, B (-H1, -H2) Interface Parameter Value Nominal voltage 12 Nominal current max. 120 mA Instead of common lamps also LED lamps (-H1 V2, -H2 V2) can be used. In this case a appropriate pre-resistor must be conducted serial to the LED. An additional resistor parallel to the LED prevents the ECU from detecting an open circuit at this warning lamp. CAN INTERFACES Display CAN Two independent Display CAN interfaces are provided for displaying or recording engine data. When displaying engine data, it must be ensured that data of both CAN interfaces is used, providing truly redundant data indication or data indication of suitable reliability, consistent with the safety objective of the final application. The proof of consistency with the safety objective of the final application is the responsibility of the installer. Maintenance CAN To be able to connect the Maintenance CAN A and B with the B.U.D.S Aircraft USB-toCAN converter the Maintenance CAN A and B should be connected with two separate Sub-D DE9 (9-pin) sockets. It is highly recommended to conduct those connectors due to the fact that the B.U.D.S. Aircraft is a central element when it comes to diagnosis and maintenance of this engine. CAN Type Description HIC Pin Sub-D DE9 Pin Maintenance CAN A CAN_LOW_2_A 11 (HIC A) 2 CAN_GND_2_A 10 (HIC A) 3 CAN_HIGH_2_A 12 (HIC A) 7 CAN_LOW_2_B 15 (HIC B) 2 CAN_GND_2_B 14 (HIC B) 3 CAN_HIGH_2_B 16 (HIC B) 7 Maintenance CAN B It is recommended not to connect maintenance and diagnostic interfaces Lane A and Lane B together. Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 15 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTALLATION OVERVIEW – 915 I TYPE C24 915 i TYPE C 24 Figure 10.11: Harness Interface Connector A-Schematic 77–00–00 Page 16 February 01 2024 Part Function 1 Harness Interface Connector A 2 Warning Lamp A (-H1) 3 Warning Lamp A (LED) (-H1 V2) 4 Resistor 1.5 kΩ (-R6) 5 Resistor 1 kΩ (-R7) 6 Display CAN A 7 Maintenance CAN A Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 10.12: Harness Interface Connector B-Schematic Part Function 1 Harness Interface Connector B 2 Warning Lamp B (-H2) 3 Warning Lamp B (LED) (-H2 V2) 4 Resistor 1.5 kΩ (-R8) 5 Resistor 1 kΩ (-R9) 6 Display CAN B 7 Maintenance CAN B Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 17 February 01 2024 BRP-Rotax INSTALLATION MANUAL Cockpit Airframe side Connector X5 PIN Type Function X5.1 Aircraft GND for Warning Lamps Ground X5.2 Warning Lamp 14 V output EMS/Fuel pump Signal X5.3 Warning Lamp Command Input (Start Power / Battery Backup) Signal X5.4 Warning Lamp 28 V output Aircraft Signal NOTE For improved clarity, see diagrams in Chapter 92-00-00 “Wiring diagrams”. 77–00–00 Page 18 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL WARNING LAMPS – 915 I TYPE C24 Warning Lamp A, B (-H1, -H2) 915 i TYPE C 24 Interface Parameter Value Nominal voltage 12 V Nominal current max. 120 mA Instead of common incandescent lamps also LED lamps (-H1 V2, -H2 V2) can be used. In this case a appropriate pre-resistor must be conducted serial to the LED. An additional resistor parallel to the LED prevents the ECU from detecting an open circuit at this warning lamp. CAN INTERFACES – 915 I TYPE C24 Display CAN 915 i TYPE C 24 Two independent Display CAN interfaces are provided for displaying or recording engine data. When displaying engine data, it must be ensured that data of both CAN interfaces is used, providing truly redundant data indication or data indication of suitable reliability, consistent with the safety objective of the final application. The proof of consistency with the safety objective of the final application is the responsibility of the installer. Maintenance CAN To be able to connect the Maintenance CAN A and B with the B.U.D.S Aircraft USB-toCAN converter the Maintenance CAN A and B should be connected with two separate Sub-D DE9 (9-pin) sockets. It is highly recommended to conduct those connectors due to the fact that the B.U.D.S. Aircraft is a central element when it comes to diagnosis and maintenance of this engine. CAN Type Description HIC Pin Sub-D DE9 Pin Maintenance CAN A CAN_LOW_2_A J (HIC A) 2 CAN_GND_2_A B (HIC A) 3 CAN_HIGH_2_A K (HIC A) 7 CAN_LOW_2_B J (HIC B) 2 CAN_GND_2_B B (HIC B) 3 CAN_HIGH_2_B K (HIC B) 7 Maintenance CAN B It is recommended not to connect maintenance and diagnostic interfaces Lane A and Lane B together. Effectivity: 915 i A / C24 Edition 0/Rev. 5 77–00–00 Page 19 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 20 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: 78–00–00 EXHAUST SYSTEM TOPICS IN THIS CHAPTER System description .................................................................................................................................3 System limitations .................................................................................................................................3 Interface description ...............................................................................................................................4 Interface overview .................................................................................................................................4 Mechanical interfaces ............................................................................................................................5 Effectivity: 915 i A / C24 Edition 0/Rev. 5 78–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 11.1: Exhaust system 78–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION The complete system is volume of supply and is certified together with the engine. For a detailed system description refer to latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual (OM). Modifications Modifications of the system by the OEM (e.g. cut the exhaust) may be done, if following requirements are met: • All exhaust parts added by the OEMs are decoupled (weight and vibration) from the exhaust provided • Exhaust back pressure must not exceed following limits: NOTE If no modifications have been made, there is no need to check the back pressure. System Limit Min. Max. Exhaust back pressure (ambient pressure: 1000 mbar (14.50 psi)) 155 mbar (2.24 psi) 180 mbar (2.61 psi) Exhaust back pressure (ambient pressure: 900 mbar (13.05 psi)) 175 mbar (2.53 psi) 205 mbar (2.97 psi) Exhaust back pressure (ambient pressure: 800 mbar (11.60 psi)) 195 mbar (2.82 psi) 230 mbar (3.33 psi) Exhaust back pressure (ambient pressure: 700 mbar (10.15 psi)) 215 mbar (3.11 psi) 255 mbar (3.69 psi) Effectivity: 915 i A / C24 Edition 0/Rev. 5 78–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW Figure 11.2: Exhaust interfaces 78–00–00 Page 4 February 01 2024 1 Muffler assy. 2 Exhaust pipe 3 Exhaust manifold assy. 4 Resonator assy. Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL MECHANICAL INTERFACES Exhaust tail pipe Figure 11.3: Exhaust tail pipe position Interface Parameter Value Tail pipe material 1.4845 (X8CrNi25-21) Effectivity: 915 i A / C24 Edition 0/Rev. 5 78–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 6 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: 79–00–00 LUBRICATION SYSTEM TOPICS IN THIS CHAPTER System description .................................................................................................................................3 System limitations .................................................................................................................................3 Crankcase pressure measurement .........................................................................................................3 Measuring of the vacuum .......................................................................................................................5 Oil hose requirements............................................................................................................................7 Interface description ...............................................................................................................................8 Interface overview .................................................................................................................................8 Oil tank dimensions ...............................................................................................................................8 Oil tank interfaces................................................................................................................................10 Oil pump ............................................................................................................................................. 