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Hi Dave,
One of the first things I would do it use the two
simulation modes of the EC2 to verify (or not) that all connectivity to the
injectors and ignition is there. It sounds like you spark is probably
OK. But, without the engine running, turn on EC2 power (CPU and
injectors) (but NOT the fuel pumps) put the
EC2 in mode 1 (with fuel pumps OFF) and push the store
button. The injectors should click like crazy simulating firing at 3000
rpm and you should easily hear them without the engine running. They will
continue clicking until you remove power or move the mode selector wheel
to a different mode.
If you do not hear the clicking then you can start
trouble shooting the electrical (you can use mode 8 the same way for the
ignition - push the store button and get continuos spark plug
firing).
Controller B should work fine for starting purposes.
The temp sensor won't make that much difference in the temps we have
now.
Also IF you set the CS
at TDC then that is incorrect and would have
the ignition timing way off.
To set the static time, the E shaft pulley should be
rotated until it reads 35Degree Before Top Dead Center (TDC) (details under
Initial Timing Adjustment in the EC2 instructions (page 4 in my
copy))
Then the CS distributor body should be unclamped (loosen
the bolt) , pulled out slightly and rotated so that one pole (the one with
the red dot if it is present, but it doesn't really matter) of the
two pole stator is pointed right at the metal core of the reluctor coil inside
the CS case.
You may have to fiddle a couple of times to get the
CS to slip into the right gear tooth. But get the stator aligned to the
metal core of the reluctor coil as close as you can.
Then clamp the CS distributor body down with its
bolt. The EC2 timing is initially set at 26 deg TBD assuming you have set
it up the static timing so it is at 35 Deg BTDC. If you have then when you
start 26 deg BTDC is the ignition timing you will have.
If I understood you correctly about setting the CS, you
actually have about 10 deg After Top Dead Center set which would be way too
retarded. This may not be your problem as you should still get some pops,
but it could be a contributor.
Good luck, want to hear that thing is running
Ed
----- Original Message -----
Sent: Wednesday, May 30, 2007 12:23 AM
Subject: [FlyRotary] First Start... Well... Not
Quite..
> Thats right... Not
quite.
>
> Tonight Chris and I conducted a little "surge" of our
own and gave it a
> go. Er.. No Go.
>
> Here's the lowdown..
and We will entertain all pointers, no matter how
> obvious.
>
> For those new to the group, Chris and I have a Mazda 13B 2nd gen turbo
> rotary engine, mated to a Velocity SE (the small one). Our install in
> normally aspirated at this time. We have Tracy Crook's Real World
> Solutions Engine Controller (EC-2) and his PSRU/re-drive (RD-1B).
> Tracy's engine monitor (EM2) is not installed yet.We have dual
>
batteries, and when finished, will have dual alternators and essentially
> two independent busses run by 2 different electrical systems in this
all
> electric airplane. Mistral intake with integral throttle body in
place.
>
> Over the past week or so, we have sealed the oil lines,
and have oil
> flow from the engine's oil pump, through the cooler in the
front and
> then to a 2nd cooler under the aft cowl, thence to the block.
PSRU oil
> comes off the rear iron out the stock oil pressure port. Stock
oil
> pressure relief valves are in place (80# in the back, 135# or so in
the
> front)
>
> Electrical: Have been cranking in short
spurts for about 2 weeks. During
> that time, we have powered the EC2. We
have put the injectors and their
> resistors in line (we have low
impedance injectors x 4). Injectors have
> been clicked open with power
across the terminals. Crank angle sensor
> was installed by me a LONG
time ago, but i remember being meticulous
> about installing it at TDC on
one of the front rotor faces at that time.
> Prior to our efforts today,
chris took a junk spark plug, hooked it to
> one of the rear coils (the
most accessible), grounded the plug and
> cranked. We had spark.
>
> Manifold plumbing: We have two AN4 hoses from the intake to the
> firewall. We have pinhole restrictions in both ends of the manifold
> pressure tubing to dampen pressure fluctuations at the EC2's manifold
> pressure sensors. We verified airflow through both restrictions prior
to
> start attempt.
