AE300 Wizard Manual

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AE300-Wizard
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Copyright © 2017, Austro Engine GmbH
AE300-Wizard
User Guide
These technical data and the information contained therein are the property of Austro
Engine GmbH and may not be reproduced either in full or in part or passed on to a third
party without written consent from Austro Engine GmbH.
This text must be included in any full or partial reproduction of this documentation.
Copyright © Austro Engine GmbH
Date:
Wiener Neustadt, 2023-Jul-31
Author:
Austro Engine GmbH
Rudolf-Diesel-Straße 11
2700 Wiener Neustadt
AUSTRIA / EUROPE
Revision:
14
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Table of Contents
1
Preface ................................................................................................. 10
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Congratulation ............................................................................................ 10
Subject ....................................................................................................... 10
Objective .................................................................................................... 10
Scope ......................................................................................................... 10
Intended Audience ...................................................................................... 10
Purchased Parts Package ............................................................................. 11
Austro Engine Legal Notices ......................................................................... 11
1.7.1
Copyright Notice .................................................................................. 11
1.7.2
License Restrictions Warranty/Consequential Damages Disclaimer ............ 11
1.7.3
Warranty Disclaimer ............................................................................. 11
1.7.4
Hazardous Applications Notice ............................................................... 11
1.7.5
Trademark Notice ................................................................................ 12
1.7.6
Third-Party Content, Products, and Services Disclaimer ............................ 12
2
Limitations ........................................................................................... 13
3
Requirements ...................................................................................... 14
3.1
3.2
3.3
4
Software ..................................................................................................... 14
3.1.1
Operating System ................................................................................ 14
3.1.2
.NET Environment ................................................................................ 14
3.1.3
Visual C++ Runtime Library .................................................................. 14
3.1.4
Driver for USB/CAN Adapter .................................................................. 14
3.1.5
AE300-Wizard ...................................................................................... 14
Hardware.................................................................................................... 15
3.2.1
Computer System................................................................................. 15
3.2.2
USB/CAN Adapter................................................................................. 15
3.2.3
USB DataMatrix Scanner ....................................................................... 15
3.2.4
CAN Extension Cable ............................................................................ 15
Aircraft ....................................................................................................... 16
3.3.1
Ground Power Supply ........................................................................... 16
New Installation .................................................................................. 17
4.1
4.2
4.3
4.4
4.5
Pre-Conditions............................................................................................. 17
Download and Installation via .ZIP-File .......................................................... 17
Automatic Installation .................................................................................. 18
Manual Installation ...................................................................................... 18
4.4.1
.NET Environment ................................................................................ 18
4.4.2
Driver for PCAN-Adapter (USB/CAN) ...................................................... 19
4.4.3
AE300-Wizard and Visual C++ Runtime Library ....................................... 19
Installation for Evaluating Log Files ............................................................... 19
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Download Upgrade Package ......................................................................... 20
Remove Previous AE300-Wizard Version ........................................................ 20
Install Upgrade Package............................................................................... 20
Overview and First Steps .................................................................... 21
6.1
6.2
6.3
CAN Connection .......................................................................................... 21
Starting the AE300-Wizard ........................................................................... 21
Setting up the Aircraft .................................................................................. 21
6.3.1
Engine Running ................................................................................... 21
6.3.2
Engine not Running .............................................................................. 21
6.3.2.1
6.3.2.2
6.3.2.3
6.3.2.4
6.3.2.5
6.4
6.5
6.6
6.7
7
User Guide
Upgrade Installation ........................................................................... 20
5.1
5.2
5.3
6
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Ground Power Supply .....................................................................21
Electric Fuel Pumps ........................................................................21
Alternator ......................................................................................22
Avionics .........................................................................................22
Engine Master / Electric Master Switch ............................................22
Start of Diagnostic Session ........................................................................... 23
Saving of Data during a Diagnostic Session.................................................... 25
Saving Screenshots from Data Displays ......................................................... 25
End of Diagnostic Session ............................................................................ 25
Modes of Operation ............................................................................. 26
7.1
Offline Mode ............................................................................................... 26
7.1.1
Primary Display – Left Page................................................................... 26
7.1.1.1
7.1.1.2
7.1.1.3
7.2
Maintenance Mode ...................................................................................... 28
7.2.1
Primary Display – Left Page................................................................... 28
7.2.1.1
7.2.1.2
7.2.1.3
7.2.2
Maintenance Tab ...........................................................................28
Engine Logs Tab ............................................................................29
Live View Tab ................................................................................30
Primary Display – Right Page................................................................. 31
7.2.2.1
7.2.2.2
7.2.2.3
7.3
Maintenance Tab ...........................................................................26
Engine Logs Tab ............................................................................26
Live View Tab ................................................................................27
Engine Data-Tab ............................................................................31
Statistics Tab .................................................................................32
Fault Details Tab ............................................................................33
Qualified Maintenance Mode ......................................................................... 34
7.3.1
Primary Display – Left Page................................................................... 34
7.3.1.1
7.3.1.2
Update SW Tab..............................................................................34
IQA Tab ........................................................................................35
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Diagnostic Procedures ......................................................................... 36
8.1
Analyzing Operational Data .......................................................................... 36
8.1.1
Engine and ECU Operating Hours Counters ............................................. 36
8.1.2
Operational Statistics ............................................................................ 37
8.1.2.1
8.1.2.2
8.2
8.2.7
8.2.8
Displaying Fault Code Memory Entries .............................................51
Displaying Engine Operational Statistics ...........................................52
Offline Analysis Using the Event Recorder ............................................... 53
8.2.8.1
8.2.8.2
8.2.9
Overview of the FCM Functionality ..................................................46
Displaying Fault Details ..................................................................48
Clearing the Fault Code Memory .....................................................50
Offline Analysis Using the Engine Log ..................................................... 51
8.2.7.1
8.2.7.2
The Event Recorder Window ...........................................................54
Using Filters in the Event Recorder ..................................................55
Offline Analysis Using the Data Logger ................................................... 56
8.2.9.1
8.2.9.2
8.3
Table Format .................................................................................37
Bar-Graph Format ..........................................................................38
Routine Maintenance ................................................................................... 40
8.2.1
Engine Log File .................................................................................... 41
8.2.2
Event Recorder File .............................................................................. 42
8.2.3
Data Logger File (Full Flight Time) ......................................................... 43
8.2.4
Partial Data Logger File (Fraction of Flight Time) ..................................... 45
8.2.5
Trouble Shooting ................................................................................. 46
8.2.6
Using the Fault Code Memory (FCM) ...................................................... 46
8.2.6.1
8.2.6.2
8.2.6.3
Saving Data Logger Displays as Screenshots ....................................57
Interpreting the Data Logger Display ...............................................57
Live View .................................................................................................... 60
8.3.1
Live View – Online Analysis and Recording ............................................. 60
8.3.1.1
8.3.1.2
8.3.1.3
8.3.2
8.3.3
8.3.4
8.3.5
Live View – Standard Mode .............................................................60
Live View – Expert Mode ................................................................63
Live View – Aux Signal ...................................................................63
Live View – Online Analysis using Pre-Defined Measurements ................... 63
Live View – Online Analysis Using User-Defined Measurements ................. 65
Live View – Offline Analysis ................................................................... 66
8.3.4.1
8.3.4.2
8.3.4.3
Live View – Defining and Saving a “LiveView-Config” .......................66
Live View – Importing Live View Recordings ....................................67
Live View – Analyzing Live View Recordings .....................................68
Live View – Working with Austro Engine Support..................................... 69
8.3.5.1
8.3.5.2
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“LiveView-Config” Files ...................................................................69
Live View Data saved during Measurements ....................................69
IQA Codes ............................................................................................ 70
9.1.1
9.1.2
9.1.3
9.1.4
9.1.5
9.1.6
Overview............................................................................................. 70
Reading IQA Codes .............................................................................. 71
Saving IQA Codes ................................................................................ 72
Entering IQA Codes .............................................................................. 73
Scanning Injector IQA Codes ................................................................. 74
EECU Replacement ............................................................................... 75
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EECU Software Update ........................................................................ 78
10.1 FCT Naming Convention up to Baseline 25..................................................... 78
10.2 FCT Naming Convention starting with Baseline 26 .......................................... 78
10.3 Minimum Requirements ............................................................................... 79
10.4 Overview of the Software Update Process...................................................... 79
10.5 Detailed Steps of the Software Update Process .............................................. 81
10.6 Documentation of Software Update Process ................................................... 85
10.7 Software Update Retry ................................................................................. 86
10.8 Error Handling during Software Updates ........................................................ 87
10.8.1 Pre-Flash Conditions ............................................................................. 87
10.8.2 Automatic Retries ................................................................................. 87
10.8.3 Aborts ................................................................................................. 88
10.8.4 Unsuccessful Completion ...................................................................... 89
10.8.5 Successful Completion .......................................................................... 90
11
Calling for Support .............................................................................. 91
11.1 Saving Failure Information ........................................................................... 91
11.1.1 First Step – Engine Log ......................................................................... 91
11.1.2 Second Step – Event Recorder File......................................................... 91
11.1.3 Third Step – Data Logger File ................................................................ 91
11.1.4 Fourth Step (optional) – Live View recordings or Screenshots ................... 91
11.1.5 Fifth Step (optional) – IQA Data File ...................................................... 91
11.2 Sending Maintenance Information ................................................................. 91
12
Appendices .......................................................................................... 92
12.1 Error Messages of the AE300-Wizard ............................................................. 92
12.2 Details – Freeze Frame ................................................................................ 92
12.2.1 Combined Engine Status ....................................................................... 92
12.3 Details – Event Recorder .............................................................................. 92
12.3.1 Event Status ........................................................................................ 92
12.4 Details – LiveView ....................................................................................... 93
12.4.1 Self-Test Timeout Flags (SlfTst_stTOutErr) ............................................. 93
12.4.2 Self-Test Release Condition Flags (SlfTst_stRls) ...................................... 93
Index of Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Abbreviations and Definitions............................................................................ 9
Supported Operating Systems......................................................................... 14
Hardware Requirements ................................................................................. 15
Error Types of FCM Entries ............................................................................. 46
Combined Engine Status ................................................................................ 92
Event Status.................................................................................................. 92
Self-Test Timeout Flags.................................................................................. 93
Self-Test Release Condition Flags .................................................................... 93
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Revision History
Change Description
Author of
Change
Date
Rev.
