Champion LASAR L-1502C, Installation & Operation Manual

Page 1: ...stallation operation and troubleshooting instructions and technical information about the LASAR system L 1502C ISSUED MO DAY YEAR 01 18 96 REVISED MO DAY YEAR 03 01 09 PAGE NO COVER PAGE REV C CHAMPION AEROSPACE PROPRIETARY INFORMATION THIS DOCUMENT IS PROPRIETARY PROPERTY OF CHAMPION AEROSPACE LLC IT IS NOT TO BE COPIED OR REPRODUCED IN ANY MANNER NOR SUBMITTED TO OTHER PARTIES FOR EXAMINATION WI...

Page 2: ...d Liberty South Carolina U S A 29657 2009 ChampionAerospace LLC www championaerospace com CHAMPION AEROSPACE LLC PROPRIETARY INFORMATION Subject to the restrictions on the Title page ISSUED PAGE REV PAGE NO REVISED MO DAY YEAR 01 18 96 L 1502 03 01 09 C i ...

Page 3: ...SSUED PAGE REV PAGE NO REVISED MO DAY YEAR 01 18 96 03 01 09 C ii Log of Revisions Pages Rev No Description Revised Date A Modified format All 5 20 96 B Modified Format Added provisions All 6 27 97 for cockpit enunciator light and tachometer Added LVCH connector lubricant Added Troubleshooting with a computer Various text changes to improve clarity C This revision changes the company from All 3 01...

Page 4: ...E PREPARATION 2 3 2 2 4 INSTALL MAGNETO DRIVE GEARS 2 4 2 2 5 ENGINE SET UP 2 4 2 2 6 INSTALL SENSOR MAGNETO LEFT ENGINE POSITION 2 4 2 2 7 INSTALL NON SENSOR MAGNETO RIGHT ENGINE POSITION 2 5 2 2 8 ALIGN THE ENGINE CRANKSHAFT TO TDC 2 5 2 2 9 ALIGN LEFT MAGNETO TO TDC 2 5 2 2 10 ALIGN ENGINE CRANKSHAFT TO BTDC 2 6 2 2 11 SYNCHRONIZE LEFT AND RIGHT MAGNETO CONTACT POINTS 2 6 2 2 12 CHECK SENSOR AN...

Page 5: ...L LOW VOLTAGE CONTROL HARNESS 2 14 2 5 3 RECONFIRM COMPLETION OF ALL STEPS IN SECTION 2 2 2 14 3 0 LASAR OPERATION 3 1 3 1 LASAR SYSTEM PRE FLIGHT CHECK 3 1 3 2 LASAR SYSTEM POST FLIGHT CHECK 3 1 3 3 MIXTURE LEANING 3 1 3 4 IN FLIGHT RESTART 3 2 3 5 GROUND HANDLING 3 2 4 0 DOCUMENTATION 4 1 5 0 LASAR SYSTEM MAINTENANCE SCHEDULES 5 1 5 1 LASAR SYSTEM MAINTENANCE SCHEDULES 5 1 5 1 1 INSPECTION INTER...

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Page 7: ...est revision of the appropriate LASAR manual or product support document be referenced Contact Champion Aerospace to be sure you have the latest manual or support document revision before performing any work All reasonable attempts were made to make this manual as complete and accurate as possible If you have any questions comments corrections or require clarification of any information contained ...

Page 8: ...rts reworked parts obtained from non Champion Aerospace approved sources or parts the service history of which is unknown or cannot be authenticated may have been subjected to unacceptable stresses or temperatures or have other hidden damage not discernible through routine visual or usual nondestructive testing techniques This may render service work with this part even through originally manufact...

Page 9: ...ing instructions for the LASAR system LASAR publication number L 1503 LASAR Maintenance Manual should be referenced for details relating to the maintenance of LASAR systems The information in this manual is divided into six sections Section One provides an overview on system components and a basic technical reference on the design and operation of LASAR systems Section Two contains installation in...

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Page 11: ...g advance is reduced by the CHT control feature engine performance improvements resulting from optimized ignition timing will be reduced In extreme situations where the engine continually operates at maximum cylinder head temperatures LASAR will command the same ignition timing as provided by conventional magnetos resulting in comparable engine performance Two different limits climb and cruise are...