11 Installation notes...................................................................................................................................14 Installation overview ............................................................................................................................14 Oil lines ..............................................................................................................................................14 Oil radiator (optional) ...........................................................................................................................15 Filling and purging of the oil system .....................................................................................................16 Validation of installation ........................................................................................................................19 Crankcase pressure measurement .......................................................................................................19 Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 12.1: Lubrication system, TYPICAL 79–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed System description refer to the latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual (OM). m WARNING Non-compliance can result in serious injuries or death! The lubrication system must be designed such that the permissible operating temperatures and maximum values are not exceeded. CRANKCASE PRESSURE MEASUREMENT Measurement of the mean crankcase pressure at min. 50 °C (122 °F) operating temperature and full throttle, this ensures correct oil return from crankcase (blow-by gas). Figure 12.2: Measurement of crankcase pressure 1 Pressure indicator 3 Magnetic plug (position for adapter) 2 Allen screw M8x20 (position for crankshaft locking screw NOTICE Leakage may occur! Always use a new sealing ring with Allen screw M8 (position for crankshaft locking screw). Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL NOTICE Do not remove the magnetic plug for prolonged periods and do not use the measurement equipment during flight operations. A pressure sensor (pressure gauge with liquid damping) can be fitted instead of the magnetic plug or the crankshaft locking screw. The magnetic plug or the crankshaft locking screw is removed and the pressure sensor is fitted. Magnetic plug The thread for the magnetic plug must be M12x1.5 (metric). m WARNING Non-compliance can result in serious injuries or death! If the readings exceed the pressure limits, then the flow resistance in the oil return line from oil sump to oil tank is too high in the current engine installation (contamination, restrictions of cross-section, etc.). This condition is unsafe and must be rectified immediately. 79–00–00 Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL MEASURING OF THE VACUUM Figure 12.3: Measuring of the vacuum, TYPICAL 1 Suction oil hose 2 3 Pressure gauge with liquid damping for vacuum Oil pump housing Measure the vacuum in the suction oil hose- from the oil tank via the oil cooler to the engine oil pump - at a distance of max. 100 mm (4 in.) from the oil pump suction connector. Pressure loss Pressure loss in suction line (p_ambient – p_oil pump inlet) must not exceed 350 mbar (5 psi) between 70 °C – 90 °C (158 °F – 194 °F) oil temperature. m WARNING Non-compliance can result in serious injuries or death! The vacuum must be verified over the complete engine operation range. If the oil is cold, the flow resistance increases, which means that not enough oil will flow on the suction side. Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL Oil tank installation positions Oil tank System Limit Min. Max. Angular deviation - 10° + 10° Tank position in relation to engine +40 mm (+1.57 in.) –360 mm (-14.17 in.) Figure 12.4: Oil tank installation position, TYPICAL The oil tank must be installed on a low-vibration position and not on the engine directly. The oil tank cover and the oil drain screw must be easily accessible. NOTE The oil tank has to positioned on its z-axis such that the normal oil level is always between 0 and –360 mm (-14.17 in.) on the z-axis. 79–00–00 Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL m WARNING Non-compliance can result in serious injuries or death! At higher positioning of the oil tank, oil might leak through clearances at bearings back into crankcase. Oil tank will be empty and all oil will be in the crankcase. If fitted too low it might happen that the oil filter will be drained. In that case oil pressure will be too low for the first seconds after starting the engine. OIL HOSE REQUIREMENTS Main oil pump (Oil circuit, engine) At negative pressure of -500 mbar (-7.25 psi) and a oil temperature of 150 °C (302 °F) the oil lines must not collapse. A minimum inner diameter of at least 10 mm (0.39 in.) should be used. NOTE Obey the pressure requirements on interfaces as specified, see crankcase pressure and vacuum measurement. Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW Figure 12.5: Lubrication system interfaces 1 Oil pump inlet (hydraulic interface) 2 Oil return outlet (hydraulic interface) 3 Oil return outlet (turbocharger) (hydraulic interface) 4 Oil tank in- and outlets (hydraulic interface) 5 Oil filter (hydraulic interface) OIL TANK DIMENSIONS Oil tank The oil tank must be mounted by using appropriate clamps. 79–00–00 Page 8 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 12.6: Oil tank dimensions Oil tank 2 Oil dipstick 3 Oil bayonet cap 4 Hex. screw M12x2 5 Gasket ring C 12x18 6 Profile clamp 163 7 Oil tank cover 1 Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL OIL TANK INTERFACES Oil tank inlet and outlet Figure 12.7: Oil tank interfaces 1 Oil tank inlet 2 Oil tank outlet 3 Vent fitting 4 Oil tank inlet (turbo charger) NOTE The oil tank cover is also marked: IN — oil tank inlet, OUT — oil tank outlet. NOTICE Both oil tank inlets must be connected with the oil return outlets. 2x Oil tank inlet Interface Parameter Value Screw socket M18x1.5 or 3/4–16 UNF Tightening torque 25 Nm (18 ft. lb) Oil tank outlet 79–00–00 Page 10 February 01 2024 Interface Parameter Value Screw socket M22x1.5 or 7/8–14 UNF Tightening torque 25 Nm (18 ft. lb) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Vent fitting Interface Parameter Value Outside diameter 8 mm (0.31 in.) Slip–on length 15 mm (0.59 in.) m WARNING In any case the vent fitting must ensure a release of pressure from the oil tank at any time. Otherwise oil could emerge into the turbo housing which conveys through the exhaust. Formation of smoke is possible. Oil tank inlet (turbo charger) Interface Parameter Value Screw socket M10 x 1 Tightening torque 15 Nm (133 in. lb) OIL PUMP Oil pump inlet The oil pump inlet must be connected directly with the oil tank outlet. Interface Parameter Value Screw socket M22x1.5 or 7/8–14 UNF Tightening torque 25 Nm (18 ft. lb) Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL Oil return outlet The oil return outlet must be connected directly with the oil tank inlet. NOTICE Both oil return outlets need to be used. Only the oil return lines on magneto side must be used. The hoses must have approx. the same length. Figure 12.8: Oil return outlets 1 Oil return outlet (turbocharger) Interface Parameter Value Screw socket M18x1.5 or 3/4–16 UNF Tightening torque 25 Nm (18 ft. lb) The oil return outlet (turbocharger) must be connected directly with the oil tank inlet (turbocharger). 