Initial document, first draft.
Mannsberger
2009-03-19
0
Update to include Wizard V1051 functionality
Mannsberger
2009-04-20
1
Update to include review comments
Mannsberger
2009-04-23
2
Update to include USB/CAN adapter order
number
Mannsberger
2009-05-07
3
Update to include Wizard V1055 new
functionality (6.2.4), update ground usage and
alternator setup (4.2.3.2), update new AR form
(Appendix 9.4)
Mannsberger
2009-09-24
4
Update to include Wizard V1100 new
functionality (Live View, Engine-Log offline
analysis, GUI)
Mannsberger
2009-12-18
5
Error corrections
Mannsberger
2010-01-15
6
Update to include Wizard V1200 new
functionality (ECU SW update,
compressed/encrypted log files)
Mannsberger
2010-11-09
7
Update to include layout of Self-Test Flags
(Available in Live View) in Appendix
Update to Wizard V1.3.0.xxx
Kucera Walter
2016-05-10
8
Fixed minor bugs in User Guide
Update to AE300-Wizard V1.3.2.xxx
Kucera Walter
2016-11-09
9
Update flash procedure to ECU SW VC33.6.
Kucera Walter
2017-04-10
10
Update new LiveView features (AE300-Wizard
V1.3.4.xxx). Fixed minor bugs.
Kucera Walter
2017-07-25
11
Update new Event Recorder features (AE300Wizard V1.3.5.xxx). Fixed minor bugs.
Kucera Walter
2017-11-10
12
Required for Baseline 23 (still compatible with
older versions). Update of LiveView. Minor bugs
fixed.
Dietmüller
2019-09-03
13
Required for Baseline 26. Introduction of
extended flash container.
Mannsberger
2023-07-31
14
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Abbreviations
Abbreviation
Designation
act.
AE
.ae3
active
Austro Engine
Extension of AE300-Wizard files (compressed and encrypted)
AE300
AR
Austro Engine 300, marketing name of engine E4
Authorization Request
Atmos.
Atmospheric
bin
binary
BATT
BPA
CAN
Battery
Boost Pressure Actuator
Controller Area Network; CAN bus is a message-based protocol, designed
specifically for automotive applications.
CR
Common Rail
Cyl.
Cylinder
DatRec
Data Logger
d.c.
duty cycle
DTC
E4
Diagnostic Trouble Code
Internal project name (Engine 4)
ECU
Engine Control Unit (in this manual used synonymously to EECU)
EECU
Electronic Engine Control Unit
EECS
Electronic Engine Control System
EEPROM
Electric Erasable Programmable Read Only Memory
E/E
Electric / Electronic System Engineering department (of AE)
Eng.
Engine
EvRec
Event Record
EvtRec
Event Recorder (also Event-Rec)
ExtFCT
Extended Flash Container (a file containing the ECU-SW, new version)
FCM
Fault Code Memory
FCT
Flash Container (a file containing the ECU-SW)
GND
Ground
GUI
Graphical User Interface
hex
HW
hexadecimal (in the meaning of sedecimal)
Hardware
ICM
Interconnection module
ID
Identification
IE
MS Internet Explorer
IQA
Injector Quantity Adjustment (German: IMA, Injektor Mengen Abgleich)
ISO
The International Standardization Organization known as ISO, is an
international standard-setting body composed of representatives from various
national standards organizations.
Kl
Kl15
Contact, Terminal
Switched battery plus through ignition switch (“engine master” switch)
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Designation
Kl30
Battery plus (“electric master” switch)
Kl31
Kl50
KWP2000
KWPonCAN
MAX
MIN
MS
.NET
Engine ground
Starter control
Keyword Protocol 2000 (Diagnostic Protocol)
KWP2000 on the CAN Bus
Value above maximum allowed value (overflow)
Value below minimum allowed value (underrun)
Microsoft (as in MS Windows, MS Internet Explorer)
.NET Framework is a software framework developed by Microsoft that runs
primarily on Microsoft Windows.
NPL
Value is not plausible
OEM
Original Equipment Manufacturer
pas.
PCAN
Passive
PEAK-System CAN hardware or driver
PCV
Pressure Control Valve
PDF
Portable Document Format. PDF is a file format, which enables presentation
and exchange of documents independent of the original software, hardware or
operating system. Originally developed by Adobe, PDF is now an open
standard of ISO.
Press.
Pressure
RAM
Random Access Memory
RecMng
Record Manager
ROM
Read Only Memory
rpm
revolutions per minute (engine or propeller speed)
RTC
Real Time Clock
SIG
Signal disconnected or broken
SSHD
Solid State Hard Disk
SW
Software
Temp.
Temperature
Trq.
Torque
UBatt
Battery voltage
USB
Universal Serial Bus; USB is an industry standard that defines the cables,
connectors and communications protocols used in a bus for connection,
communication, and power supply between computers and electronic devices.
UTC
Universal Time Coordinated (Greenwich Mean Time)
VC++
Visual C++ (from Microsoft)
Vcc
Voltage of the common collector (positive power supply)
XML
eXtensible Markup Language
Table 1
Abbreviations and Definitions
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Preface
1.1
Congratulation
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Thank you for buying the AE300-Wizard software including the AE300-ECU-Dongle/Converter
(in the rest of the document called AE300-Dongle). Install the AE300-Wizard software
including the AE300-Dongle driver. Connect the CAN plug (9-pins) of the AE300-Dongle to
the AE300 EECU and the USB plug to an USB port of your PC (usually a notebook) and you
will be able to measure and log several configurable engine parameters.
1.2
Subject
The AE300-Wizard is a diagnostic tool required to perform both maintenance in the field and
serial production tasks on the Austro Engine (AE) AE300 series engine (E4, E4P) and its
electronic engine control system (EECS).
1.3
Objective
The tool will ease maintenance and will allow AE to provide full “After Sales” support.
Production activities like necessary coding of variants and serial numbers, configuring
software, writing RTC, etc. will be provided for AE use only.
1.4
Scope
This user guide describes installation and operation of the AE300-Wizard.
Although it provides hints and recommendations on how to employ the Wizard for
maintenance and production tasks it does not replace nor supersede the approved
maintenance and build manuals.
Revision 14 of this guide describes the AE300-Wizard starting with version 1.3.19.450.
1.5
Intended Audience
This document is intended as a learning aid to be used by maintenance technicians and
engineers attending AE300 training classes required as a prerequisite for qualified
maintenance organizations. It provides also additional background information and user
guidance for field maintenance and troubleshooting procedures assisted be functions of the
AE300-Wizard.
Engineers performing serial production tasks will find additional descriptions in the approved
build manual.
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Purchased Parts Package
The package contains the following parts.
The CD containing the AE300-Wizard program installer, Visual C++ 2010, .NET
environment version 4.0 and the CAN driver for the AE300-Dongle.
The AE300-Dongle connects the EECU (9-pin CAN connector) to your PC (USB
connector).
The User Manual you are reading as a PDF file.
1.7
Austro Engine Legal Notices
1.7.1 Copyright Notice
Copyright © 2017, Austro Engine Corporation and/or its affiliates. All rights reserved.
1.7.2 License Restrictions Warranty/Consequential Damages Disclaimer
This software and related documentation are provided under a license agreement containing
restrictions on use and disclosure and are protected by intellectual property laws. Except as
expressly permitted in your license agreement or allowed by law, you may not use, copy,
reproduce, translate, broadcast, modify, license, transmit, distribute, exhibit, perform,
publish, or display any part, in any form, or by any means. Reverse engineering,
disassembly, or decompilation of this software, unless required by law for interoperability, is
prohibited.
1.7.3 Warranty Disclaimer
The information contained herein is subject to change without notice and is not warranted to
be error free. If you find any errors, please report them to us in writing.
1.7.4 Hazardous Applications Notice
This software and hardware is developed for usage in aircraft with an AE300 engine in
ground mode. It is not developed or intended for use in any other (e.g., inherently
dangerous) applications, including applications that may create a risk of personal injury. If
you use this software or hardware in dangerous applications, then you shall be responsible
to take all appropriate fail safe, backup, redundancy, and other measures to ensure its safe
use. Austro Engine Corporation and its affiliates disclaim any liability for any damages caused
by use of this software or hardware in dangerous applications.
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Trademark Notice
Austro Engine and AE300-Wizard are trademarks or registered trademarks of Austro Engine
Corporation and/or its affiliates.