Page 12: ...of magneto rotation within six seconds These starting sparks have roughly 300 more energy than sparks produced by conventional magnetos The enunciator light if equipped should turn off when the engine is cranking and the controller is operating in the automatic mode Ignition energy delivered by LASAR remains at the high setting until the engine reaches 700 RPM at which time the controller reduces ...

Page 13: ...gnition system operating in the backup mode windmill the engine above 500 rpm Piloting Operation of the LASAR system is transparent to the pilot under most conditions Unless the aircraft is equipped with a cockpit enunciator light the pilot is typically unaware of the two million logic and control command decisions that take place inside the controller every second What the pilot does experience w...

Page 14: ... LEFT MAGNETO Magneto with crankshaft speed position sensor Typically installed in the left position of the engine as viewed from the cockpit Identified by ten 10 pin connector RIGHT MAGNETO Magneto without crankshaft speed position sensor Typically installed in the right position of engine as viewed from the cockpit Identified by eight 8 pin connector LVCH HARNESS Low voltage control harness Conn...

Page 15: ...trictions on the Title page ISSUED PAGE REV PAGE NO REVISED MO DAY YEAR 01 18 96 03 01 09 C 1 5 1 6 Blank Figure 1 1 LASAR Component Layout Engine Non Sensor Magneto Sensor Magneto Manifold Pressure Line Switch Master Solenoid LASAR Controller GND GND Black Red Green Blue CHT Probe Some Applications Orange Enunciator Light Some Applications To Aircraft Bus Brown Tachometer Some Applications Fuse o...

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Page 17: ...Disconnect aircraft battery Install LASAR controller Prepare engine Install magneto drive gears Set up engine for magneto installation Install magnetos on engine Time magnetos to engine Check sensor and contact point synchronization Install ignition harness Confirm magneto switch operation Install low voltage control harness Connect manifold pressure source power Connect LASAR controller Reconnect...

Page 18: ...or affect the aircraft structure Minor rerouting of wiring or relocation of the accessories may be required The LASAR controller and associated cables should be mounted away from heat sources clear of the exhaust engine control linkages and any other system critical to the airworthiness of the aircraft B Position the LASAR controller so that the cable connector is facing downward or toward the cen...

Page 19: ...o av oid in te rf eren c e b et wee n riv e t he a ds an d c o nt ro ller m ou nt ing brac k e t L ay o ut h ole p at te rn a nd fit c o nt ro ller p rior to d rillin g h ole s through firewall See Installation Instructions Fig 2 1 for addition detail Firewall Kick View Looking Aft At Firewall Figure 2 3 LASAR System Installation 2 2 3 Engine Preparation A Remove the existing ignition system from ...

Page 20: ...e within the specified torque range remove the nut and lightly lap the bottom of the nut with a piece of emery cloth and repeat steps C and D 2 2 5 Engine Set Up A Align engine to the Base Timing Angle on the compression stroke of cylinder number one 2 2 6 Install Sensor Magneto Left Engine Position NOTE The sensor magneto is identified by the 10 pin connector NOTE Left and right magnetos refer to...

Page 21: ... timing pin is fully seated WARNING DO NOT USE THE DISTRIBUTOR BLOCK HOLES LABELED L OR R B With the crankshaft aligned to the BTDC position install the right magneto onto the right position on the engine Attach the magneto grounding strap to the engine accessory housing Tighten the clamp nuts finger tight to hold magneto in place WARNING MAGNETOS MUST BE PROPERLY GROUNDED TO ENSURE PROPER OPERATI...

Page 22: ...to Contact Points A If the RIGHT BKR PT light is off when the SynchroLASAR is turned to the ON or RIGHT BKR PT position rotate the housing of the right magneto counterclockwise for left rotation magnetos or clockwise for right rotation magnetos as viewed facing the magneto distributor blocks until the RIGHT BKR PT light turns on Proceed to Step C B If the RIGHT BKR PT light is on when the SynchroL...

Page 23: ...itch Operation A Confirm ignition switch operation prior to connecting the LASAR controller or operating the LASAR ignition system With conventional magnetos the ignition switch may be wired to ground the non impulse coupled or non retard breaker magneto when the starter is engaged Further ignition switch systems utilizing a starter switch separate from the magneto selector switch may ground the n...

