Chapter 77 - Engine Indicating - Discovery Aviation 77 ENGINE INDICATING . ENGINE INDICATING ... ENGINE INDICATING ... display system for all engine and systems monitoring information

ENGINE INDICATING XL-2 AIRPLANE

P/N 135A-970-100 Chapter 77 REVISION C Page 1 of 34

CHAPTER 77

ENGINE INDICATING


Chapter 77 P/N 135A-970-100 Page 2 of 34 REVISION C

Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.


P/N 135A-970-100 Chapter 77 REVISION ~ Page 3 of 34

Table of Contents

SECTION 77-00 GENERAL 5 SECTION 77-40 SERVICING THE VM1000FX 7

SECTION 40-01 VM1000FX SYSTEM PROCEDURES 7 DPU REMOVAL 8 DPU INSTALLATION 10 DISPLAY PANEL REMOVAL 12 DISPLAY PANEL INSTALLATION 14 HEALTH STATUS ANNUNCIATOR REMOVAL 15 HEALTH STATUS ANNUNCIATOR INSTALLATION 17 PRIMARY BATTERY CURRENT SENSOR REMOVAL 19 PRIMARY BATTERY CURRENT SENSOR INSTALLATION 22 OIL PRESSURE SENSOR REMOVAL 25 OIL PRESSURE SENSOR INSTALLATION 27 OIL TEMPERATURE SENSOR REMOVAL 28 OIL TEMPERATURE SENSOR INSTALLATION 30 ENGINE HOURS RE-PROGRAMMING PROCEDURE FOR VM1000FX 32

SECTION 40-02 VM1000FX TROUBLESHOOTING 33


Chapter 77 P/N 135A-970-100 Page 4 of 34 REVISION ~

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P/N 135A-970-100 77-00 REVISION ~ Page 5 of 34

Section 77-00 General The airplane uses a Vision MicroSystems VM1000FX integrated engine instrument display system for all engine and systems monitoring information.

The system consists of a Display Processing Unit (DPU) mounted behind the CB (circuit breaker) panel, a display panel mounted in the instrument panel, and sensors for certain engine and systems related functions installed at several locations (see below). In addition, information about a number of engine functions is derived directly from the FADEC system. This information is transmitted electronically to the DPU, and displayed on the VM1000FX indicator.

The VM1000FX unit itself is powered from the Primary A power bus only through circuit breaker CB032 (VM1000). The data card model SBC100 mounted inside the VM1000FX DPU is powered from both Primary A and Secondary B buses through CB014 (B3/HSA) and CB027 (A3/HSA).

Backlighting of the display panel is provided via a connection from the airplane panel lights dimmer to the DPU (not to the panel itself). A small inverter in the DPU converts airplane lighting DC voltage to the AC voltage required by the panel backlight.

Table 77-1 shows what information the VM1000FX panel displays and its source: Information displayed Information source Sensor location Manifold pressure FADEC intake manifold (2) RPM FADEC SSA (speed sensor assembly) on

crankcase Oil Pressure oil pressure sensor firewall Oil Temperature oil temperature sensor oil cooler adaptor Fuel Pressure FADEC fuel distribution block (4) Exhaust gas temperatures FADEC (4) cylinder exhaust pipe

temperature probes (4) cylinder head temperatures FADEC (4) cylinder head temperature

sensors Electrical system voltage “voltage monitor” circuit breaker airplane power “A” distribution bus Alternator output amperage ammeter sensor behind instrument panel Engine percent power FADEC computed internally

Table 77-1 Information displayed on the VM1000FX Panel

In the event that errors occur in the transmission of data from the FADEC to the VM1000FX, the digital RPM display will be replaced by the display “CE xx,” where “xx” is the number of errors encountered (from 00 to 99). If the display advances rapidly to “CE 99,” assume the interconnection between the FADEC and the VM1000FX is defective.


77-00 P/N 135A-970-100 Page 6 of 34 REVISION ~

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P/N 135A-970-100 77-40 REVISION C Page 7 of 34

Section 77-40 Servicing the VM1000FX The components of the VM1000FX system (DPU, display panel, sensors, interconnecting cables) are not field-serviceable. Servicing any of these components is at the unit replacement level only.