All Microsoft trademarks are used under license and are trademarks or registered trademarks
of Microsoft. PCAN is a trademark or registered trademark of the PCAN Corporation.
Other names may be trademarks of their respective owners.
1.7.6 Third-Party Content, Products, and Services Disclaimer
This software or hardware and documentation may provide access to or information about
content, products, and services from third parties. Austro Engine Corporation and its
affiliates are not responsible for and expressly disclaim all warranties of any kind with
respect to third-party content, products, and services unless otherwise set forth in an
applicable agreement between you and Austro Engine. Austro Engine Corporation and its
affiliates will not be responsible for any loss, costs, or damages incurred due to your access
to or use of third-party content, products, or services, except as set forth in an applicable
agreement between you and Austro Engine.
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Limitations
WARNING
Using the AE300-Wizard for measurements during flight is not permitted!
The AE300-Wizard and its AE300-Dongle have the following limitations:
•
Use only in conjunction with the Austro Engine AE300 series engine.
•
Use only with an Austro Engine EECU (part number E4B-92-000-000).
•
Use no other device parallel to the AE300-Wizard to maintain the EECU firmware.
•
The AE300-Wizard is only available in English (The AE300-Wizard may be installed
on a system with a different system language, but the GUI will remain in English.
Although all system messages, i.e. file requesters, will be shown in the system
language.)
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Requirements
3.1
Software
3.1.1
User Guide
Type:
Copyright © 2017, Austro Engine GmbH
Operating System
Tool
bit
SP
Version
MS Windows 7
32/64
1
6.1.7601
Microsoft
MS Windows 10
64
-
10.0.10240
Microsoft
MS Windows 11
64
-
22H2 (22621)
Microsoft
Table 2
Manufacturer
Remark
Only with service pack 1
Supported Operating Systems
Note: Installation requires (local) administrator privileges. Ongoing Wizard operation does
not require administrator privileges.
3.1.2 .NET Environment
The minimum requirement for MS .Net Framework is version 4.0 with Service Pack 2 German
or English language version (dotNetFx40_Client_x86_x64.exe). This version is supplied on
the AE300-Wizard distribution CD or compressed .ZIP-file.
3.1.3 Visual C++ Runtime Library
MS VC++ 2010 redistributable runtime library. This library is supplied on the AE300-Wizard
distribution CD or compressed .ZIP-file as part of the AE300-Wizard software.
3.1.4 Driver for USB/CAN Adapter
PEAK System HW driver for the high-speed CAN-to-USB adapter. This driver is supplied on
the AE300-Wizard distribution CD or compressed .ZIP-file.
3.1.5
AE300-Wizard
It is recommended to use the latest version of the AE300-Wizard software. Use at least
version 1.3.19.450 to support extended Flash Containers of SW Version VC33.7 (Baseline 25
and 26).
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Hardware
3.2
3.2.1
Computer System
The requirements to the PC Hardware are:
Characteristic
Minimum
PC System
Recommended
Standard x86 desktop PC or laptop system
No. of CPU Cores
1
2 or more
Clock Frequency [GHz]
2
at least 2.8
RAM [GByte]
4
8 or more
HD Space (free)
[MByte]
Additional HD Space
[MByte]
100
for a full Wizard installation (including .NET Framework, VC++
redistributable library and HW drivers)
~100
(will be a good starting point) for log files and aircraft data
Table 3
Hardware Requirements
Note: 4 GByte RAM are required as a minimum space if no other program is concurrently
running! Otherwise, more RAM is necessary.
Note: It is recommended to use a Solid-State Disk (SSD).
3.2.2 USB/CAN Adapter
A special USB/CAN adapter (provided with the AE300-Wizard) is required to physically
connect the CAN bus of the EECU to a USB port (at least USB 2.0) of the PC system. It
provides a CAN bus male connector on one end and an USB-B connector on the other.
Additionally, this adapter also acts as a license dongle to enable the AE300-Wizard in one of
two operating modes defined by the license:
- AE-order number “IPEH-002021-M CAN-USB Adapter M” to unlock “Maintenance mode”
- AE-order number “IPEH-002021-QM CAN-USB Adapter QM” to unlock “Qualified
maintenance mode”
3.2.3 USB DataMatrix Scanner
A specially programmed DataMatrix scanner is optionally available from Austro Engine to
support scanning of IQA codes from injectors (see chapter “9.1.5 Scanning Injector IQA
Codes” on page 74). This is not a required item, but a recommended one to prevent
misreading of IQA codes:
- Part#”TBD” hand held IQA scanner
3.2.4 CAN Extension Cable
It is recommended to use an RS-232 extension cable (female to male connectors) of about
2m (7ft) length for a convenient connection from the USB/CAN adapter of the PC/laptop to
the diagnostic plug in the aircraft cockpit.
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3.3.1
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Aircraft
Ground Power Supply
For diagnostic sessions to be performed while the engine is NOT running it is important to
avoid draining the aircraft battery.
Therefore, it is recommended to connect external ground power to the aircraft when
performing diagnosis for more than 15 minutes.
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New Installation
4.1
Pre-Conditions
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Austro Engine provides a distribution either on CD or as a compressed .ZIP-file of the AE300Wizard for initial installation of the tool, the required runtime libraries, and device drivers.
This “installation pack” also includes the folder “Documentation” which contains the AE300Wizard User Guide (this document) and a Power Point presentation as well as predefined
practical exercises for self-study purposes.
Before starting installation disconnect any USB/CAN adapter!
Note: Keep in mind, that installation requires (local) administrator privileges!
Download and Installation via .ZIP-File
4.2
The complete “installation pack” (as .ZIP-File) can be downloaded from the AE homepage
with the following procedure:
•
•
•
Visit the AE homepage with this link:
https://partners.diamondaircraft.com/s/files
Navigate to the "Engine Software" menu then select "AE300-Wizard."
Download the file named "AE300 Wizard Zip."
Upon completion of the download, extract the .zip-file.
•
•
•
•
Locate the downloaded "AE300 Wizard Zip" file on your computer.
Right-click on the file.
From the context menu, select "Extract All."
A dialog box will appear to guide you through the extraction process. Choose the
destination where you want to extract the files, and then click "Extract."
After the extraction process, you should have the following file structure:
Now you can proceed with the installation following chapter “4.3 Automatic Installation” or
“4.4 Manual Installation”.
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Automatic Installation
For automatic installation simply double-click on “setup.bat” to execute the sequence of
required steps.
Note: Ensure that you have administrative privileges on your Windows system to
successfully complete the installation
Note: If you do not have .NET environment installed already, the version 4.0 will be
installed, and the PC usually reboots after installation.
Note: If you have an older version then 4.0 installed, version 4.0 will be installed without
rebooting the PC.
4.4
Manual Installation
If manual installation is required, follow the steps outlined below:
.NET Environment
Attention: Close all applications before installing the .NET environment. Otherwise, data
4.4.1
loss can result!
The installation of .NET Framework depends on the language environment and the
architecture. Install the version of the .NET Framework mentioned in chapter “3.1.2 .NET
Environment” on page 14. You can find the supported version on the distribution CD or
compressed .ZIP-file:
Data\DotNetFX40\Error! Reference source not found.
Double clicking on the files initiates the installation which will guide the user through the
process.
Note: After installation of the .NET environment the PC usually reboots!
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4.4.2 Driver for PCAN-Adapter (USB/CAN)
Before connecting the USB/CAN adapter to the PC/laptop system for the very first time the
following HW driver must be installed:
Data\PeakOemDrv.exe
Double clicking on the file initiates the installation which will guide the user through the
process:
- Accept license agreement
- Select/accept installation folder
- Select “PCAN-USB Driver”
-
Click on Next to continue with the installation
After the HW driver installation is complete:
- Connect your USB/CAN adapter to a free USB port on your PC
- The new HW will be recognized by Windows XP and a message box will show up asking
you for instructions on how to continue.
- Select automatic installation of PCAN USB driver
4.4.3 AE300-Wizard and Visual C++ Runtime Library
The AE300-Wizard is provided as an MS-Installer package:
Data\AE_Wizard.msi
Double clicking on the file name initiates the installation which will guide the user through
the process:
- Select a target folder (e.g.,
"C:\Program Files (x86)\Austro Engine\AE 300 - Wizard")
After the installation has finished it is also recommended to
- install a shortcut on your desktop pointing to your personal folder (e.g., "My
Documents\Austro Engine\AE300-Wizard" in standard installations). This allows easy
access to stored log files and folders created during diagnostic sessions.
4.5
Installation for Evaluating Log Files
If you want to analyze log files only, the driver for the PCAN adapter will not be necessary.
You only have to perform the following steps:
•
Install .NET environment (see chapter “4.4.1 .NET Environment” on page 18), and
•
Install the AE300-Wizard and the Visual C++ runtime library (see chapter “4.4.3
AE300-Wizard and Visual C++ Runtime Library” on page 19).
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Upgrade Installation
Users with a working installation of an older AE300-Wizard release who wish to perform an
upgrade rather than a new installation can do so, using an MS-Installer (upgrade) package
which is downloadable from the Austro Engine homepage:
Data\AE_Wizard.msi
5.1
Download Upgrade Package
Log in to the customer section of the Austro Engine homepage using your assigned
username and your password to download the latest AE300-Wizard upgrade package:
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
5.2
If you have not done so already, please contact Austro Engine “After Sales” at
(service@austroengine.at) to obtain your login for the customer area.