79–00–00 Page 12 February 01 2024 Oil return outlet Interface Parameter Value Screw socket M10 x 1 Tightening torque 15 Nm (133 in. lb) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Figure 12.9: Oil return outlet (turbocharger) Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES General The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). INSTALLATION OVERVIEW Oil Filter Hydraulic Governor Oil Pump Module Oil Pump Oil Pressure Regulator Oil Pump Oil Pump Housing Engine (Crankcase) 1 Oil Cooler 2 Oil Sump (Turbo) Turbo Charger Ventilation Socket Oil Tank AE 5iS_0201 Figure 12.10: Lubrication system overview 1 Engine circuit 2 Turbocharger return line OIL LINES At negative pressure of -500 mbar (-7.25 psi) and a oil temperature of 140 °C (284 °F) the oil lines must not collapse. A minimum inner diameter of at least 10 mm (0.39 in.) should be used. 79–00–00 Page 14 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Oil tank venting line Following points should be considered when installing the oil tank venting line: • Route the line without kinks and avoid sharp bends • Route the venting line in a continuous decline. Otherwise a drain bore at the lowest point should be foreseen to drain any condensate. Figure 12.11: Bypass opening 1 Bypass opening 2 Cowling NOTE Water is a by-product of the combustion of fuel. Most of this water will dissipate from the combustion chamber with the exhaust gases. A small amount will reach the crankcase and must be disposed of through a venting line. The venting line must be protected from any kind of ice formation for condensation by using e.g. isolation protection or a routing in a hose with hot air flow. Additionally a bypass opening should be foreseen before the cowling outlet. OIL RADIATOR (OPTIONAL) Essential parts of the cooling system, such as radiator, etc., are available for this engine from BRP-Rotax. See also SI-PAC-014.Oil radiator /-sets. m WARNING Non-compliance can result in serious injuries or death! The furnishing of proof in accordance to the latest FAR and EASA, has to be conducted by the aircraft manufacturer. Specifications of the oil radiator The radiator must be designed to dissipate approx. 30 kW (28.43 BTU/s) of thermal energy at take-off performance. Weight: max. 0.82 kg (1.8 lb) for oil radiator “extra large”. NOTICE The oil radiator must not restrict oil flow. Test system as per section “Checking the oil circuit”. Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 15 February 01 2024 BRP-Rotax INSTALLATION MANUAL FILLING AND PURGING OF THE OIL SYSTEM Introduction Ensure that oil lines are connected correctly and secured. Also ensure that the oil cooler (if fitted) is in the suction line between the oil tank and the oil pump, see following figure. Verify that the oil tank is filled up to the maximum level (to the top of the flat portion of the dipstick). The capacity of the oil system without oil cooler and connection lines is approx. 3l (0.66 gal.). Additional oil (up to 0.5 litres (0.13 gal)) may be added to the tank for the purpose of this procedure. Instruction The following work procedures must be carried out for purging the oil system: 1. Disconnect oil return lines (2) from the oil tank. 2. Place the free end of the return lines into a suitable container (4) below the engine. 3. Plug open connections on oil tank with suitable air tight cap. 4. Remove the spark plug connections. 5. For easier rotation of engine remove one spark plug from each cylinder. NOTE Prevent any foreign objects entering the spark plug hole. 6. Using a compressed air line, pressurize the oil tank through its vent fitting (6) (on the neck of the tank). Adjust the compressor outlet regulator so that the air line pressure is between 0.4 bar (5.8 psi) and 1 bar (14.5 psi). Do not exceed 1 bar (14.5 psi). NOTE The oil tank bayonet cap is not pressure-tight, some air can escape. 7. Turn the engine by hand in direction of normal rotation until the first pressure indication appears on the oil pressure gauge. Normally this will take approx. 20 turns. Depending on installation it may take up to 60 turns. NOTE Do not use the starter for this purpose. Fit propeller and use it to turn the engine by hand. NOTE The oil tank may empty and as a result introduce air into the oil system. Pay attention to the oil level and fill tank as required. 8. Stop the pressurization. 9. Open the cap for the oil return lines on the oil tank and reconnect the engine oil return lines to the tank. Ensure that the suction oil line and oil return line are connected to proper fittings on the oil tank. Note: If the oil lines from engine to oil tank are incorrectly connected, severe engine damage may result. 10. Re-fit the spark plugs. Restore aircraft to original operating condition. 11. Residual oil may have accumulated in the crankcase. Return it to the oil tank by following the oil level check procedure in the relevant Operators Manual (OM). 79–00–00 Page 16 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 12. Fill the oil in the tank up to the full mark on the dipstick. 13. Carefully check all lubrication system connections, lines and clamps for leaks and tightness. ENVIRONMENTAL NOTE Protect the environment! Do not spill oil and pay attention for adequate disposal. Figure 12.12: Setup for purging the oil system Effectivity: 915 i A / C24 Edition 0/Rev. 5 1 Suction line 2 Oil return line 3 Free end 4 Temporary oil collection tank 79–00–00 Page 17 February 01 2024 BRP-Rotax INSTALLATION MANUAL 79–00–00 Page 18 February 01 2024 5 Oil return line 6 Vent fitting 7 Plug (2x) 8 Temporary connection for purging Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL VALIDATION OF INSTALLATION General The validation procedures described in this chapter do not claim to be complete. The correct execution and compliance with all given system limitations and interface descriptions as well as with standards and norms given by authorities must be proven by the aircraft manufacturer. CRANKCASE PRESSURE MEASUREMENT 1. Remove magnetic plug or crankshaft locking screw. 2. Attach pressure sensor (pressure gauge with liquid damping). The thread for the magnetic plug must be M12x1,5 (metric). The thread for the crankshaft lock pin hole must be M8. 3. Start the engine according the Operators Manual (OM) and read the crankcase pressure value at full throttle. 4. Compare the read out value with the limitations for the crankcase pressure specified in the section “System Limitations” of this chapter. If the readings exceed the pressure limits, then the flow resistance in the oil return line from oil sump to oil line is too high in the current engine installation (contamination, restrictions of cross-section etc.) This condition is unsafe and must be rectified immediately. 5. Re-install magnetic plug or screw into crankshaft locking pin hole. When reinstalling the screw always use a new gasket. Effectivity: 915 i A / C24 Edition 0/Rev. 5 79–00–00 Page 19 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 20 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: 80–00–00 STARTING TOPICS IN THIS CHAPTER System description .................................................................................................................................3 System limitations .................................................................................................................................3 Interface description ...............................................................................................................................4 Interface overview .................................................................................................................................4 Electrical interfaces ...............................................................................................................................4 Installation notes.....................................................................................................................................6 Installation overview ..............................................................................................................................6 Wiring...................................................................................................................................................7 Starter relay assy. technical data .............................................................................................................9 Validation of installation ........................................................................................................................ 11 Effectivity: 915 i A / C24 Edition 0/Rev. 5 80–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL Figure 13.1: Starting, TYPICAL 80–00–00 Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SYSTEM DESCRIPTION For a detailed System description refer to the latest issue of the Operators Manual (OM). SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual (OM). Ambient temperatures System Limit Electric Starter Min. - 40 °C (- 40 °F) Max. 80 °C (176 °F) Thermal durability Suitable for short starting periods only. Activate starter for max. 10 seconds (without interruption), followed by a cooling period of 2 minutes. Aircraft ground The engine block must be connected to the aircraft using a properly sized ground strap (minimum the same cable cross section as starter supply), to provide the required starter current and to avoid static electricity between the engine and the aircraft. Effectivity: 915 i A / C24 Edition 0/Rev. 5 80–00–00 Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW Figure 13.2: Starter interfaces 1 Positive terminal 2 Negative terminal ELECTRICAL INTERFACES Positive terminal 915 i TYPE A Interface Parameter Min. Max. Input voltage: Input load:* * for resistance of starter circuit Rsmax = <20 mOhm Nominal 12 V 20 A 350 A5 The terminal must be conducted as M5 screw connection suitable for cable lug according to DIN 46225. Tightening torque: Min. 3 Nm (27 in.lb) Max. 5 Nm (44 in.lb). 