Related Manuals for E-MAG LYCOMING 200-6XL Series
Summary of Contents for E-MAG LYCOMING 200-6XL Series
- Page 1 Series 200-6XL –+ Installation and Product Documentation Operating Guide Instruction Set for Lycoming™ Styled 6 Cylinder EXPERIMENTAL Engines V 200-6XL .041 LYCOMING™ Style...
- Page 2 Nothing stated by E-MAG in this manual, its employees, owners, agents, representatives, or affiliates should be construed as overriding or invalidating the engine manufacturer’s instructions. E-MAG has NOT performed testing on the wide variety of engines in popular use and cannot offer specific advice as to proper/suitable ignition configuration.
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Page 3: Table Of Contents
SHORT-CUT ............................4 INSTALLATION AND OPERATION ....................5 COCKPIT CONTROLS........................5 CONTROL PLUG WIRING ........................6 SETUP AND CONTROL SWITCHES ....................7 LED AND TONE SIGNALS ......................... 8 ENGINE ATTACHMENT ........................8 PLUG WIRES – CYLINDER ASSIGNMENTS ................... 9 AUTO PLUGS AND ADAPTERS ....................... 9 MANIFOLD PRESSURE (MAP) ....................... - Page 4 This manual will include supplemental notes, comments, and tips that will appear as blue text. Different versions of this manual are available for Lycoming™ style and Continental™ style engines. Both versions can be downloaded from the E-MAG web site. ™ Lycoming is a registered trademark of Avco Corporation.
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Page 5: Short-Cut
V 200-6X.40 12/1/21 Engine performance mods (compression, induction, fuels, etc) might lower your target MIN and MAX settings. V 200-6X.41 4/25/23 Suggestion for long primary battery cable runs (RV10s, canards, others). Clarify: Pull-Thru test verifies bank firing order only. Cannot be used to check tracking accuracy. -
Page 6: Installation And Operation
a) MIN (BLUE LED) matches engine manufacturers recommended magneto firing angle. b) MAX (WHITE LED) marks the maximum cruise firing angle. Default MAX is 9-degrees before MIN. 4) Basic Setup is complete. Finish installing plugs and plug wires, MAP plumbing, blast tube cooling, and do the Pull-Thru test. -
Page 7: Control Plug Wiring
E-MAG – remove before installation. Note 2: E-MAG p-lead wire does not make radio noise and does not require shielding. If replacing a magneto, your existing shielded p-lead wire can be re-used. If doing so, the outer shield needs to be trimmed clean and kept well clear of all other terminations. -
Page 8: Setup And Control Switches
Note 7: Tach signal is a 3 pulse/rev, low true, 33% duty cycle, 10 to12-volt pulse - see Appendix 3. E-MAG’s tach output is a courtesy feature, unrelated to the ignition’s primary purpose. Due to the variety of instrument options available, our ability to support and troubleshoot interface issues is limited. -
Page 9: Led And Tone Signals
(a limitation of this style LED). Engine Attachment First, verify the studs and clamps on hand are compatible with the E-MAG flange. E-MAG flange is 0.19” thick - not compatible with 0.31” clamps common with certain magnetos. Remove magneto spacers (highlighted area in photo) and long studs. -
Page 10: Plug Wires - Cylinder Assignments
Aircraft engines are typically tapped for 18mm spark plug threads. To use 14mm automotive style plugs, E-MAG can provide auto plug adapters. There are numerous auto spark plug styles and temperature ranges available through various outlets. E-MAG has NOT studied the relative durability or performance of different plug brands and styles. -
Page 11: Manifold Pressure (Map)
Long Reach (LR) vs. Short Reach (SR) Cylinders Cylinders are made with two different spark plug thread depths. Match spark plugs and plug adapters (LR or SR) to the cylinder depth when ordering. 1) LR or SR cylinders can be identified by the aircraft spark plug call-out for your engine. -
Page 12: Setpoints
2) The cockpit Mode Switch (required for boosted engines) provides a simple manual override that puts both ignitions in Fixed Mode, where MAP input is not a factor – see Mode Switch elsewhere in this manual. Note: All Lycoming™ cylinders have a primer port that can be used to access manifold pressure. Use a standard 1/8”... - Page 13 finger tight. Rotate the ignition to any convenient orientation and then alternately tighten mounting clamp nuts to 17 ft/lb. 2) DIR Color-Burst: Verify bus power and Kill Switches are both OFF. Connect the ignition circular Control Plug and then turn bus power ON. LED will provide a Color-Burst sequence (in the first ½...
- Page 14 b) MIN Setpoint to see GREEN - BLUE – GREEN – see Note 1. c) MAX Setpoint to see GREEN - WHITE – GREEN– see Note 1. Prior to operation you need to connect plugs and plug wires, manifold pressure (MAP) plumbing, and blast tube cooling –...