Use your favorite browser to go to http://www.austroengine.at.
Type in your username and password to access the customer area.
Select “customer area” → “Manuals” → “AE300-Wizard”.
Download “AE300-Wizard → Wizard Software version 1.3.19.450” (use always
the latest software version).
Download “AE300-Wizard → Wizard User Guide” and save it on your PC-system
(e.g., on the “Desktop”) for later use.
Remove Previous AE300-Wizard Version
To avoid possible incompatibilities between previously installed libraries and new versions
included in the new AE300-Wizard upgrade package it is highly recommended to manually
remove the current AE300-Wizard package first – before attempting installation of the
upgrade package. Any aircraft data or log files already stored on your PC-system will remain
in “My Documents”, they will not be removed by the following procedure:
Step 1:
Step 2:
Step 3:
5.3
“Start” → “Control Panel” → “Add or Remove Programs”.
Look for the entry “AE300-Wizard” and select the “Remove” option.
Close “Add or Remove Programs”, close “Control Panel”.
Install Upgrade Package
Double clicking on the upgrade package downloaded as described in “5.1 Download Upgrade
Package” initiates the upgrade installation which will guide the user through the process:
- Select a target folder (e.g.,
"C:\Program Files (x86)\Austro Engine\AE 300 - Wizard") where the program
should be installed.
After the installation has finished, it is also recommended to install a shortcut on your
desktop pointing to your personal folder (in standard installations is this "My
Documents\Austro Engine\AE300-Wizard"). This allows easy access to stored log files and
folders created during diagnostic sessions.
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Overview and First Steps
After successful completion of the installation the following chapter will guide you through
the basic steps required to operate the AE300-Wizard.
CAN Connection
6.1
-
Connect the USB/CAN adapter to a USB port of the PC.
Connect the CAN adapter to the aircraft CAN (Diagnostic) plug using a CAN extension
cord if required.
Starting the AE300-Wizard
6.2
-
Double click the AE300-Wizard icon on your desktop.
The Wizard will start up and depending on the USB-dongle detected one of three
operating modes will be available. For details see chapter “7 Modes of Operation” on
page 26.
Setting up the Aircraft
6.3
For safety reasons certain functions of the AE300-Wizard are available only in a safe context
(e.g., aircraft on the ground, engine not running etc.). Below is a summary of those
considerations.
6.3.1
Engine Running
If the AE300-Wizard is connected to a running engine only diagnostic functions which do not
interfere with engine control are allowed by the ECU firmware:
- «Engine Data» tab on the right page displays real time engine data and status
continuously for BOTH ECUs (Note: The Garmin G1000 displays engine data and status
for the ACTIVE ECU only).
- Real time clock and operating hours counters displayed in «Engine Data» tab are not
updated but frozen at the time of Connect ECU button has been pressed.
-
Fault Code Memory can be read and cleared on running engine.
-
Note:
Event records and data logs CANNOT be downloaded from a running engine.
6.3.2 Engine not Running
If the engine is not running the primary concerns are in respect to battery exhaustion and to
prevent damage of engine components.
6.3.2.1 Ground Power Supply
Diagnostics session lasting longer than 15-20 minutes (e.g., downloading data logger data)
may drain the aircraft battery.
In twin engine aircraft one engine may be running and supplying power while the other
(stopped) engine can be diagnosed. If both engines are stopped or in single engine aircraft
the use of a ground power supply is highly recommended.
6.3.2.2 Electric Fuel Pumps
Pull circuit breakers of both fuel pumps to prevent overheating, fuel over pressure and
possible damage.
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6.3.2.3 Alternator
For aircraft equipped with alternator regulators part number E4A-91-100-000 (“old
regulators”):
If the engine is not running (both engines not running in case of DA42), the alternator
regulator is sensing a battery voltage below 29V and therefore excites the alternator to
produce an output voltage. This excitation current will result in overheating and possible
damage of the alternator and unnecessary battery drain (5A excitation current if rpm = 0).
To prevent the above from happening the following two methods are recommended:
- Use a precisely STABILIZED ground power supply set to 29V (29V…30V) (set and
checked before connecting to the aircraft). First connect the power supply to the ground
power receptacle and THEN turn on electric master and engine master – with this the
alternator regulator senses the higher battery voltage and doesn’t excite the alternator.
- If no stabilized ground power supply is available, the harness connector to the alternator
must be disconnected (see maintenance manual for location of the connector).
For aircraft equipped with alternator regulators part number E4A-91-200-000
(“new regulators”):
This new regulator can detect the stopped alternator and DOES NOT EXCITE the
alternator thus preventing the overheating problem for the excitation coil. The procedures
described above are therefore not required for those aircraft.
6.3.2.4 Avionics
Pull circuit breakers of avionics and systems not required for diagnosis to save battery power
especially if no ground power is available (downloading data logger data may take up to 30
minutes or longer).
6.3.2.5 Engine Master / Electric Master Switch
Turn on the engine master only for the engine to be diagnosed.
During shut down, turn off the engine master first, then wait (about 10 seconds) until the
engine instruments displayed on the cockpit display show a “red cross” before turning off the
electric master. This allows the ECU to perform “clean-up tasks” like writing data from RAM
to non-volatile memory (e.g., data logger data).
Note: Not doing so will cause erroneous entries into the Fault Code Memory during the next
start up. For instance, a “data logger failure” with the error type: “No valid lead out
sequence from last session was found”.
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Start of Diagnostic Session
After the AE300-Wizard has started it will initialize and try to detect the (license) type of
USB/CAN adapter used. If no USB/CAN adapter could be found the following dialog-box will
be displayed:
In this case no interactive diagnostic session with an ECU will be possible
After accepting this dialog box, the AE300-Wizard will be activated in its “offline”
mode
If for instance a “Maintenance” type USB/CAN adapter was found the following
«Maintenance» display will appear:
-
-
Press Connect ECU to logically connect to the EECU to be diagnosed:
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Example:
- The two green lights indicate that connection to both ECUs has been established
- Below the green lights information about serial numbers and revisions is displayed.
- On the right-hand half of the screen the real time engine data and status information is
displayed. Data sent by the “active” ECU is indicated by a white background color.
- On the bottom of the right-hand half of the screen the engine and ECU operating hour
counters and real time clock setting can be found.
Note: This information is not being updated during the diagnostic session, but sampled
and frozen at the time connection to the corresponding ECU has been established.
- Both caution lamps are on (pictured by the two red lights) indicating that there are
entries in the Fault Code Memory.
-
Pressing Read Fault Code Memory will provide more details, e.g.:
-
Pressing Clear Fault Code Memory will provide an auto-save functionality. The DTC
(Diagnostic Trouble Code) memory, the engine statistic and the IQA values will be saved
in the file:
“AE300-Wizard\Engine_Log\AutoSave_Engine_Log_YYYYMMDD_nnnnn.ae3”.
For further assistance see chapter “8 Diagnostic Procedures” on page 36.
Hint: Since version 1.3.4.xxx it is not possible to start the Wizard (accidently) twice.
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Saving of Data during a Diagnostic Session
The various diagnostic functions provide the capability to save data like “Engine Logs”,
“Event Logs”, “Data Logs” or IQA data on the PC system for later offline analysis.
- Offline analysis doesn’t require a USB/CAN-adapter dongle
- Default location for saved data is: “My Documents\Austro Engine\AE300-Wizard”
-
Data is organized by folders like: “Engine_Log”, “Flash”, “HexDump”, “LiveView”, etc.
-
Data is saved in a compressed and encrypted format (“.ae3” file extension) for offline
analysis using the AE300-Wizard or other tools
6.6
Saving Screenshots from Data Displays
If just the current display of data (primarily for fault details, event recorder or data logger) is
to be saved, the mechanisms built into MS Windows can be used:
- Select the window to be saved (i.e., event recorder and data logger display their data in
separate windows) using the mouse,
- Press “Alt” plus “PrintScreen” key simultaneously (on German keyboards
“Alt”+“Druck”) to transfer the screenshot into the clipboard memory,
-
Start the graphics program (e.g., MS Paint) or word processor (e.g., MS Word) of your
choice and press “Ctrl” plus “V” key simultaneously to insert the screenshot from the
clip board into the graphics or word document (on German keyboards “Strg” + “V”),
-
Save the resulting document containing your screenshot,
In case of graphics file formats, TIF format (with LZW compression) should be preferred
over JPG to avoid compression artifacts which will reduce readability of small letters.
6.7
End of Diagnostic Session
After finishing diagnosis, downloading and saving maintenance data the logical connection to
the EECU should be terminated by pressing the Disconnect ECU button.
-
After that the AE300-Wizard may be closed.
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Modes of Operation
Depending on the license type provided by the USB/CAN-Dongle, the AE300-Wizard offers
one of three possible operating modes and their set of functions.
Offline Mode
7.1
This mode of operation, does not require a USB/CAN adapter dongle as described in chapter
“6.4 Start of Diagnostic Session on page 23”. It is very useful to analyze and interpret
downloaded data or to define measurement configurations at the office instead of in the
cockpit.