5. When electric starter is activated 80–00–00 Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Positive terminal 915 i TYPE C24 Interface Parameter Min. Max. Input voltage: Input load:* * for resistance of starter circuit Rsmax = <20 mOhm Nominal 24 V 20 A 350 A6 The terminal must be conducted as M5 screw connection suitable for cable lug according to DIN 46225. Tightening torque: Min. 3 Nm (27 in.lb) Max. 5 Nm (44 in.lb). Negative terminal The engine block must be connected to the airframe using a properly sized ground strap (minimum the same cable cross section as the starter supply), for carrying the starter current and to avoid static electricity between the engine and the airframe. 6. When electric starter is activated Effectivity: 915 i A / C24 Edition 0/Rev. 5 80–00–00 Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL INSTALLATION NOTES General The representation of components in this chapter which are not within scope of the delivery is only symbolic. The design shown in this chapter does not represent a specified execution but should support the understanding of the system. The final design, the selection and specification of parts according to the respective applicable regulations, the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the responsibility of the aircraft manufacturer. The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual (OM) can be supervised by the pilot. The execution of the installation must allow the operation of the engine according to the Operators Manual (OM). INSTALLATION OVERVIEW 915 i TYPE A Figure 13.3: Engine starting circuit 80–00–00 Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL 915 i TYPE C24 Figure 13.4: Engine starting circuit WIRING The minimum cable cross-section for the line from the battery to the starter relay and from there to the electric starter and for the ground line (start system) depends on the cable length “I“(= Sum of the supply line and ground line of the electric starter) and has to be calculated according to the following table. I [m] I [ft] Amin. [mm2] Amin. [in2] Amax. [mm2] Amax. [in2] AWGmin. <4 <13 20.408 0.031 25 0.039 4 4<I<4.5 13<I<14.8 22.959 0.036 35 0.054 3 4.5<I<5 14.8<I<16.4 25.51 0.04 35 0.054 3 5<I<5.5 16.4<I<18 28.061 0.043 35 0.054 2 5.5<I<6 18<I<19.7 30.612 0.047 35 0.054 2 6<I<6.5 19.7<I<21.3 33.163 0.051 35 0.054 2 6.5<I<7 21.3<I<23 35.714 0.055 50 0.078 1 7<I<7.5 23<I<24.6 38.265 0.059 50 0.078 1 7.5<I<8 24.6<I<26.2 40.816 0.063 50 0.078 1 8<I<8.5 26.2<I<27.9 43.367 0.067 70 0.109 0 8.5<I<9 27.9<I<29.5 45.918 0.071 70 0.109 0 Effectivity: 915 i A / C24 Edition 0/Rev. 5 80–00–00 Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL I [m] I [ft] Amin. [mm2] Amin. [in2] Amax. [mm2] Amax. [in2] AWGmin. 9<I<9.5 29.5<I<31.2 48.469 0.075 70 0.109 0 9.5<I<10 31.2<I<32.8 51.02 0.079 70 0.109 0 The internal resistance of the battery and the resistance of the electrical system (wires, contact points, relay contacts) largely determine the performance of the starting system. Therefore, the total loop resistance (RSmax) may not exceed 0.015 Ω. RSmax= Ć© R = RiBatt +RC Starter relay +RL + ROther 80–00–00 Page 8 February 01 2024 Symbol Description RiBatt Inner resistance of battery RC Starter Relay Contact resistance starter relay RL Line resistance ROther Any other resistor (e.g. Master relay, contact resistance...) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL STARTER RELAY ASSY. TECHNICAL DATA NOTICE Activation of starter relay limited to short duration. The duty cycle over an interval of 4 minutes is 25%. Figure 13.5: Starter relay 1 Main current connections 3 Mounting point Nominal voltage 12 V/DC Control voltage min. 6 V / max. 18 V 2 Control wiring Switching current max. 75 A (permanent) max. 300 A/1 s (short duration) Permissible ambi- min. -40 °C (-40 °F) / max. +100 °C (212 °F) ent temperature Weight See Chapter 72–00–00 section Weight. Main current connections M6 screw connection (tightening torque 4 Nm (36 in.lb.)) suitable for cable terminals according to DIN 46225 (MIL-T-7928; PIDG or equivalent). Control wiring 6.3x0.8 plug connector suitable for Faston connector (female) according to DIN 46247 (MIL-T-7928; (PIDG) or equivalent). Effectivity: 915 i A / C24 Edition 0/Rev. 5 80–00–00 Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL Grounding Figure 13.6: Starter relay 80–00–00 Page 10 February 01 2024 1 Starter relay 2 Hex. nut M6 3 Washer 6.4 4 Terminal S 5 Ground 6 Bolt/screw 7 Terminal B 8 Terminal M 9 Wiring harness (Engine) Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL VALIDATION OF INSTALLATION General The validation procedures described in this chapter do not claim to be complete. The correct execution and compliance with all given system limitations and interface descriptions as well as with standards and norms given by authorities must be proven by the aircraft manufacturer. Effectivity: 915 i A / C24 Edition 0/Rev. 5 80–00–00 Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 12 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: 92–00–00 WIRING DIAGRAMS TOPICS IN THIS CHAPTER General This Chapter contains the wiring diagrams for each relevant engine system installation. The wiring diagrams have the same numbering system and abbreviations as used in this Manual Title Drawing Number Rev. Number Number of Sheets Wiring diagram ROTAX® 915 I Type A AE_5iS_0160 0 1 Wiring diagram ROTAX® 915 I Type C24 AE_5iS_0830 0 1 Effectivity: 915 i A / C24 Edition 0/Rev. 5 92–00–00 Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 2 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Chapter: APPENDIX OPERATIONAL AND INSTALLATION CONSIDERATIONS TOPICS IN THIS CHAPTER Scope ......................................................................................................................................................2 Fuel pumps and power supplies..............................................................................................................3 Engine starting, Start power switching system and Starting system .......................................................4 Lane select switching system – Ignition switching..................................................................................5 Failure behavior and Warning annunciation to the pilot ..........................................................................6 Simplified EMS Matrix 915 i A Series .......................................................................................................7 Hypothesis on warning lamp execution in the aircraft ...........................................................................15 System availability and reliability ..........................................................................................................16 Electrical bonding .................................................................................................................................17 Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 1 February 01 2024 BRP-Rotax INSTALLATION MANUAL SCOPE The current version of the Operators Manual provides information on pilot action in the case of abnormal engine operation (see Chapter 4, section 4.1: Engine failures in flight). The current information (table) provides a very conservative position which might not allow to tap the full potential of the engine’s operational ability if referring to this table only. For this reason, an additional section in written form is provided in the Installation Manual, explaining engine behavior in very simple form, with the intention to allow the installer tailoring evaluation of system behavior and failure severity classification and thus pilot action for a specific aircraft installation. Prediction of pilot action is not possible to the engine system designer entirely, since this may vary with actual conditions arising from installation in a specific aircraft (SEP, MEP, Aircraft Type, Operational Conditions, etc.). It therefore might seem appropriate to provide a more detailed description of the engine system behavior in the case of failures, rather than providing a given pilot reaction, not knowing about the aircraft installation in every detail. With upcoming installation