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Page 15: Pull -Thru Test
Blast target Electrical System Condition E-MAG’s power dip protection helps guard against severe voltage drops that occur when the starter motor is engaged. However, in the event of a compromised electrical system (low battery, long cable runs, undersized cable, corroded terminals, cold engine, etc.) bus voltage may not rebound as the starter speeds up (as is normal). -
Page 16: Tuning Max
i) When the engine is rotated the wrong direction. ii) If ignition DIR does not match engine rotation. iii) When Mode Switch is in FIX position and engine is moving at hand pull-thru speeds. iv) Plugs fire only once per cycle. You cannot back up and fire them again. Keep pulling thru in the normal direction. -
Page 17: Operating Notes
above) settings will fire at the same MIN/magneto position. The ignition will still provide higher spark energy and that alone will have some effect on behavior. If temperature issues are encountered under these conditions you might test with a slight reduction of MIN firing position, or look into corrections outside the ignition –... - Page 18 2) Wasted spark ignitions (E-MAG and others) fire spark plugs in pairs. On any given cycle only one cylinder, within a Bank pair, is in the compressed “firing” position. At that same moment, the companion cylinder is between the intake and exhaust strokes with both valves open. A wasted spark ignition will fire plugs in both cylinders within the Bank.
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Page 19: Maintenance
(elevate) cut-out speeds. Keep this in mind if ever investigating the cause of elevated cut-out speeds. E-MAG bench tests every ignition to verify they self-power, open air spark, down to 700 rpm prior to shipment. This is well below most in-flight idle speeds. - Page 20 7) Reinstall the ignition - see Setup instructions. 8) Verify proper operation including: a) Perform Ignition Checks on each ignition – see Ignition Check section for guidelines: i) Basic internal alternator Ramp Check. ii) Internal alternator Cut-Out test – record results in logbook for L, R, Both. Mode Switch Check, if installed.
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Page 21: Wiring Diagram
Wiring Diagram • Power and Ground 20 AWG, all others 22 AWG • Colors refer to optional pre-assembled cable. Circuit Alternator Breaker Test Switch (red) bus power 14V-28V (note 1) (blue) tach (3 ppr) Can Be Combined tach (black) cockpit ground (yellow) p-lead/kill switch Kill Switch (P-Lead) MODE SWITCH *... - Page 22 Note 1: Long power cable runs to a remote main battery* may need to route ignition bus power through a dedicated 16 AWG cable to the battery. This avoids sharing a long power cable with the starter motor, a combination that can exaggerate power dips and inhibit ignition operation while cranking.
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Page 23: Appendix 1 - Spark Plugs & Adapters
Appendix 1 – Spark Plugs & Adapters Short Reach Plugs (uses SR plug adapter) 1) NGK Spark Plug BR8ES 2.5mm center electrode. Stock #3961 has a solid terminal tip (preferred). Stock #5422 has a screw on tip – if used make sure the tip is well secured. 2) NGK Spark Plug BR8EIX iridium electrode with solid tip. -
Page 24: Appendix 2 - Engine Tc Locator
Appendix 2 – Engine TC Locator TC Locator mode is visited, if only briefly, when storing ignition TC during Setup step 3. The first step in that procedure is to move engine to TC. Lycoming™ styled engines have marks on the flywheel to easily locate engine TC. -
Page 25: Appendix 3 - Tach Electrical Specifications
Appendix 3 – Tach Electrical Specifications 1) Bus power – circular connector pin A (red) 12, 24, or 48 volt systems a) Minimum - 10 volts b) Maximum - 58 volts c) Current draw from bus: i) less than 0.5 amp (normal operating conditions) ii) less than 1.0 amp (maximum draw with no-op internal alternator) 2) Tach –... -
Page 26: Appendix 4 - Installation Checklist
2) Ignition gasket. 3) Mounting Studs – Two 31C-13 studs (specify when ordering) will replace the longer studs used with magneto mounting spacers that will be removed prior to E-MAG installation. Auto Plug Adapter set includes 1) 6 auto plug adapters - specify “LR” long-reach, “SR” short-reach, adapters when ordering. - Page 27 4) 1 crimp tool. Other Optional Parts **specify when ordering** 1) Pre-wired circular control plug with 96” of color-coded wire pigtail in nylon braid sheath. Wires are epoxy potted in a slightly shorter connector head (in lieu of Standard Control Plug above). We suggest the standard connector kit if you already have imbedded wiring that you plan to re- use.
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Page 28: Appendix 5: Harness Fabrication (Leads)
Appendix 5: Harness Fabrication (leads) Trim-To-Fit Harness Lead kits use our custom low-noise, distributed inductance, plug wire that is not shielded. We have no (zero) reports of noise problems from customers using this wire when properly installed and in good condition. If you do hear spark noise, something is not installed or functioning properly. Plug “clicking”... - Page 29 Terminals and Boots Coil ends - The brass terminals and 90-degree flat-backed boots are for the coil end connections. Run the wire completely through the boot so you have a couple of inches extended past the boot. This will give you room to work the wire and terminal. A light coating of SILICONE SPRAY (not included) is required to lubricate the wire as you work it through the boot.
- Page 30 In either case, if you don’t feel and/or hear the terminal snap, remove and inspect for irregularities or damage. If needed, replacement terminals can be provided by E-MAG. If not properly secured the leads can come lose, which risks interrupting ignition operation, and can damage the ignition coil.