7.1.1
Primary Display – Left Page
7.1.1.1 Maintenance Tab
7.1.1.2 Engine Logs Tab
Buttons to:
-
Load (import) and display an engine log file ( Load Engine Log )
-
Load (import) an event recorder hex dump file ( Load EvRec )
-
Load (import) a data logger hex dump file ( Load DataLog )
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7.1.1.3 Live View Tab
Buttons to:
-
Load (import) a Live View file recorded previously ( Load Live View Recording )
-
Adjust the desired sample interval from 0.1s to 3s
-
Load (import) a user defined Live View configuration file ( Load LiveView-Config )
-
Save (export) a user defined Live View configuration file ( Save LiveView-Config )
Check/boxes to:
- Switch from standard to expert mode to gain access to over 150 internal ECU-signals
- Enable an auxiliary signal, which might be used on request by Austro Engine support
personal. It allows to select one ECU-internal signal per ECU which is not on the dropdown list and has to be configured by its hex address.
Drop-down lists to:
- Define a set of Live View signals to be recorded from each ECU (“ECU A/B Signals”)
- Select one of 5 predefined measurements for display and recording of relevant Live View
signal sets:
○ “Boost-Pressure-Test”,
○ “PowerLever-Test”,
○ “Propeller Selftest”,
○ “Rail-Pressure-Test”, and
○ “Ca-Cr-Angle-Test”.
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Maintenance Mode
7.2
This is the standard mode of operation. Suitable for routine diagnostic and maintenance
tasks to be performed by engineers while trouble shooting or servicing the AE300 series
engine. It is available with the “Maintenance” type USB/CAN-Dongle (see chapter “3.2.2
USB/CAN Adapter”)
The primary display is parted into two halves called pages. Those pages can be used
independently of each other to display different information. The left-hand page contains the
buttons and data entry fields, while the right-hand page will display information gathered
from the EECU. Tabs on the top of each page are to be used to select the type of
information to be displayed.
7.2.1
Primary Display – Left Page
7.2.1.1 Maintenance Tab
-
ECU connection status (ECU connected/not connected and active/passive)
Engine serial number (engine type and serial number)
ECU serial number
ECU SW version
ECU HW version
ECU Caution lamp status (on/off)
Area to display entries of the “Fault Code Memory” (FCM)
Buttons to:
-
Establish a logical connection to the ECU ( Connect ECU )
-
Terminate a logical connection to the ECU ( Disconnect ECU )
-
Read the contents of the Fault Code Memory ( Read Fault Code Memory )
-
Clear (reset) the Fault Code Memory ( Clear Fault Code Memory )
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7.2.1.2 Engine Logs Tab
Buttons to:
- Save ECU/Engine ID, contents of Fault Code Memory and engine operating statistics into
one engine log file ( Save Engine Log )
-
Read and interactively display the engine operating statistics ( Read Statistics )
-
Load and display an event recorder HexDump ( Load EvRec )
-
Download event recorder data and save the HexDump file ( Save EvRec )
-
Load, display and interactively work with the data logger ( Load DataLog )
-
Download and save the full (about 80h flight time) Save DataLog , or partial (e.g. last
flight, about 3-5h) data logger data to a HexDump Save DataLog Fraction
-
Download and save Engine Log, Event Rec and partial data logger data (for the flight
time specified, e.g. 3h) in one automatic session – Save Save Log Files
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7.2.1.3 Live View Tab
Buttons to:
-
Record a Live View session ( Record Live View )
-
Load (import) a Live View file recorded previously ( Load Live View Recording )
-
Adjust the desired sample interval from 0.1s to 3s
-
Load (import) a user defined Live View configuration file ( Load LiveView-Config )
-
Save (export) a user defined Live View configuration file ( Save LiveView-Config )
Check/boxes to:
- Switch from standard to expert mode to gain access to over 150 internal ECU-signals
- Enable an auxiliary signal, which might be used on request by Austro Engine support
personal. It allows to select one ECU-internal signal per ECU which is not on the dropdown list and has to be configured by its hex address.
Drop-down lists to:
- Define a set of Live View signals to be recorded from each ECU (“ECU A/B Signals”)
- Select one of 5 predefined measurements for display and recording of relevant Live View
signal sets (“Boost-Pressure-Test”, “PowerLever-Test”, “Propeller Selftest”, “RailPressure-Test”, “Ca-Cr-Angle-Test”)
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Primary Display – Right Page
7.2.2.1 Engine Data-Tab
Real time engine data of both ECUs, updated every 20ms
- Caution lamp status (on/off)
- ECU status (active/passive)
- Voter decision (which ECU should be active as result of the voter decision matrix)
- Battery voltage
- Engine performance (currently developed power as a percentage of the maximum power
available, same as indicated on the Garmin G1000)
- Propeller speed
- Engine oil pressure
- Engine oil temperature
- Gearbox oil temperature
- Coolant temperature
- Fuel flow
- Fuel pressure warning (low fuel pressure warning, same as indicated on the Garmin
G1000)
Timers which are updated only once during initial connection to the ECU
- Total ECU power on time (the accumulated time this ECU has been powered up,
regardless of the engine running or not – i.e. engine master on)
- Total ECU engine control time (the accumulated time this ECU was actively controlling
the running engine)
- Total engine run time (the accumulated time the engine was running controlled by
either ECU-A or ECU-B. This is the official engine hours counter)
- Real time clock (full timestamp provided by the internal RTCs)
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7.2.2.2 Statistics Tab
Shows statistical information of engine usage over its total live time. 8 predefined physical
parameters are sampled once per second and it is accumulated how many hours the engine
has been operated in one of 8 ranges of these specified physical parameters:
- Propeller speed
(8 ranges: 1850 – 1910 – 1970 – 2030 – 2090 – 2150 – 2210 – 2270 – 2330 rpm)
- Coolant temperature
(8 ranges: -30 – -11.25 – 7.5 – 26.25 – 45 – 63.75 – 82.5 – 101.25 – 120 °C)
- Engine oil pressure
(8 ranges: 0 – 1 – 2 – 3 – 4 – 5 – 6 – 7 – 8 bar)
- Engine oil temperature
(8 ranges: -30 – -8.75 – 12.5 – 33.75 – 55 – 76.25 – 97.5 – 118.75 – 140 °C)
- Gearbox oil temperature
(8 ranges: -30 – -8.75 – 12.5 – 33.75 – 55 – 76.25 – 97.5 – 118.75 – 140 °C)
- Battery voltage
(8 ranges: 16 – 18.25 – 20.5 – 22.75 – 25 – 27.5 – 29.5 – 31.75 – 34 V)
- Atmospheric pressure
(8 ranges: 400 – 487.5 – 575 – 662.5 – 750 – 837.5 – 925 – 1012.5 – 1100 mbar).
These ranges correspond to the following pressure altitudes in standard atmosphere:
23564 – 18892 – 14856 – 11291 – 8088 – 5175 – 2499 – 2 – -2290 ft.
- Power lever position
(8 ranges: 0 – 12.5 – 25 – 37.5 – 50 – 62.5 – 75 – 87.5 – 100 %)
Buttons to:
-
Switch between table and bar graph display ( Show/Hide Chart )
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7.2.2.3 Fault Details Tab
Provides details about the Fault Code Memory entries which have been selected on the left
page:
- ECU status at time of failure (i.e., “active” or “passive”)
- Number of occurrences of selected Diagnostic Failure Code (DTC)
For the FIRST and the LAST occurrence of the selected DTC (for example in case of the
same problem occurring intermittently over a period of time) environmental conditions have
been logged at the time the failure occurred. Each DTC has its own set of predefined
environmental conditions relevant to the failure:
- Time stamp (day of month, hours, minutes, and seconds)
- Combined engine status (see appendix “12.2.1 Combined Engine Status” on page 92)
- 4 environmental conditions different for each DTC (e.g., engine speed, battery voltage,
status words, rail pressure, ECU temperature, etc.)
- An empty display area for additional trouble shooting information which will be made
available in the future.
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Qualified Maintenance Mode
7.3
This mode of operation provides all functions of the previously explained “maintenance
mode” with the addition of handling ECU SW updates as well as IQA coding (Injector
Quantity Adjustment) for advanced maintenance to be performed by qualified engineers.
It is available with the “Qualified Maintenance” type USB/CAN-Dongle (see chapter “3.2.2
USB/CAN Adapter”)
7.3.1
Primary Display – Left Page
7.3.1.1 Update SW Tab
-
Display of progress information during SW updates (flash progress information)
Display of status and/or result of the SW update (“success”, “failure” statement or error
information and recommended further steps).
Buttons to:
-
Select the SW to be written into the ECU ( Load Flash Container )
-
Cancel the update process at user request at any time ( Cancel )
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7.3.1.2 IQA Tab
-
IQA codes displayed separate for ECU-A and ECU-B (both ECUs must hold the same IQA
codes)
Input fields for each cylinder to be able to enter IQA codes into both ECUs either
manually or by using a handheld 2D-DataMatrix scanner
Buttons to:
-
Download the IQA codes currently stored in ECU-A and ECU-B ( Read All Cylinders )
-
Save IQA data which has been downloaded from the ECUs into a file together with
engine/EECU-ID ( Save IQA data to file )
-
Load IQA data from a file into the input fields of each cylinder
( Load IQA data from file )
-
Write IQA data from the input fields of each cylinder into the ECUs either one by one
( Write Cyl. 1 through ( Write Cyl. 4 ) or at once ( Write all Cylinders )
-
Save IQA data which has been entered into the input fields of each cylinder into a file
(without engine/EECU-ID) ( Save IQA data to file )
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Diagnostic Procedures
This chapter details the most important diagnostic steps to be performed during routine
maintenance or fault finding.