projects based on different aircraft certification specifications it is now found that the current documentation should be refined and or changed to better meet the demands of installers. This written document should furthermore provide a better understanding for interpretation and implementation of the following topics: • Fuel pumps and power supplies • Engine starting, start power switching system and Starting system • Lane select switching system – Ignition switching • Failure behavior and warning annunciation to the pilot • Failure consideration beyond Installation Interfaces • Hypothesis on warning lamp execution in the aircraft • System availability and reliability • Electrical bonding APPENDIX Page 2 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL FUEL PUMPS AND POWER SUPPLIES The 915 i A Series provides the possibility to supply fuel pumps from the engine electric supply system. It provides a connector for connection of two electric fuel pumps (not engine type design) and furthermore the possibility to actuate these fuel pumps via the HIC (Harness Interface connector). At the HIC position two fuel pump switching systems (not engine type design) are required to provide the fuel pump ON/OFF function. From engine system perspective these fuel pump switching systems are required to allow a real check of the functional performance of each pump, meaning completely switching off the opposite fuel pump, while the current engaged fuel pump must supply the engine stand alone. The 915 i A Series power supply system comprises two separate permanent magnet alternators (engine internal, on a single stator but completely physically separated), two independent Voltage regulators, including voltage smoothening capacitors, etc. This forms two independent power supply sources which are each able to power the Engine Management System (EMS) entirely. These power supply systems produce power once the engine is turning, each completely independent and completely galvanic separated from the aircraft power supply (when Start power OFF and backup battery OFF). For this reason, there is no dependence and interaction between engine power supply and aircraft power supply at all. The two power supply systems are not specifically dedicated to the two fuel pumps. They are rather dedicated to the entire EMS, meaning power supply system Generator A is supplying the entire EMS including both fuel pumps in common operation mode. In the case of a faulty power supply system Generator A the power supply system Generator B is automatically engaged and supplying the EMS including both fuel pumps. This means not only a backup pump receives an independent power supply but rather each control system including each fuel pump has a redundant independent power supply. Engagement of the backup power supply system Generator B is done by the Engine Control Unit (ECU) in the case of over voltage and under voltage. If the voltage of power supply system Generator A decreases significantly or at all, the control transition of the power supplies is additionally done per mechanical means (relays drop out). These mechanism allow engagement of backup power supply under every probable circumstance. If power supply system Generator B is used to supply the aircraft electrical system (possible in common operation mode) it must be noted that in case of failure this power supply system B is disconnected from the aircraft to serve as the backup to the EMS. The ECU does not control and monitor the fuel pumps. The EMS provides the possibility to supply and control the fuel pumps. The aspect “directly driven fuel pump” as required in various aircraft certification specifications is interpreted as follows: • The fuel pump is directly driven in an electrical manner, as it is supplied by a power supply system which is directly driven from the crankshaft, self-supplying the system as long as the engine is rotating (as it would be the case on a typical mechanical system). • From a human factor perspective it is desired, that a main pump may not be switched off inadvertently. This aspect must be resolved per the arrangement of the fuel pump switching system on aircraft level. The arrangement may be such, that the main pump is always ON during flight, while switching OFF is just feasible for fuel pump checking purpose during preflight checks. Prevention of inadvertent operation of switching action is common practice with ignition systems. Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 3 February 01 2024 BRP-Rotax INSTALLATION MANUAL ENGINE STARTING, START POWER SWITCHING SYSTEM AND STARTING SYSTEM The 915 i A Series engines requires provision of electric power supply for EMS startup (startup power to ECU, sensors, etc.). This is done by a start power switching system (not engine type design), which provides power to the EMS via the Fuse box interface (X3, EMS GND). The 915 i A Series provides the possibility to supply a starter relay (not engine type design) from the EMS and to actuate the starter relay via the HIC. This arrangement can form a part of a complete starting system with interfaces at the starter, starter relay connector and HIC connector of the engine wiring harness. When the engine is started the engine internal power supply system Generator B is supplying the EMS. At a certain engine speed , and after a certain amount of stable operating time, the ECU commands power supply system A to take over. power supply system Generator A remains engaged except in the case of failures. This procedure ensures that both power supply systems are checked prior to flight. It is therefore important that a start power switching system releases power prior to commanding power supply system A. This is important so as not to compromise the check of power supply system Generator B. APPENDIX Page 4 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL LANE SELECT SWITCHING SYSTEM – IGNITION SWITCHING Certification Specifications might call out specific requirements for ignition systems, whereas this seems to be sometimes driven by classical configurations where the only engine related piece of electronics is represented by the ignition system itself. The 915 i A Series engine features a complete electronic system including redundant controllers, ignition, injection, power supply, turbo actuation, etc. The ignition system is not to be segregated from the entire system and therefore a classical magneto check needs to be extended to all functions an EECS performs. With the 915 i A Series engines each individual lane (including controller, sensors, actuators) needs to be checked prior to flight, ensuring a full functional check of a system, other than just checking for availability of the ignition system only. This is done by providing a Lane select switching system (not engine type design) to each HIC of the engine system. Ignition switching needs to be interpreted as part of the Lane select switching system which should be in line with the intent of certification specifications. The two Lane select switching systems are switchable independently (redundant HIC) and just foreseen for engine related functions including ignition. Appropriate separation from other aircraft electrical circuits is required as it might also be defined by aircraft certification specifications. Inadvertent operation of an ignition system needs to be implemented per the design of the Lane select switching system on aircraft level. Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 5 February 01 2024 BRP-Rotax INSTALLATION MANUAL FAILURE BEHAVIOR AND WARNING ANNUNCIATION TO THE PILOT Prediction of pilot action in the case of engine failure is not possible to the engine system designer entirely, since this may vary with actual conditions arising from installation in a specific aircraft (SEP, MEP, type of aircraft, Operational conditions, etc.). It seems more appropriate to provide a detailed description of the engine system behavior in the case of failures to empower the installer to derive pilot action related to the current installation situation. It must be noted that the information provided in the following section is an extract of supposable failure scenarios with the intention to just indicate information relevant to the installer. The EMS comprises redundant controllers (ECU) which facilitate different system modes. These system modes are Auto_AB which is the common operation mode and Auto_A, Auto_B, Only_A, Only_B, which are alternate system modes. The alternate system modes are engaged either during pre-flight checks or during presence of faults/failures. It is important to understand that each mode is capable providing full control over the engine, respectively providing full power/thrust from the engine. The control modes just differ in efficiency of engine operation. The ECU distinguishes between fault and failures, whereas a fault prescribes a scenario of low severity, not causing system mode change. A failure leads to a system mode change. The presence of a fault is indicated by a flashing warning lamp. The presence of a failure is indicated by warning lamp which is permanent on. Each individual Lane is equipped with a warning lamp. The system is equipped with a redundant Display CAN interface for annunciation of a broad range of engine data additionally. APPENDIX Page 6 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL SIMPLIFIED EMS MATRIX 915 I A SERIES Item (Failure/ Fault) System Affect- Warning ed Lamp A Lane Warning Lamp B System Mode Engine effect Crankshaft Position Sensor (CPS) Sensor A ON OFF Auto_B No change of engine power; single ignition and single injection Crankshaft Position Sensor (CPS) Sensor B OFF ON Auto_A No change of engine power; single ignition and single injection Manifold Air Pressure Sensor (MAPS) Sensor A ON OFF Auto_B No change of engine power; single ignition and single injection Manifold Air Pressure Sensor (MAPS) Sensor B OFF ON Auto_A No change of engine power; double ignition and single injection Manifold Air Temperature Sensor (MATS) Sensor A ON OFF Auto_B No change of engine power; single ignition and single injection Manifold Air Temperature Sensor (MATS) Sensor B OFF ON Auto_A No change of engine power; double ignition and single injection Throttle Position Sensor A flashing OFF Auto_AB No change of engine power; double ignition and single injection Throttle Position (in range failure) Sensor A ON OFF Auto_B No change of engine power; single ignition and single injection Ambient Air Pressure Sensor (AAPS) Sensor A ON OFF Auto_B No change of engine power; single ignition and single injection Ambient Air Pressure and Temperature Sensor (AAPTS) Sensor A ON OFF Auto_B No change of engine power; single ignition and single injection Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 7 February 01 2024 BRP-Rotax INSTALLATION MANUAL Item (Failure/ Fault) System Affect- Warning ed Lamp A Lane Warning Lamp B System Mode Engine effect Ambient Air Temperature Sensor A flashing OFF Auto_AB No change of engine power; double ignition and single injection Coolant Temperature Sensor (CTS) Sensor A flashing OFF Auto_AB No change of engine power; double ignition and single injection EGT (1-4) Sensor A flashing OFF Auto_AB No change of engine power; double ignition and single injection Knock Sensor A flashing OFF Auto_AB No change of engine power; double ignition and single injection Display CAN A Annunciation A OFF OFF Auto_AB No change of engine power; double ignition and single injection Display CAN B Annunciation B OFF OFF Auto_AB No change of engine power; double ignition and single injection Maintenance CAN Lane A Data Bus A OFF OFF Auto_AB No change of engine power; double ignition and single injection Maintenance CAN Lane B Data Bus B OFF OFF Auto_AB No change of engine power; double ignition and single injection Coil 1/3 Actuator A ON OFF Auto_B No change of engine power; single ignition and single injection Coil 2/4 Actuator B OFF ON Auto_A No change of engine power; single ignition and single injection; Double ignition control mode intended in Auto_A but one ignition failed, therefore single ignition in effect Injector 1/2/ 3/4 (INJ) Actuator A ON OFF Auto_B No change of engine power; single ignition and single injection APPENDIX Page 8 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Item (Failure/ Fault) System Affect- Warning ed Lamp A Lane Warning Lamp B System Mode Engine effect Injector 5/6/ 7/8 (INJ) Actuator B OFF ON Auto_A No change of engine power; double ignition and single injection Warning Lamp (WL) Annunciation A OFF OFF Auto_AB No change of engine power; double ignition and single injection; Check immediately with display or during next engine start (Warning lamp check) Warning Lamp (WL) Annunciation B OFF OFF Auto_AB No change of engine power; double ignition and single injection; Check immediately with display or during next engine start (Warning lamp check) Oil Temperature Sensor (OTS) Sensor B OFF flashing Auto_AB No change of engine power; double ignition and single injection Oil Pressure Sensor (OPS) Sensor B OFF flashing Auto_AB No change of engine power; double ignition and single injection Loss of EMS Ground Port Power Supply A ON OFF *(ON) Only_B No change of engine power; single ignition and single injection *) if system electric fuel pump supply is used the following applies: No change of engine power; single ignition and single injection if both fuel pumps are ON (Take-off/Landing procedure) Loss of EMS Ground Port Power Supply B OFF ON Only_A No change of engine power; single ignition and single injection Power Supply ECU Lane A Power Supply A ON OFF Only_B No change of engine power; single ignition and single injection Power Supply ECU Lane B Power Supply B OFF ON Only_A No change of engine power; single ignition and single injection Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 9 February 01 2024 BRP-Rotax INSTALLATION MANUAL Item (Failure/ Fault) System Affect- Warning ed Lamp A Lane Warning Lamp B System Mode Engine effect Generator Selector Power Supply - flashing flashing Auto_AB No change of engine power; double ignition and single injection; Automatic switch from Generator A to Generator B, no charging of aircraft battery if Generator B is the only charging source Generator A Power Supply - flashing flashing Auto_AB No change of engine power; double ignition and single injection; ECU performs automatic change to Generator B; in addition check via display and/or current gauge; no charging of aircraft battery if Generator B is the only charging source Generator B Power Supply - OFF OFF Auto_AB No change of engine power; double ignition and single injection; no charging of aircraft battery if Generator B is the only charging source. Additional description: In common operation both ECU Lanes monitor the active power supply system, in this case System A (Generator A). Important: ECU does not recognize power supply system B failure in this common operating state. Check is done during next engine start. Immediate check can be done with Ampere/Voltage indication in aircraft. Rectifier regulator A Power Supply - flashing flashing Auto_AB No change of engine power; double ignition and single injection; ECU performs automatic change to Generator B; in addition check via display and/or current gauge; no charging of aircraft battery if Generator B is the only charging source APPENDIX Page 10 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Item (Failure/ Fault) System Affect- Warning ed Lamp A Lane Warning Lamp B System Mode Engine effect Rectifier regulator B Power Supply - OFF OFF Auto_AB No change of engine power; double ignition and single injection; no charging of aircraft battery if Generator B is the only charging source. See additional description “Generator B”. Specific Failures within Fusebox (Capacitors, Fuses, Relays...) leading to Generator change (to Generator B) Power Supply - flashing flashing Auto_AB No change of engine power; double ignition and single injection; ECU performs automatic change to Generator B; in addition check via display and/or current gauge; no charging of aircraft battery if Generator B is the only charging source Specific Failures within Fusebox (Capacitors, Fuses, Relays...) leading to loss of electric power supply system Generator B Power Supply - OFF OFF Auto_AB No change of engine power; double ignition and single injection; no charging of aircraft battery if Generator B is the only charging source. See additional description “Generator B”. Boost Pressure Sensor (BPS) Sensor A ON OFF Auto_B No change of engine power; single ignition and single injection Boost Pressure Sensor (BPS) Sensor B OFF ON Auto_A No change of engine power; double ignition and single injection Ambient Air Pressure Sensor (AAPS) Sensor B OFF ON Auto_A No change of engine power; double ignition and single injection Pressure Control Valve (PCV) Actuator A ON OFF *(ON) Auto_B No change of engine power; single ignition and single injection; *) 915 iSc A provides electric power supply to PCV and Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 11 February 01 2024 BRP-Rotax INSTALLATION MANUAL Item (Failure/ Fault) System Affect- Warning ed Lamp A Lane Warning Lamp B System Mode Engine effect main fuel pump from same fuse box output. If system electric fuel pump supply is used and power supply to PCV/Main fuel pump fails the following applies: No change of engine power; single ignition and single ignition if both fuel pumps are ON (Take-off / Landing procedure) IFSD in cruising if only one fuel pump (Main) is ON >>Normal Emergency Procedure (Engine ReStart) >> Both WL are activated because of engine stall. WL activation is irrelevant because engine and annunciation stops immediately. Pressure Control Valve (PCV) Actuator B OFF ON Auto_A No change of engine power; double ignition and single injection Overboost Pressure Control Valve (OBV) Actuator A flashing OFF Auto_AB No change of engine power; double ignition and double injection Lane Select Switch A Power Supply A ON OFF Only_B No change of engine power; single ignition and single injection Lane Select Switch B Power Supply B OFF ON Only_A No change of engine power; single ignition and single injection Fuel pump 1 (Main) Fuel system - OFF * (ON) OFF *(ON) Auto_AB No change of engine power; single ignition and single ignition if both fuel pumps are ON (Take-off / Landing procedure) IFSD in cruising if only one fuel pump (Main) is ON >>Normal Emergency Procedure (Engine Re-Start) >> Both WL are activated because of engine stall. WL activation is irrelevant because engine and annunciation APPENDIX Page 12 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL Item (Failure/ Fault) System Affect- Warning ed Lamp A Lane Warning Lamp B System Mode Engine effect stops immediately. See also dependence of electric power supply associated with PCV. Fuel pump 2 (Aux) Fuel system - OFF OFF Auto_AB No change of engine power; double ignition and single injection; Check during next engine start Fuel pump 1 switching system (Main) Fuel system - OFF * (ON) OFF *(ON) Auto_AB No change of engine power; single ignition and single ignition if both fuel pumps are ON (Take-off / Landing procedure) IFSD in cruising if only one fuel pump (Main) is ON >>Normal Emergency Procedure (Engine Re-Start) >> Both WL are activated because of engine stall. WL activation is irrelevant because engine and annunciation stops immediately. See also dependence of electric power supply associated with PCV. Fuel pump 2 switching system (Aux) Fuel system - OFF OFF Auto_AB No change of engine power; double ignition and single injection; Check during next engine start Start switching system Starting system - OFF *(flashing) OFF Auto_AB 1) If failure occurs during engine run: No change of engine power; double ignition and double injection. *) 915 iSc A provides electric power supply to OBV and starting system from the same fuse box output. If system electric starting supply is used and power supply to OBV / Starting system fails the following applies: additional to 1) OBV fault and WL A flashing Starter Relay Starting system - OFF OFF Auto_AB No change of engine power; double ignition and double injection; no effect on EMS / ECU; Failure detection at next Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 13 February 01 2024 BRP-Rotax INSTALLATION MANUAL Item (Failure/ Fault) System Affect- Warning ed Lamp A Lane Warning Lamp B System Mode Engine effect engine start, Engine (Re-) Start not possible. Start Power Switching System Power up system - OFF OFF Auto_AB No change of engine power (unless windmilling); double ignition and double injection; no effect on EMS / ECU Battery Backup Switching System Backup PS - OFF OFF Auto_AB No change of engine power; double ignition and double injection; no effect on EMS / ECU APPENDIX Page 14 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL HYPOTHESIS ON WARNING LAMP EXECUTION IN THE AIRCRAFT Aircraft Certification Specifications and related guidance call out for lamp indication colors RED in the case of a warning, YELLOW/AMBER in the case of a caution, GREEN in the case of safe operation. Whereas RED calls out for immediate crew action and YELLOW/AMBER indicates degraded conditions without immediate crew action. For the 915 i A Series the warning lamp color is not mandated in the engine Installation Manual. As shown in the extract of supposable failure scenarios (see previous sections), the EMS provides an automatic reaction in the case of faults/failures, still producing sufficient power/thrust in a relevant critical flight phase. The transition to an alternate mode does not implicate manual pilot action. The warning annunciation through the warning lamps indicates the state of an individual Lane. Based on these facts the meaning of warning Lamp indication is to be associated with YELLOW/AMBER entirely. The differentiation between flashing and permanent ON can be ignored in a straight forward approach in terms of ease of interpretation. The indication of a flashing lamp allows for additional differentiation of the failure severity if desired. A warning lamp that is “just flashing” does not lead to a system mode change. This means even in the case of an additional failure the system provides an alternate system mode. If flashing lamps are not acceptable the flashing must be filtered at the installers discretion. If the approach described in the previous section is not found to be acceptable (use just YELLOW/AMBER) the warning lamp signals from the ECU will need to be converted at the installers discretion. Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 15 February 01 2024 BRP-Rotax INSTALLATION MANUAL SYSTEM AVAILABILITY AND RELIABILITY In the course of development and certification, the 915 i A Series has been assessed in terms of safety and reliability. The system is essentially single fault tolerant with respect to LOPC/LOTC. This means there’s an existing (small) number of single faults which can lead to LOPC/LOTC. However, these failure modes in combination with other existing failure modes are in line with the reliability targets on engine level, which is associated with the term “essentially single fault tolerant”. Following systems are beyond the scope of the engine EMS (not Engine Type Design) but are relevant interface considerations in the course of the engine FTA. Therefore probability rates have been budgeted and are provided here within for installation guidance. These budgeted rates represent conservative reliability numbers and should be well achievable. For 915 i A Series , assuming that electrical/electronic fuel pumps are used and powered from the engine EMS: FTA Top Event “LOPC – Loss of Power Control” • "Battery Backup Fault": The budgeted LOPC FTA probability rate is 1E-4 (failure mode description: no or insufficient backup power supply) • “Lane Select Switching System Fault”: The budgeted LOPC FTA probability rate for a single lane select switching system is 1E-4 (failure mode description: no or insufficient power supply through lane select switching system). Two independent lane select switching systems are required • “Electrical/electronic fuel pump switching system Fault” is 1E-4 (failure mode description: no or insufficient power supply to fuel pump through switching system). Two independent fuel pump switching systems are required FTA Top Event “ISDE – Inability to shutdown engine" • “Fuel Shut Off Valve”: The budgeted ISDE FTA probability rate is 1E-4 (failure mode description: fuel shut off valve permanent on/open) • “Electrical/electronic fuel pump switching system fault”: The budgeted ISDE FTA probability rate of a single electrical/electronic fuel pump switching system is 1E-4 (failure mode description: fuel pump switching system fails to open). Two independent fuel pump switching systems are required • “Lane Select switching system fault”: The budgeted ISDE FTA probability rate of a single lane select switching system is 1E-4 (failure mode description: lane select switching system fails to open). Two independent lane select switching systems are required APPENDIX Page 16 February 01 2024 Effectivity: 915 i A / C24 Edition 0/Rev. 5 BRP-Rotax INSTALLATION MANUAL ELECTRICAL BONDING The engine’s frame/body is connected to the airframe and there is no floating potential all the time. The EMS GND is electrically isolated during flight. The engine system is not susceptible to, nor a source of electrostatic discharge. The EMS is most likely located aircraft internally and charging activity is expected to be low (static charge increases with air velocity and friction effect). The electrical system provides a finite working resistance (MOhm range) which is electrically dissipative in terms of electrostatic charge. Charging effect is therefore expected to be low if any. Effectivity: 915 i A / C24 Edition 0/Rev. 5 APPENDIX Page 17 February 01 2024 BRP-Rotax INSTALLATION MANUAL INTENTIONALLY LEFT BLANK Page 18 February 01 2024 Effectivity: 915 i A / C24 BRP-Rotax INSTALLATION MANUAL Index A Battery ...............................................................21 Bypass line .........................................................10 Fine filter ............................................................ 