Section 40-01 VM1000FX System Procedures This section contains the removal and installation procedures for the Display Processing Unit, display panel, Health Status Annunciator, and the various sensors. There is also a procedure for reprogramming the VM1000FX to reflect the correct number of engine hours.

For procedures to remove and install the Health Status Annunciator indicator panel, mounted to the instrument panel, refer to Chapter 31 – Indicating/Recording Systems.


77-40 P/N 135A-970-100 Page 8 of 34 REVISION C

DPU REMOVAL Perform this procedure to remove the DPU from the airplane.

This device contains electro-statically sensitive parts. Take ESD precautions before handling this or any other electronic device on the airplane.

1. Write down the current engine operating hours.

2. Pull circuit breaker BAT 1 (CB001) to OPEN.

3. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF.

4. Locate two post lamps installed near the upper panel edge and remove hoods. Set them aside for later installation.

5. Locate and remove seven (7) 8-32 machine screws securing the circuit breaker panel to the instrument console. Retain these screws for later installation.

The following step will remove the CB panel. There are a number of electrical wire harness connections to the instrument console and ground plane. Take care when removing the CB panel from the instrument console Guide wire harnesses during the removal process in order to prevent damage.

6. Prepare a protective cushion surface just below and in front of the circuit breaker panel console position.

Figure 77-1 Circuit Breaker Panel



7. Gently pull the circuit breaker panel out of the instrument console and pivot face down in front of the console on the protective cushion surface.

8. Connect an anti-static strap from you body to the metallic surface of the power distribution harness.

9. Disconnect engine data processing unit ribbon cable connector PVM03A from DPU connector PVM03.

10. Disconnect engine data processing unit cable connector PVM01 from DPU connector PVM01.

11. Disconnect engine data processing unit cable connector PVM04 from DPU connector PVM04.

12. Remove four (4) 6-32 screws holding the DPU mounting bracket to the circuit breaker panel assembly. See Figure 77-2 for the location of the DPU mounting screws.

13. Remove the DPU and mounting bracket as an assembly.

14. Verify software version.

15. Write down the DPU serial number.

16. If the installation of the DPU will take place later, install the CB panel in to the instrument console. Secure the instrument panel with the seven screws removed in step 5 above.

This completes the DPU Removal procedure.

Figure 77-2 DPU Bracket Mounting Screws



DPU INSTALLATION Perform this procedure to install the DPU into the airplane.


1. Ensure all electrical switches are off.

2. If installing a replacement DPU immediately after removing the previous DPU indicator, then proceed to step 8 below.











9. Install new DPU using the four screws removed in step 12 in the DPU Removal procedure.

10. Connect engine data processing unit’s ribbon cable connector PVM03A from DPU connector PVM03.

11. Connect engine data processing unit’s cable connector PVM01 from DPU connector PVM01.

12. Connect engine data processing unit’s cable connector PVM04 from DPU connector PVM04.

13. Verify software version.

14. Install the CB panel in to the instrument console.

15. Secure the panel with the screws removed earlier.

16. Use the Engine Hours Re-Programming Procedure for VM1000FX on page 32, to set the value of the engine hours recorded in the DPU Removal procedure on page 8 of this chapter

This completes the DPU Installation procedure.



DISPLAY PANEL REMOVAL Perform this procedure to remove the VM1000FX display panel.




3. Place a cover over the pilot yoke control.

4. Have a large block of soft foam on your lap to place the instrument panel on.

5. Remove the top two screws and one of the bottom screws from the VM1000FX display panel.

6. Remove the ten screws securing the instrument panel to the instrument console. See Figure 77-4 for location of the screws.

7. Gentle pull the instrument panel towards you, placing it face down on to the block of soft foam rubber.

8. Do not to disturb electrical connections, pitot or static lines.

Figure 77-4 Location of the Screws Securing the Instrument Panel




10. Disconnect ribbon connector, remove display panel.

11. Remove the remaining screw securing display panel to instrument panel.

12. Gently push the display into the instrument panel and let the display drop down through the bottom of the instrument console.

13. If the installation of the VM1000FX display panel will take place later, install the instrument panel in to the instrument console. Secure the instrument panel with the ten screws removed in step 6 above.