Note: The following procedures assume, that both the AE300-Wizard and the aircraft have
been set up and are connected as described in chapter “6 Overview and First Steps” on page
21.
8.1
Analyzing Operational Data
Both ECUs maintain a non-volatile memory each to store statistical information about the
operation of the engine throughout the whole engine/EECU Lifetime (if the EECU is being
replaced, the operational data accumulated so far will be lost).
- This statistical data can be read and interpreted by maintenance organizations
- The counters used to develop the statistical engine data, engine and ECU run times as
well as the real time clocks (RTC) cannot be reset nor modified in the field.
8.1.1 Engine and ECU Operating Hours Counters
The official engine operating hours to determine service intervals, use in written logs, service
bulletins and so on are being found on the «Engine Logs» tab:
Steps:
1) Connect to ECU
2) Select «Engine Logs» tab
Information:
a) ECU A has been powered up (“electric master” = ON) for 296 h 12 min 39 sec while
ECU B was powered for 300 h 40 min 29 sec
b) ECU A was actively controlling the running engine for 106 h 51 min 36 sec while ECU
B had control of the engine for 29 h 17 min 55 sec
c) The total engine run time so far is 136.16 h (the sum of “b)”)
Note: The two real time clocks of ECU A and B are not synchronized and will deviate over
time. The time is displayed in UTC and valid from the year 2000 through 2100.
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Operational Statistics
Provides statistical information about the operation of the engine over its total lifetime.
8 predefined physical parameters are sampled once per second and it is accumulated how
many hours the engine has been operated in one of 8 ranges of these specified physical
parameters. This information can be viewed on the «Statistics» tab in table as well as in
graphical format.
8.1.2.1 Table Format
Steps:
1) Connect to ECU
2) Select «Engine Logs» tab
3) Click on Statistics button
Information:
•
For example, the lower table indicates, that so far the engine has spent 1.8 hours in
propeller speed range 1, 2.9 h in range 2, 0.1 h in range 3, 0.4 h in range 4, 0.8 h in
range 5, 0.7 h in range 6 and 0.8 h in range 8 – while being controlled by ECU B.
•
Similar statistics are provided for coolant temperature, engine oil pressure, engine oil
temperature, gearbox oil temperature, battery voltage, atmospheric pressure, and
power lever position.
•
Information is given in decimal hours.
•
The ranges (e.g. “range 1” of the power lever position is defined as 0% to 12.5%) are
detailed in chapter “7.2.2.2 Statistics Tab” on page 32.
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8.1.2.2 Bar-Graph Format
Steps:
1) Connect to ECU
2) Select «Engine Logs» tab
3) Click on Read Statistics button
4) Click on Show/Hide Chart for ECU A
5) Click on Show/Hide Chart for ECU B
6) Select the physical parameter (e.g., “propeller speed”) by clicking its line in the table
Information:
Propeller speed
Coolant temperature
Engine oil pressure
Engine oil temperature
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Gearbox oil temperature
Battery voltage
Atmospheric pressure
Power lever position
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Routine Maintenance
During routine maintenance (e.g., 50h/100h inspections) the AE300-Wizard shall be used to
download the following maintenance-relevant data from the EECU and to have this data sent
to Austro Engine for trend monitoring and to generate preventive maintenance information.
Attention:
○ The engine must be stopped during downloading of event recorder or data logger
data!
○ During these operations the ECU will not be able to perform the normal engine
control functions.
○ The downloading activities (stopping of one ECU, while the Twin-ECU is still active)
may cause false entries to be logged into the fault code memory.
○ Therefore, downloading of data shall be performed in the following sequence:
1)
Save “Engine Log File”, see chapter “8.2.1 Engine Log File” on page 41
will ensure to save the original failure information.
2)
Save “Event Recorder File”, see chapter “8.2.2 Event Recorder File” on
page 42.
3)
Save “Data Logger File”, see chapters “8.2.3 Data Logger File (Full Flight
Time)” on page 43 and “8.2.4 Partial Data Logger File (Fraction of Flight
Time)” on page 45.
4)
Clear the “Fault Code Memory”,
see chapter “8.2.6.3 Clearing the Fault Code Memory” on page 50
will ensure to clear any false FCM entries.
○ Before attempting to download event recorder or data logger data, the aircraft shall
be set up to use ground power and the fuel pumps and alternator(s) shall be
disabled as described in chapter “6.3.2 Engine not Running”.
○ Depending on the amount of flight time stored in the RecMng-Flash downloading of
the event recorder data will take a few minutes.
○ Depending on the amount of flight time stored in the RecMng-Flash downloading of
the data logger data can take up to 40 minutes for both ECUs combined. Per 1 hour
of recorded flight time about 0,5 minutes of download time for both ECUs is
required.
The resulting data files shall be sent to Austro Engine for further analysis, see appendix
“11.2 Sending Maintenance Information” on page 91 for contact information.
Attention:
Since AE300-Wizard version 1.2.0.xxx data files downloaded from the ECU are saved in a
new compressed and encrypted format (“.ae3” file extension). This reduces the file size
dramatically (about 1/10th of the size of the previous XML format) and enhances privacy of
the data contained. These two factors make it easier to transfer files produced by the
AE300-Wizard via the standard e-mail systems used on the internet.
The “new” AE300-Wizard can read and interpret the “old” file format (saved by AE300Wizards before V1.2.0.xxx), but it will save only the “new” files, which cannot be read by the
“old” AE300-Wizard versions.
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8.2.1 Engine Log File
The engine log file is a convenient way to download and save the basic information relevant
for maintenance organizations and flight departments by clicking on one single button:
ID-Information
Data used to describe a particular installation (engine serial, EECU serial, software, and
hardware revisions, etc.) will be downloaded from the EECU.
Operational data
The operational data described in chapter “8.1 Analyzing Operational Data” on page 36,
especially the contents of the “engine statistics” counters, will be downloaded from the
EECU.
Fault Code Memory
Each AE300-ECU saves failure information into a non-volatile Fault Code Memory (FCM). This
FCM can hold up to 20 different faults detected, including 9 environmental conditions (e.g.,
timestamp, voltages, temperatures, pressures, etc.) which are specific for each possible
failure and are sampled and stored at the time the failure occurred. The full contents of the
FCM will be included in the engine log file download.
Steps:
1) Connect to ECU
2) Select «Engine Logs» tab
3) Click on Save Engine Log button
4) Select file name
5) Press Save button
6) A compressed and encrypted engine log of the name “Engine_Log_YYYYMMDD.ae3”
is available in “My Documents\Austro Engine\AE300-Wizard\Engine_Log”.
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8.2.2 Event Recorder File
Each AE300-ECU contains non-volatile flash memory storage (called RecMng-Flash) which is
used to store “events” during operation of the engine. Events can be simple information
(e.g., which ECU has been switched to “active”) or mark the beginning (or end) of an
abnormal situation with one of the physical parameters observed. These events include a
diagnostic trouble code (DTC) describing the situation occurring, a status field marking begin
or end of the abnormal situation and a full time-stamp.
Some events are defined as critical and will occur together with caution lamp activation (e.g.,
“fuel pressure too low”) while other events will be recorded but will not be accompanied by
an activation of the caution lamp (e.g., “propeller speed deviation below normal range”).
To download and analyze those events allows to detect trends or to gain an understanding
of problem areas requiring closer attention during the inspection. See chapter “8.2.7 Offline
Analysis Using the Engine Log” on page 51 for details on fault finding using the event
recorder.
The following steps will ask the AE300-Wizard to download the event recorder data from
both ECUs and to save this hex dump into a compressed and encrypted file.
Steps:
1) Connect to ECU
2) Select «Engine Logs» tab
3) Click on Save EvRec button
4) Select file name
5) Press Save button
6) A compressed and encrypted EventRec of the name “EvRec_YYYYMMDD.ae3” is
available in “My Documents\Austro Engine\AE300-Wizard\HexDump”.
The engine must be stopped to perform an Event Recorder download!
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8.2.3 Data Logger File (Full Flight Time)
Each AE300-ECU contains non-volatile flash memory storage (called RecMng-Flash) which is
used to store 16 channels of signals. These signals are being sampled at an interval of 1
second as long as the ECU is powered up. Both ECUs perform this task independently of
each other and have their own separate RecMng-Flash memory.
Currently the following signal channels have been defined:
- Boost pressure
- Barometric air pressure (measured inside the EECU enclosure)
- Engine oil pressure
- Rail pressure
- Power lever position
- Coolant temperature
- Intake air temperature
- Battery voltage
- Fuel pressure (measured after the electric fuel pump)
- Gearbox oil temperature
- Engine oil temperature
- Duty cycle of propeller actuator (combined d.c., ranging from -100% to +100%)
- Engine status (combined bit mask, see appendix “12.2.1 Combined Engine Status”)
- Engine oil level
The RecMng-Flash provides space for the 16 channels at a 1s sampling rate for about 90
hours of flight time, depending on the number and duration of flights. It is organized as a
“ring buffer” holding always the most recent flight hours (about 80-90 hours).