Page 24: ...be followed to ensure that all connector and contact surfaces are free from all contaminants prior to assembly CAUTION DO NOT ATTEMPT TO CLEAN CONNECTORS USING COMPRESSED AIR OR BY INSERTING TOOLS TEST PROBES COTTON SWABS BRUSHES OR ANY OTHER OBJECTS INTO THE CONTACT AREAS CONTAMINATED CONNECTORS MAY BE CLEANED BY IRRIGATION WITH ISOPROPYL ALCOHOL OR MINERAL SPIRITS A Apply a liberal amount of M 5...

Page 25: ...al of the electrical system master solenoid A 10 amp inline fuse or circuit breaker which can be used as a switch should be installed as part of the input power wiring The LASAR controller should receive electrical power only when master switch is on H Attach the BLACK lead to a suitable grounding point common to the master solenoid ground I Review the remaining sections of this manual to determin...

Page 26: ... away from heat generating sources mechanical stresses and abrasion C Check for proper installation of the magnetos and controller D Check to confirm removal of all installation tools 2 2 18 Label Fuel Tank Filler Opening A Confirm that the airframe and engine fuel systems contain fuel with a minimum grade of 100 octane B Confirm that the fuel tank filler opening is placarded with a label which in...

Page 27: ... controllers This section does not apply to LASAR controllers which are not configured with the CHT control feature Install the LASAR ignition system as described in Section 2 2 before continuing 2 3 1 Identify Cylinder for CHT Probe Assembly Installation NOTE The full timing advance function of LASAR ignition systems equipped with CHT control requires the proper signal from a functioning CHT prob...

Page 28: ...r to the CHT instrument manufacturer for information regarding the type of probe which is being removed The following descriptions can be used to determine the correct probe assembly part number required for installation Single Point Thermistor Probe Assembly M5340 01 This probe should be installed when there is no CHT probe installed in the hottest cylinder Dual Point Thermistor K Probe Assembly ...

Page 29: ...d the aircraft where such service is available Because LASAR provides multi level mechanical backup ignition no changes in piloting procedures are necessary if the cockpit light becomes illuminated during flight When operating in the backup mode the orange wire of the Low Voltage Control Harness provides a return ground path for the enunciator light through the controller If the light is receiving...

Page 30: ...patibility with LASAR systems Other aircraft tachometers may interface with conventional magneto P leads to receive engine speed signals LASAR systems however do not provide the same P lead signals or wiring attachment points as conventional systems As an alternative the LASAR controller generates the engine speed signal shown in Figure 2 9 This signal may be transmitted to the tachometer by conne...

Page 31: ...seconds and then automatically shift to automatic mode operation The cockpit enunciator light if equipped will become extinguished E Proper functioning of the cockpit enunciator light should be confirmed each time a magneto check is performed WARNING DO NOT ATTEMPT FLIGHT IF A LASAR SYSTEM PERFORMANCE FAILURE OR ENGINE PERFORMANCE FAILURE ARE DETECTED 3 2 LASAR SYSTEM POST FLIGHT CHECK A After com...

Page 32: ...e Fuel consumption for a given power setting should not be higher than the amount specified in the original flight manual 3 4 IN FLIGHT RESTART A Automatic Mode Restart the engine using the normal engine start procedures detailed in the engine operating manual Engine may be windmilled above 500 RPM as an alternative B Backup Mode When operating in the backup mode LASAR magnetos have no provision f...

Page 33: ...ge ISSUED PAGE REV PAGE NO REVISED MO DAY YEAR 01 18 96 03 01 09 C 4 0 DOCUMENTATION A Make all appropriate logbook entries LASAR is approved either by the engine manufacturer or by STC and requires the appropriate logbook entry or FAA form 337 to be filed with the FAA B Attach appropriate Flight Manual Supplement to aircraft flight manual C Complete warranty registration card for LASAR system and...

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Page 35: ...nting 3 Manifold Pressure connections 4 Magneto to engine ground strap 5 Vent holes 5 1 3 500 Hour Inspections A Inspections 1 Low Voltage Control Harness LVCH wiring and connections 2 LASAR Controller mounting 3 Manifold Pressure connections 4 Magneto to engine ground strap 5 Vent holes 6 Ball bearing assembly 7 Distributor block and gear 8 Rotor gear and vane 9 Hall effect sensor 10 Coil 11 Cont...