This completes the Display Panel Removal procedure.



DISPLAY PANEL INSTALLATION Perform this procedure to install the VM1000FX display panel.


To clean face of display panel, only use a soft cloth dampened with clear water, then wipe dry. Do not use any solvents or other cleaning products to clean face of display panel.


2. If installing a replacement display panel immediately after removing an existing display panel, then proceed to step 7 below.






8. Connect ribbon cable to replacement display panel and secure.

9. Place display panel in instrument panel cutout and secure with the screws removed in the Display Panel Removal procedure.

10. Install instrument panel into the instrument console taking care not to disturb electrical connections, pitot or static lines.

11. Secure the instrument panel with the ten instrument panel screws.

12. Apply power to airplane electrical system and perform functional check of integrated engine instrument system.

This completes the Display Panel Installation procedure.



HEALTH STATUS ANNUNCIATOR REMOVAL Perform this procedure to remove the health status annunciator, HSA, from the airplane.








7. Do not to disturb electrical connections, pitot, or static lines.


Figure 77-5 Location of the Screws Securing the Instrument Panel



9. Disconnect P/J7, P/J9, and P/J20 from the HSA module. See Figure 77-6 for location of these connectors.

10. The cable for P/J03 goes from the instrument panel to the instrument console. Disconnect P/J03.

Failure to disconnect P/J03 can cause damage to the secondary battery system as the terminal connector on wire P24A10 is treaded through the current sensor on the HSA.

11. Remove the wire P24A10 from the terminal on switch SW005.

12. Carefully thread the wire back through the current sensor.

13. Remove the four screws securing the HSA to the instrument panel.

14. Secure the wire P24A10 to the same terminal on switch SW005.

15. If the installation of the HSA will take place later, install the instrument panel in to the instrument console. Secure the instrument panel with the ten screws removed in step 5 above.

This completes the Display Panel Removal procedure.

Figure 77-6 HSA Control Unit Showing the Mounting Screws, Connectors and Switch SW005



HEALTH STATUS ANNUNCIATOR INSTALLATION Perform this procedure to install the health status annunciator, HSA.



2. If installing a replacement the HSA immediately after removing an existing HSA, then proceed to step 7 below.






8. Disconnect P/J03.

9. Disconnect wire P24A10 from switch SW005.

10. Loop the wire through the current sensor as shown in Figure 77-7. From P03 route the wire P24A10 upward through the current senor ring, making two loops through the sensor, wire enters at the bottom. The ring terminal end will exit at the top of the sensor.

Figure 77-7 Showing the Looping of the Wire Through the Current Sensor



11. Secure the HSA to the bracket using the four screws from step 13 of the Health Status Annunciator Removal procedure.

12. Connect P/J7, P/J9, and P/J20 from the HSA module. See Figure 77-6 for location of these connectors.

13. Connect P/J03.

14. Install instrument panel into the instrument console taking care not to disturb electrical connections, pitot, or static lines.

15. Secure the instrument panel with the ten instrument panel screws.

16. Apply power to airplane electrical system and perform functional check of integrated engine instrument system.

This completes the Health Status Annunciator Installation procedure.



PRIMARY BATTERY CURRENT SENSOR REMOVAL Perform this procedure to remove the primary battery current sensor.













8. Disconnect wire P03B6 from terminal 2 of TB01 on the power distribution harness. See Figure 77-9 for location of the terminals on TB01.

Use caution when disconnecting wire P03A6 from terminal 2 of TB01. There can be primary battery voltage on the terminal.

9. Disconnect wire P10A6 from terminal 3 of TB01 on the power distribution harness.

10. Cut the terminal end from wire P10A6.

11. Thread wire P10A6 back through the current sensor. See Figure 77-10 for location of the primary power current sensor.

Figure 77-9 Right Side the Power Distribution Assembly Showing Location for the Connection for Wire P10A6



12. Disconnect the four wires from the primary power current sensor board.

13. Remove the two screws that secure the current sensor board to the mounting bracket.

14. Remove the board.

15. If the installation of the current sensor will take place later, secure wire P10A6 such that it will not come in contact with other circuits, save current sensors board screws, and install the instrument panel in to the instrument console. Secure the instrument panel with the ten screws removed in step 4 above.