Caution:
Before attempting to download Data Logger data the following criteria must
be met:
- The aircraft shall be set up to use ground power and the fuel pumps and alternator(s)
shall be disabled as described in chapter “6.3.2 Engine not Running” on page 21,
- Depending on the amount of flight time stored in the RecMng-Flash downloading of the
data logger data can take up to 40 minutes for both ECUs combined,
- The engine must be stopped to perform a Data Logger download.
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Steps:
1) Connect to ECU
2) Select «Engine Logs» tab
3) Click on Save DataLog button
4) Select file name for the data logger file (“DatLog_YYYYMMDD.ae3)
5) Press Save to store the compressed and encrypted DatLog in
“My Documents\Austro Engine\AE300-Wizard\HexDump”.
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8.2.4 Partial Data Logger File (Fraction of Flight Time)
For quick analysis of the most recent flight(s) an abbreviated download is available to save
troubleshooting time by avoiding download of unwanted historical data.
Steps:
1) Connect to ECU
2) Select «Engine Logs» tab
3) Enter number of recent flight hours to be downloaded
4) Click on Save DataLog Fraction button
5) Select file name for the data logger file (“DatLog_YYYYMMDD.ae3”)
6) Press Save to store to “My Documents\Austro Engine\AE300-Wizard\HexDump”.
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Trouble Shooting
To help in fault finding missions, the AE300-Wizard processes and interpretations described
below are recommended.
Note: The following procedures assume that all precautions concerning aircraft setup (see
chapter “6.3 Setting up the Aircraft” on page 21) and downloading of data (see chapter “8.2
Routine Maintenance” on page 40) are well understood and taken care of.
8.2.6
Using the Fault Code Memory (FCM)
8.2.6.1 Overview of the FCM Functionality
Each AE300 ECU uses a non-volatile memory (EEPROM) to store up to 20 fault entries. A
fault entry is defined by its unique “diagnostic trouble code” (DTC). The description of each
possible DTC can be found in the latest revision of the “Maintenance Manual AE300”
(document number E4.08.04).
8.2.6.1.1
Diagnostic Trouble Code
Each FCM entry contains the first and last (in case of multiple occurrences) occurrence of a
particular DTC. An occurrence is further described by one of 4 possible error types which are
named MAX, MIN, SIG and NPL. The exact meaning of the error type depends on the DTC
but in general the following explanation is valid.
Error Type
Signal
Explanation
MIN
underrun
indicates a violation of a lower limit
MAX
overrun
indicates a violation of an upper limit
SIG
missing
indicates a totally missing signal
NPL
not plausible
indicates a signal which is not plausible
Table 4
Error Types of FCM Entries
8.2.6.1.2 Error Type
Example:
A problem caused by the boost pressure actuator power stage or circuit.
-
The DTC “2526” translates into “Boost pressure actuator power stage failure”. This
translation will be done automatically by the AE300-Wizard when reading the FCM.
For this DTC all 4 error types have been defined and have the following meaning:
○ MAX: “Short circuit to BATT of BPA power stage output”. This means, the voltage
measured by the ECU at the output stage is higher than the limit defined. A possible
explanation could be a short circuit to UBatt for example.
○ MIN: “Short circuit to GND of BPA power stage output”. This means, the voltage
measured by the ECU is lower than the defined limit. A possible explanation could
be a short circuit of the actuator wire to the airframe or to a shielding wire (GND).
○ SIG: “Open circuit of BPA power stage output”. This means, the ECU doesn’t detect
any electric current flowing through the output stage when activated. A possible
explanation could be a broken actuator wire or connector problem.
○ NPL: “Excess temperature of BPA power stage”. The ECU SW includes a variety of
plausibility checks, and this failure usually indicates that some values (e.g., sensor
values) do not agree. In the case of the boost pressure actuator power stage, this
error type is used to indicate overheating of the output stage.
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Caution Lamp
Depending on its severity, a fault will just be entered into the FCM or in addition the pilot will
be notified via a warning message of the cockpit display system (= caution lamp relevant
faults).
8.2.6.1.4
Multiple Occurrences
If a failure situation “heals” itself (e.g., a faulty signal drops back within normal limits) the
entry of this DTC will remain in the FCM, but it will not be marked as “active” anymore. If
the same DTC occurs again (as is the case with intermittent faults) the FCM entry will be
updated to include this new occurrence as the “last” occurrence and the “occurrence”
counter of this FCM entry will be incremented by one. For example, if a sensor wire is
rubbing against the engine, causing intermittent shorts – the first short observed will be
permanently entered as the “first” occurrence, the last of multiple shorts will be entered as
“last” occurrence and the occurrence counter will display how often this failure occurred
since the last time the FCM has been reset or overwritten.
8.2.6.1.5
Freeze Frame
For each occurrence of a DTC, up to 9 environmental conditions sampled at the time of
failure are stored in the FCM. This set of environmental conditions is called “freeze frame”.
For each possible DTC a specific freeze frame has been defined to aid in trouble shooting a
certain fault with as much pertinent information as possible.
Current definition of the freeze frame:
- Env1:
Time of failure, day of month (due to space constraints months and year are
not stored)
- Env2:
Time of failure, hours
- Env3:
Time of failure, minutes
- Env3:
Time of failure, seconds
- Env4:
Combined engine status (see appendix “12.2.1 Combined Engine Status)
- Env5:
Depending on the DTC, engine speed, propeller speed or battery voltage
- Env6:
Depending on the DTC
- Env7:
Depending on the DTC
- Env8:
Depending on the DTC
- Env9:
Depending on the DTC
When the AE300-Wizard reads the FCM and displays the fault details it automatically
converts the stored freeze frame data into readable physical units wherever possible (i.e.,
pressures in hPa, temperatures in °C and so on).
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8.2.6.2 Displaying Fault Details
Displaying the contents of the FCM and interpreting the fault details can be done either
interactively by connecting the AE300-Wizard to the aircraft as described above, or offline by
importing a previously downloaded “engine log” as indicated in chapter “7.1.1.2 Engine Logs
Tab” on page 26. The offline analysis functionality is available since AE300-Wizard version
1.1.0.xxx.
Steps to interactively read the FCM:
1) Connect to ECU
2) Select «Maintenance» tab
3) Click on Read Fault Code Memory button
Interpretation for ECU A:
- Caution lamp on → caution lamp relevant faults are active in FCM.
- Upper window in left hand page («Maintenance» tab) displays the FCM-contents of ECUA, specifically the summary of the “last” occurrence of each DTC stored in the FCM.
- All fault entries marked in the “active” column are current failures, entries without the
mark are “old” entries for information (faults which occurred but are healed).
- All fault entries marked in the “Lamp” column are caution lamp relevant, meaning they
cause (or did cause in the case of inactive faults) activation of the caution lamp.
- DTC column provides the diagnostic trouble code of the failure in question.
- Short description is a translation of the DTC into a textual description of the failure.
- Error type is a translation of the actual error type into a textual description.
- Text which is too wide for its column can be viewed be either using the horizontal scroll
bar of the window or by “grabbing” the divider of the column and moving it right or left
(as in Excel for example).
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By selecting a line in the fault summary window of an ECU, the detailed FCM entry will be
shown:
Interpretation for ECU A:
- Occurrence “1” → This DTC occurred once.
- This fault is currently active.
- This fault is not caution lamp relevant (the pilot will not be notified of this situation).
- The DTC 1E02 translates into a “data logger failure”.
- The error type of both the first and last occurrence was the same.
- The error type SIG indicates that “No valid lead out sequence from last session was
found” (requires horizontal scrolling of the text display). This means, the data logger
was unsuccessful when trying to find the end (“lead out”) of the data recorded on the
previous flight during the current initialization phase. This usually happens, when the
engine is killed (e.g., via “electric master” = OFF) without enough time to go through its
after run phase where the house keeping tasks (like writing the lead out) are being
performed. This is no sever failure just an information to explain that a certain part of
the data logger may not be in sequence or missing some data.
- The FIRST fault occurred on the 22nd of the month.
- The LAST fault occurred on the 22nd of the month.
- The engine status was “11110010 bin” which means ECU-A was passive, the voter
switch was either in “auto” or “B” position, the squat switch was depressed (aircraft on
ground) and the engine was in “start” mode when the fault occurred
(see appendix “12.2.1 Combined Engine Status” for details on the bit mask).
- The engine speed was “0 rpm” (engine not started yet).
- The state of the internal data logger state machine was “0”
(information for engineering support only).
- The state of the data logger release conditions was “0001010 bin”
(information for engineering support only).
- The state of the record manager release conditions was “00000011 bin”
(information for engineering support only).
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8.2.6.3 Clearing the Fault Code Memory
After performing maintenance, troubleshooting or downloading of event recorder/data logger
data the FCM should be reset (cleared) to have a fresh starting point for the next routine
maintenance.
Steps:
1) Connect to ECU
2) Select «Maintenance» tab
3) Click on Read Fault Code Memory button
4) Click on Clear Fault Code Memory button to reset (clear) the stored failures. To
prevent inadvertent clearing of the FCM without saving the contents (thus losing the
failure information), the AE300-Wizard automatically downloads and saves an Engine
Log File with the syntax:
“AutoSave_Engine_Log_YYYYMMDD_xxxxxx”
before clearing the FMC (“_xxxxxx” is a random number generated by the Wizard to
prevent overwriting of already existing AutoSave log files with the same date).
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8.2.7 Offline Analysis Using the Engine Log
Since AE300-Wizard version 1.1.0.xxx a functionality to import a previously saved engine log
for further offline analysis is available. These engine logs have been saved in XML format
with a name of the form “Engine_Log_YYYYMMDD.xml”.