11 Fuel interfaces ......................................................6 Fuel lines............................................................10 Fuel pressure regulator........................................12 Fuel pressure sensor...........................................12 Fuel pump ..........................................................12 Fuel pump Switch................................................20 Fuel pumps and power supplies .............................3 Fuel shut off valve ...............................................13 Fuel system, overview ...........................................9 Fuel tank ............................................................12 C G CAN interfaces....................................................15 CAN interfaces – 915 I Type C24..........................19 Coarse filter ........................................................ 11 Components .......................................................13 constant speed propeller........................................8 Control elements.................................................22 Conversion table .................................................12 Coolant ..............................................................12 Coolant hoses..................................................... 11 Coolant, Boiling point...........................................12 Crankcase pressure measurement ................... 3, 19 Gascolator.......................................................... 11 General ................................................................2 Grounding cables................................................20 Abbreviations........................................................6 Air cooling interfaces .............................................7 Approval of electric and electronic components .....19 Auxiliary equipment ...............................................5 B H Handling the engine ..............................................7 Hypothesis on warning lamp execution in the aircraft ..............................................................15 I E Electrical bonding................................................17 Electrical interfaces ......................... 6, 10, 7, 11, 5, 4 Electrical interfaces – 915 I Type C24 ............. 12, 10 Electrical interfaces – 916 I Type A .........................6 Engine starting, Start power switching system and Starting system .............................................4 Engine suspension..............................................13 Engine, Handling...................................................5 Engine, Preservation .............................................4 Engine, Storage ....................................................4 Engine, Unpacking ................................................5 Exhaust tail pipe....................................................5 Expansion tank ................................................... 11 F Failure behavior and Warning annunciation to the pilot...............................................................6 Filling and purging the oil system..........................16 Effectivity: 915 i A / C24 Edition 0/Rev. 5 Inlet line..............................................................10 Installation notes ........................................20, 8, 14 Installation overview ........20, 11, 10, 16, 18, 13, 14, 6 Installation overview – 915 I Type C24 ..................16 Instruction ..........................................................16 Interface description ............................. 6, 12, 9, 6, 4 Interface overview .............................4, 6, 10, 5, 4, 8 Interface overview – 915 I Type C24 .......................9 Interface overview.– 915 I Type C24 .....................12 L Lane Select Switch..............................................20 Lane select switching system – Ignition switching ....5 List of effective pages ............................................1 M Measuring of the vacuum.......................................5 Mechanical interfaces...................... 11, 6, 9, 7, 14, 8 Page 19 February 01 2024 BRP-Rotax INSTALLATION MANUAL Mechanical interfaces – 915 I Type C24 ................18 O Oil hose, Requirements .........................................7 Oil lines ..............................................................14 Oil pressure sensor ...............................................1 Oil pump............................................................. 11 Oil radiator..........................................................15 Oil tank...............................................................10 Operational and Installation Considerations ............1 P Pneumatic interfaces .............................................8 Positive terminal....................................................4 Propeller governor, hydraulic..................................8 Purging line, Requirements ....................................7 Simplified EMS Matrix 915 i Series .........................7 Start switch.........................................................20 Starter relay, Technical data ...................................9 System availability and reliability ..........................16 System description........................................ 4, 3, 5 System Description ...............................................3 System limitations ........................... 4, 3, 6, 3, 5, 4, 3 System Limitations ................................................3 T Table of amendments ............................................1 Technical documentation .....................................17 Terms...................................................................6 Type description....................................................3 V Validation of installation .......................26, 13, 19, 11 R Return line ..........................................................10 RTCA/DO-160 ....................................................19 S Safety ................................................................13 Safety information ...............................................14 Scope ..................................................................2 Scope of supply ....................................................4 Effectivity: 915 i A / C24 Edition 0/Rev. 5 W Warning lamp .....................................................15 Warning lamp – 915 I Type C24............................19 Water inlet elbow................................................. 11 Water inlet, Water outlet.........................................5 Water trap........................................................... 11 Wiring ..................................................................7 Wiring color codes............................................... 11 Wiring diagrams ....................................................1 Page 20 February 01 2024 AE_5iS_0160 Engine serial no. Type of aircraft Aircraft registration no. Rotax® authorized distributor FLYROTAX.COM ® and TM are trademarks of BRP-Rotax GmbH & Co KG. © 2024 BRP-Rotax GmbH & Co KG. All rights reserved. ">
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Key features
- Fuel-efficient operation for extended flight range and reduced operating costs
- Advanced electronic ignition system for seamless starting and smooth engine operation
- Lightweight and compact design for enhanced maneuverability and reduced aircraft weight
- Integrated cooling system for optimal temperature management and extended engine life
- Reliable and durable construction for peace of mind during every flight
Frequently asked questions
The Rotax 915 iS A is designed to operate on unleaded automotive gasoline with a minimum octane rating of 91 (RON).
The Rotax 915 iS A delivers a continuous power output of 141 horsepower at 5800 RPM, providing ample power for both recreational and professional aviation applications.
Yes, the Rotax 915 iS A utilizes an advanced electronic fuel injection system for precise fuel metering and optimized engine performance across all operating conditions.