This completes the Primary Battery Current Sensor Removal procedure.

Figure 77-10 Location of the Primary Power Current Sensor



PRIMARY BATTERY CURRENT SENSOR INSTALLATION Perform this procedure to install the primary battery current sensor into the airplane.



2. If installing a replacement current sensor board immediately after removing the previous current sensor board indicator, then proceed to step 8 below.











9. Mount the replacement current sensor board to the mounting bracket use the screws removed in step 13 in the Primary Battery Current Sensor Removal procedure on page 21.

10. Connect cable V13A20 for the current sensor board. See Table 77-2 for the correct wire connections.

Wire Color from Cable V13A20

Primary Battery Current Sensor Board Connector

White (no tracer) WHT

White/Blue BLK White/Orange RED White/Green GRN

Table 77-2 Cable Connections for the Primary Battery Current Sensor Board

11. Carefully thread wire P10A6 through the current sensor.

Thread the wire through the current sensor board BEFORE mounting a terminal to the end of the wire.

12. Mount an appropriate sized wire terminal to the end of the wire. To complete the installation of the wire terminal apply heat shrink tubing to the end of the wire.

13. Connect wire P10A6 to terminal 3 of the TB01 on the power distribution harness.

Figure 77-12 Location of TB01 Terminal 3



14. Connect wire P03A6 to terminal 2 of TB01 of the power distribution harness.

Use caution when connecting wire P03A6 from terminal 2 of TB01. There can be primary battery voltage on the terminal.

15. Install the CB panel into the instrument console.

16. Secure the CB panel to the instrument console using the screws removed in step 5 of this procedure.

This completes the Primary Battery Current Sensor Installation procedure.



OIL PRESSURE SENSOR REMOVAL Perform this procedure to remove either of the oil pressure sensors. The oil pressure sensors mount to the firewall, below the level of the Electronic Control Units, ECU. There are two sensors at this location. See Figure 77-13. The sensor on top is for the Hobbs meter, the sensor on the side is for the Health Status Annunciator. As these sensors are co-located, the procedure is the same for both. Any differences are noted in the text of the procedure.



3. Remove the upper and lower engine cowling.

4. If the airplane is equipped with an air/oil separator mounted to the firewall between the Electronic Control Units (ECU), disconnect the air/oil separator and bracket from the Electronic Control Units.

5. Refer to the exploded view shown in Figure 77-14. Have someone hold a wrench on the nut from inside the cockpit.

6. Turn the bolt securing the mounting bracket to the firewall. Remove the bolt being careful to retain the flat washers and the sleeve spacer

7. Remove the bracket securing the oil pressure sensor T-fitting to the firewall.

Figure 77-13 Location of the Oil Pressure Switch (Hobbs) and the Oil Pressure Sensor (HSA) (The Air/Oil Separator Not Shown)



8. Bring the oil pressure sensor assembly up enough to allow access to the electrical connections on the sensors.

9. If removing Hobbs oil pressure switch, go to step 13.

10. Remove the screw in the center of the connector.

11. Disconnect the cable going to pressure sensor.

12. Go to Step 14.

13. Using a Phillips screwdriver, remove the two wires that connect to the top of the Hobbs oil pressure switch.

14. Wrap the T-fitting with a rag to catch any oil.

15. Use a 7/16-inch wrench to remove the oil pressure sensor.

16. If installation of a replacement sensor will happen later, cap the open end of the T-fitting, and secure.

17. If an air/oil separator was removed, temporarily install the air/oil separator and secure.

This completes the Oil Pressure Sensor Removal procedure.

Figure 77-14 Exploded View of the Oil Pressure Mount



OIL PRESSURE SENSOR INSTALLATION Perform this procedure to install the oil temperature sensor.

1. If installing a replacement oil pressure sensor immediately after removing the previous oil pressure sensor, then proceed to step 9 below.




5. If the airplane is equipped with an air/oil separator mounted to the firewall between the Electronic Control Units (ECU), disconnect the air/oil separator and bracket from the Electronic Control Units.