Page 36: ...y The controller mounting bolts should be tight and the mounting surface should not be bent or cracked C Inspect the controller housing No cracks are permissible All cover mounting bracket and connector screws should be tight The RS232 port protection cap should be securely in place D Remove and replace any controller or pressure hose which does not meet these inspection criteria 5 2 2 Recertifica...

Page 37: ...age ISSUED PAGE REV PAGE NO REVISED MO DAY YEAR 01 18 96 03 01 09 C B Inspect all connectors and wires for corrosion contamination arcing or chafing C Inspect connector locking mechanism for breakage D Inspect low voltage control harness connections to P leads airframe power source etc Connections should be secure and insulated E Remove and replace any low voltage control harness which does not me...

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Page 39: ...stem Correct as required Magneto ignition switch must be wired so that both magnetos are on when the switch is in the both position Consult Reference Figure 2 5 or ignition switch manufacturer s manual as guide Inspect connections for leakage Inspect tubing for cracks or obstructions Correct as required Consult Sections 2 2 3 through 2 2 12 of this manual for correct timing procedures Correct as r...

Page 40: ...timing procedures Correct as required Consult Sections 2 2 3 through 2 2 12 of this manual for correct synchronization proce dures Correct as required Consult Slick L 1178 Ignition Lead Assembly Installation Manual for correct installation procedures Correct as required Consult appropriate LASAR Flight Manual Supplement or appropriate LASAR STC for minimum fuel grade requirements Correct as requir...

Page 41: ...low voltage control harness to power source and connections to controller Do not insert test probes into LCVH connectors Inspect connections for leakage Inspect tubing for cracks or obstructions Correct as required Magneto ignition switch must be wired so that both magnetos are on when the switch is in the both position Consult Reference Figure 2 5 or ignition switch manufacturer s manual as guide...

Page 42: ...not insert test probes into LCVH connectors Inspect battery for low voltage or electrolyte level Confirm correct operation of electrical system Correct as required Inspect connections for leakage Inspect tubing for cracks or obstructions Correct as required Consult Sections 2 2 3 through 2 2 12 of this manual for correct timing procedures Correct as required Consult Sections 2 2 3 through 2 2 12 o...

Page 43: ...s turned If LEFT TDC light does not turn on then the position sensor has failed and needs to be replaced If the power source low voltage control harness and connections ignition switch and magnetos have been inspected and found to be operating normally then the controller is operating in the default mode Inspect and replace as required Consult Slick manual L 1503 for inspection and troubleshooting...

Page 44: ...on and turn off as magneto rotor shaft is turned If LEFT TDC light does not turn on then the position sensor has failed and needs to be replaced The LEFT BKR PT should turn on as the magneto rotor shaft is turned If the LEFT TDC does not turn on then the backup relay has failed and the printed circuit board needs to be replaced Connect T 300 SynchroLASAR tool to magneto RIGHT BKR PT light should t...

Page 45: ...d Inspect carburetor according to carburetor manufacturer s specifications Consult Sections 2 2 3 through 2 2 12 of this manual for correct timing procedures Correct as required Consult Sections 2 2 3 through 2 2 12 of this manual for correct synchronization procedures Correct as required Consult Slick L 1178 Ignition Lead Assembly Installation Manual Section 6 0 for correct installation procedure...

Page 46: ... controllers used a flange mount RS 232 connector with four screws securing the connector to the controller housing These earlier configurations require the use of a T 233 adapter with the T 232 cable B IBM compatible computer with Windows 3 1 or Windows 95 operating software 5 2 2 Install RS 232 Cable A Remove the protective cap from the RS 232 port of the LASAR controller B Connect the T 232 cab...

Page 47: ... and should be verified within reasonable accuracy and normal expected results Engine Speed Represents the exact engine RPM updated every 2 milliseconds Average Engine Speed The average engine RPM over the preceding 2 second interval Minimum Maximum Speed Sample Two values which represent the minimum and maximum engine RPM during the time period starting with the most recent LASAR power up through...

Page 48: ... Aerospace LLC 1230 Old Norris Road Liberty South Carolina U S A 29657 http www championaerospace com Form L 1502C Slick and LASAR are registered trademarks of Champion Aerospace LLC 2009 Champion Aerospace LLC ...