>
> Fuel: Today Chris sealed up the last
of the fuel system (sealant on the
> fittings, reconnecting the vents).
We went and got 2 gals of premium
> mogas and at about this point we
decided to try and shoot for first
> start (around 4 pm). Mixed 2 oz oil
into the two gals, mixed well,
> poured into the right strake and it
trickled down to the sump. We turned
> on the lower fuel pump and were
rewarded with the sound of the fuel pump
> priming then a pressure
indication on the fuel pressure regulator's
> attached steam gauge. We
also found a leak.
>
> When I did my initial fuel system design, I
put a coarse filter (in-line
> barrel style) before the pumps, and a
large, cannister style fine filter
> downstream of the pumps but upstream
of the injectors. Rationale: coarse
> filter to keep debris out the pumps
that would clog or damage them. The
> fine filter is to keep small stuff
from clogging the injectors. When I
> last messed with the coarse filter
I apparently crossthreaded the
> AN6-1/4 pipe fitting that goes on the
inlet. Chris discovered this when
> he sealed the fuel system. We hoped
it would work for the moment. It
> didnt. Quickly removed the fine filter
from the fuel system, put a check
> valve in there SIMPLY as a union (AN6
on both ends). The fact its a
> check valve is no factor here.. its a
placeholder device. Pumped up the
> system again and got a good 20 psi
from one pump. Adjusted the regulator
> until we got a full 45 psi on one
pump. Both pumps on puts it closer to
> 55. We mopped up the small amount
of spilled gas, made sure things were
> ventilated well and carried
on.
>
> Given that we do not have the proper inlet air temp probe
installed
> (apparently it came with the EC2), I instructed Chris to
crank on
> controller B Mode 0 (the backup engine controller on Tracy's
EC2.
> Controller B does not use the temp probe input but uses a set
standard
> temp. Lights.. Camera... NOTHING. We cranked.. we had fuel
flow through
> the regulator, we had needle bounce on the pressure gauge
because the
> fuel pressure is manifold referenced.
>
> Over
the course of troubleshooting we discovered that Controller B did
> not
have spark. Controller A did. I had disconnected the wire to the
>
installed temp probe we had temporarily in there since I had heard
>
through the list that it may not work properly and I didn't want to skew
> the A controller (thats why i tried to crank on B in the first place -
> the temp probe issue).
>
> So.. what we know:
>
> We had no indication of combustion occurring. No pops. No sputters. No
> catches.
>
> Crank angle sensor must be working, because
the thing is sparking as we
> crank. (on controller A). We do not have
test mode for injectors and
> plugs. We have not gotten that
upgrade.
>
> We have fuel to the fuel pressure regulator and
PRESUMABLY downstream.
> We have not broken the couplings to confirm this
yet.
>
> We have spark on one of the coils. We will verify on all
four. New
> plugs, 7's and 9's, installed for this event. Spark verified
with an old
> plug that came with the engine.
>
> I did not
hear the injectors clicking during the cranking. I do not know
> if i
COULD have heard em clicking. I tried touching one injector during
>
cranking and did not feel anything discernable. I asked if we have a
>
sweep multimeter so that we can check this tomorrow, on all four
injectors.
>
> We tried with cold start on at first, then off,
mixture at "1 o'clock"
> (slightly rich), default program. I did not
smell fuel in the exhaust
> pipe. We have a straight pipe in place
temporarily. I had to stand next
> to the exhaust pipe to get close to
the injectors.. while cranking with
> hot plugs. In a hangar. Yea.. That
would have been loud. I think this
> (fuel) is our most likely source of
our problem here.
>
> Fuel pressure oscillated during cranking.
Does this need to be dampened?
> (this is the only instrumentation at
this point).
>
> Does program B come with default on it? (I have
not read the manual
> regarding this just yet)
>
> So..
there you have it. We were VERY close to turning dinosaurs into
>
decibels. More tomorrow. Feedback from folks familiar with the Rotary
>
and EC2 combination is highly desired.
>
> Dave
>
>
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