6. Refer to the exploded view shown in Figure 77-14. Have someone hold a wrench on the nut from inside the cockpit.

7. Turn the bolt securing the mounting bracket to the firewall. Remove the bolt being careful to retain the flat washers and the sleeve spacer

8. Remove the bracket securing the oil pressure sensor T-fitting to the firewall.

9. Install the oil pressure sensor to the T-fitting.

10. If installing Hobbs oil pressure switch, go to step 14.

11. Connect the cable going to pressure sensor.

12. Secure the connector with the screw in the center of the connector.

13. Go to Step 15.

14. Using a Phillips screwdriver, secure the two wires to the top of the Hobbs oil pressure switch.

15. Check the connector or connections on the other oil pressure sensor to make sure the connections are secure.

16. Using Figure 77-14 as a guide, assemble the mounting bracket and hardware.

17. Push the bolt through the firewall blanket to the inside of the cockpit.

18. Have some one hold the bolt from the engine compartment. Assemble the hardware from the cockpit side as shown in Figure 77-14.

19. Tighten the nut to secure the hardware.

20. Remove any rags that were absorbing oil.

21. Clean oil spilled during this procedure.

This completes the Oil Pressure Sensor Installation procedure.



OIL TEMPERATURE SENSOR REMOVAL Perform this procedure to remove the oil temperature sensor. The oil temperature sensor is located on the port side of the engine up next to the firewall. See Figure 77-15 for the location of the oil temperature sensor. The location makes it very difficult to remove and/or install. Before attempting to remove/install the sensor, check all of the wiring and connections. Make sure the fault is not in the wiring or connectors.




4. Remove the top bracket 3/8-inch bolt and ¼-inch nut that secures the wire clamp to the L-bracket. Carefully remove the cable clamp from the wire bundle.

5. Loosen the side bracket bolt and nut that secures the wire clamp to the engine support tube.

Spraying the cable clamp with a small amount of alcohol will allow the cable clamp to slide easier on the support tubing.

6. Slide the wire clamp down the tube and out of the way.

Figure 77-15 Location of the Oil Temperature Sensor



7. Cut and remove the safety wire from the sensor.

8. Carefully remove any cable ties securing the bundle of wires above the sensor.

9. Disconnect the P/J61.

10. Position the wire bundle away from the top of the oil temperature sensor.

11. Pack the area of the around the sensor to catch any oil that may come out of the fitting.

12. Use a 7/8-inch open-ended wrench to remove the oil temperature sensor.

With the two Adel wire clamps out of the way, there is just enough room to get the wrench on to the sensor and turn it just enough to break the threads free. Then bring the wrench straight down from the top and complete the removal of the sensor. See Figure 77-16 to see the correct positioning to complete the removal of the oil temperature sensor.

13. With the oil temperature sensor removed, remove the remainder of the safety wire from the sensor-mounting bracket. Install new safety wire in to the bracket to prepare for the installation of a replacement sensor.

Liberty Aerospace, Inc. recommends to start the installation of the safety wire at this point, while the sensor is out of the engine.

14. If replacing the oil temperature sensor later, plug the open hole where the sensor goes, secure all wires and connectors, secure mounting hardware.

This completes the Oil Temperature Sensor Removal procedure.

Figure 77-16 Positioning the Wrench to Remove the Oil Temperature Sensor



OIL TEMPERATURE SENSOR INSTALLATION Perform this procedure to install the oil temperature sensor.


2. If installing replacement oil temperature sensor immediately after removing the previous oil temperature sensor, then proceeds to step 6 below.


4. If installed, remove the upper and lower engine cowling.

5. Reposition the cable mounting hardware associated with the cable above the oil temperature sensor.

6. Reposition the bundle of cables above the sensor.

7. Wrap the area with a rag to absorb and oil.

8. Remove any plug from the hole for the sensor.

9. If a new safety wire was not installed previously, insert a fresh safety wire and prepare it for the sensor.

10. Assemble the oil temperature sensor’s copper crush gasket on to the sensor.

11. Insert oil temperature sensor assembly into the hole for the oil temperature sensor. Use a 7/8-inch wrench as shown in Figure 77-16 to turn-in the oil temperature sensor.

12. Torque the sensor to 220 in-lbs.

13. Complete the installation of the safety wire.

14. Connect P61 to J61.

15. Secure the cable bundle using wire ties.

16. Move the cable clamp back into position and tighten the side bracket bolt.

Figure 77-17 Oil Temperature Sensor Showing the Copper Compression Gasket



17. Assemble the wire bundle cable clamp to the L-bracket. Secure the clamp to the L-bracket using the bolt and nut removed in step 4 in the Oil Temperature Sensor Removal procedure on page 28 of this chapter.

18. Remove any rags that were absorbing oil.

19. Clean oil spilled during this procedure.

This completes the Oil Temperature Sensor Installation procedure.



ENGINE HOURS RE-PROGRAMMING PROCEDURE FOR VM1000FX To re-load engine hours, follow the steps below:

1. “Accessing Set Mode”: with power off, while pressing and holding buttons 1, 3, and 5, turn on power. Wait until displays start reading out values (approximately 15 seconds) and release buttons.

2. “Selecting Decade to Change: press button 4 once to move to next higher decade on digital engine hours display area. No visual indication is displayed until STEP 3. Pressing button moves the selection left increases decade. Upon reaching highest decade, pressing button again returns to lowest decade.

3. “Changing the Decade Value”: press button 5 to increase decade value. Increasing display above 9 increases to next decade. To erase engine hours value, select highest decade press button 5 continually until display clears. Do this TWICE, then repeat steps 1 thru 3.

4. When the display indicates the correct number of engine hours, turn VM1000FX power OFF.

5. Turn power ON and confirm current Tachometer Time has been set. Turn power OFF.

6. Check DPU functionality by normal engine starting and shutdown procedures.

7. When no defects noted, confirm compliance in logbook entry.

This completes the Engine Hours Re-Programming Procedure for VM1000FX procedure.



Section 40-02 VM1000FX Troubleshooting Table 77-3 Integrated Engine Instrument Troubleshooting

Complaint Possible cause Remedy

Replace Defective power circuit breakers (2) Defective power wiring Replace

Defective DPU Replace DPU

Defective display panel Replace display panel

VM1000FX completely inoperative (panel remains blank)

Defective ribbon cable from DPU to display Replace ribbon cable

Defective wiring from panel lights dimmer to DPU Repair

Defective inverter in DPU Replace display VM1000FX backlighting inoperative

Defective EL backlight panel in display Replace DPU

Defective oil pressure sender Replace sender Erratic or absent oil pressure indication Defective oil pressure sender

wiring Repair

Defective oil temperature sender Replace sender

Erratic or absent oil temperature indication

Defective oil temperature sender wiring Repair

Defective amp sensor Replace sensor Erratic or absent amperage indication Defective amp sensor wiring Repair

Defective VOLT MON circuit breaker Replace circuit breaker

Erratic or absent voltage indication

Defective wiring Repair wiring



Complaint Possible cause Remedy Display of momentary, erratic values, then automatically returning to normal operation, OR Blank display followed by automatic restart to normal operation mode or automatic restart to self-test diagnostic cycle first, and then the display automatically returns to normal operation, OR Display demo-mode, then returning to normal operation after CB cycle.

Defective software

Retrofit by removing DPU 4010083 with Software 3036003, Revision 1.010, or earlier, and replacing with Software 3036003, Revision 1.011, or later.

Any of following indications absent or erratic: RPM, Manifold Pressure, EGT, CHT, Fuel Flow (confirmed by indication of FADEC Health Status Annunciator or erratic engine operation)

FADEC or FADEC sensor fault

See Chapter 72 in this manual and/ or Chapter 12 in TCM Engine Maintenance Manual (TCM P/N M-22)

Interconnection fault Replace interconnection cable between FADEC and connector VM-04 on DPU.

Any of following indications absent or erratic: RPM, Manifold Pressure, EGT, CHT, Fuel Flow (FADEC Health Status Annunciator normal)

DPU fault Replace DPU

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Chapter 77 - Engine Indicating - Discovery Aviation 77 ENGINE INDICATING . ENGINE INDICATING ... ENGINE INDICATING ... display system for all engine and systems monitoring information