Since AE300-Wizard version 1.2.0.xxx the engine logs are compressed and encrypted with a
name of the form “Engine_Log_YYYYMMDD.ae3”.
8.2.7.1 Displaying Fault Code Memory Entries
The content of the FCM will be presented in the same way as it would be seen in interactive
mode.
Information to identify the engine or EECU (i.e., serial number) or the SW version will also
be presented in the usual data fields on the «Maintenance» tab.
Steps:
1) Enter “offline” mode by running the AE300-Wizard without CAN adapter
2) Select «Engine Logs» tab
3) Click on Load Engine Log button
4) Select new (“Wizard files” = default)
or old (“Xml files”) format of engine log
5) Select file name (e.g., Engine_Log_YYYYMMDD.ae3)
6) Press Open button
7) The AE300-Wizard will automatically present the FCM information like “normal”
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8) Faults are to be selected on the left-hand page and the corresponding details are
then displayed on the right hand page
8.2.7.2 Displaying Engine Operational Statistics
The content of the engine statistics counters will be presented in the same way as it would
be seen in interactive mode.
Perform steps 1) through 6) as described above and then:
7) Select «Statistics» tab
8) Click on Show/Hide Chart button
9) Select desired engine parameters by clicking on its line
10) Display any statistics view as would be done in interactive mode, directly connected
to an aircraft
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8.2.8 Offline Analysis Using the Event Recorder
Chapter “8.2.2 Event Recorder File” explains how to download the event recorder data from
the RecMng-Flash and how to save it into a hex dump file.
Chapter “7.1 Offline Mode” explains the “offline” mode of the AE300-Wizard (without a
USB/CAN-adapter dongle connected to it) which can be used to import the event recorder
hex dump file downloaded from the aircraft earlier, in the convenience of an office desk and
without draining the aircraft battery like during an interactive (live) diagnostic session.
Since AE300-Wizard version 1.2.0.xxx the event recorder files are compressed and encrypted
with a name of the form “EvRec_YYYYMMDD.ae3” while prior to version 1.2.0.xxx the files
were saved in XML format and a name of the form “HexDump_EvRec_YYYYMMDD.xml”.
Steps:
1) Enter “offline” mode by running the AE300-Wizard without CAN adapter
2) Select «Engine Logs» page
3) Click on Load EvRec button
4) Select new (“Wizard files” = default)
or old (“Xml files”) format of event recorder
5) Select file name (e.g. EvtRec_YYYYMMDD.ae3 or
HexDump_EvtRec_YYYYMMDD.xml)
6) Press Open button
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8.2.8.1 The Event Recorder Window
The previous steps will cause the AE300-Wizard to read in and interpret the selected event
recorder hex dump file and to open a new window displaying the result (combining data
from both ECUs):
Per default the events are sorted by their timestamp (the left most column)
The data displayed can be sorted in ascending or descending order by clicking on the
column headers (e.g. clicking on the DTC header will sort all events by their DTCs)
- A red background marks the “beginning” of an event (i.e., “Rail pressure below normal
range”)
- A green background marks the “end” of event (i.e., the event “Rail pressure below
normal range” has ended and the rail pressure is back to normal now)
Example:
-
Interpretation:
- April 15th, 2009 at 8:37:39 (DTC=1E34, event status=00000001, event count=122h)
- DTC 1E34 is a “rail pressure operating range” event type of MIN. The code is
automatically translated into the textual description “Rail pressure below normal range”
- The event status (see layout in appendix “12.3.1 Event Status”) is automatically
translated into “beginning of an event” (i.e. the rail pressure fell below a predefined
limit) and it was recorded at ECU-B which was also the active ECU at that time
- This was event queue entry 290 decimal (122 hex)
- April 15th, 2009 at 8:37:39 (DTC=1E34, event status=00000000, event count=123)
- Active ECU B recorded (as entry number 291dec/123hex) the end of the event “rail
pressure below normal range” (rail pressure increased again above a predefined limit)
- The timestamp resolution is 1 second, so this was a very short pressure fluctuation
- The two lines above show, that the passive ECU A detected and recorded the same rail
pressure fluctuation about 1 to 2 seconds later.
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8.2.8.2 Using Filters in the Event Recorder
Filtering event records can be realized by using the “Show Event Filter” button at the top
right-hand corner of the “Event Recorder” window. Pressing this button will result in a new
fully scalable window:
The “Events Filter” window allows to:
• Select the ECU (A or B or both)
• Select or unselect specific DTC codes
• Deselect/Select all events
• Select specified DTC codes
• Select text strings in DTC codes
(by using the checkboxes, upper left corner)
(by using the checkboxes)
(by using the button “Deselect all Events”)
(by using the “Filter String”)
(by using the case sensitive “Filter String”)
Hint: The “Deselect all Events” button will change to a “Select all Events” one after using it.
The latter two features can be (multiple) combined by using a ‘+’ character between the
conditions.
The results of the filter can be seen in the “Event Recorder” window.
Note: Viewing bigger event recorder files can result in a slow reaction after setting the filter!
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8.2.9 Offline Analysis Using the Data Logger
Chapter “8.2.3 Data Logger File” on page 43 explains how to download the data logger data
from the RecMng-Flash and how to save it into a hex dump file.
Chapter “7.1 Offline Mode” on page 26 explains the “offline” mode of the AE300-Wizard
(without a USB/CAN adapter dongle connected to it). Which can be used to load and analyze
the data logger hex dump file downloaded from the aircraft earlier, in the convenience of an
office desk and without draining the aircraft battery like during an interactive (live)
diagnostic session.
Since AE300-Wizard version 1.2.0.xxx the data logger files are compressed and encrypted
with a name of the form “DataLog_YYYYMMDD.ae3” while prior to version 1.2.0.xxx the files
were saved in XML format and a name of the form “HexDump_DataLog_YYYYMMDD.xml”.
Steps:
1) Enter “offline” mode by running the AE300-Wizard without CAN adapter
2) Select «Engine Logs» tab
3) Click on Load DataLog button
4) Select new (“Wizard files” = default)
or old (“Xml files”) format of data logger
5) Select file name (e.g. DataLog_YYYYMMDD.ae3 or
HexDump_DataLog_YYYYMMDD.xml)
6) Press “Open”
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The Data Logger Window:
The previous steps will cause the AE300-Wizard to import and interpret the selected data
logger hex dump file and to open a new window displaying the result (combining data from
both ECUs):
Time axis:
- To left = towards past time
- To right = towards present time
Navigation bar:
Signal selection:
-
Zoom in/out signal axis
A menu to select any combination
-
Zoom in/out time axis
of ECU-A and -B signals for display
-
Move up/down signal axis
-
Move left/right time axis
8.2.9.1 Saving Data Logger Displays as Screenshots
If just the current display of data logger data (as used in example 1 and 2) is to be saved,
the mechanisms built into MS Windows can be used as explained in chapter “6.6 Saving
Screenshots from Data Displays” on page 25.
8.2.9.2 Interpreting the Data Logger Display
When interpreting data logger displays the following facts should be observed:
1) If signals from both ECU-A and ECU-B are selected for the same display, i.e. to
analyze relationships of ECU-A events to ECU-B events, the time difference between
the two real time clocks have to be taken into account. (e.g. if ECU-A RTC runs 10
seconds ahead of ECU-B RTC as can be seen on the «Engine Data» tab’s RTC display,
the ECU-A events will be shifted by 10 seconds when compared to ECU-B events
even if they happened “at the same time” in real world).
2) Sample interval is 1 second, so any transients or fast changes in between those
intervals cannot be shown and the signals are interpolated from sample to sample.
3) To scan for flight cycles select “Barometric air pressure” and watch for the line to
drop below the 1000 hPa line.
4) To skip time, remember 1h = 3600 sec, 0.5 h = 1800 sec, 5 min = 300 sec, ….
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Example 1 (negative-G event):
Barometric air pressure
Rail pressure
-
-
Clicking on a point of the signal displays a full time stamp and the physical value of the
signal at that point in time (e.g. Fuel pressure 1672 hPa, at 18.02.2009 10:54:55 UTC)
The left () or right (→) arrow keys on the keyboard may be used to move the selected
point left or right by one sample per each key press for accurate positioning.
The signal of the barometric air pressure (915 hPa, 8 seconds after the low fuel pressure
event) can be converted into altitude in ISA standard atmosphere (915 hPa ~ 2800 ft.)
and shows, the event happened around 3000 ft.
The rail pressure follows the fuel pressure with practically no delay down to a minimum
of 129 bar but recovers quicker. Rail pressure is back to normal in about 5 seconds,
while the fuel pressure takes about 10 sec to recover into normal operating range.
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Example 2 (normal take-off):
Lead-in
Propeller speed
Power lever position
Combined engine status
Time line from left to right:
- Lead-in: At 20.4.2009 13:58:53 (UTC), means ECU-A was powered up and initialized at
that time (engine master ON), the data logger writes the lead in to mark the beginning
of this flight cycle
- Barometric air pressure: Starts around 980 hPa (= pressure altitude at LOAN) aircraft is
on the ground and after takeoff steadily climbing through 963 hPa (~ 1400 ft. in ISA
standard atmosphere) at 14:04:29 UTC
- Engine oil temperature: Starts around 80 °C, indicating a warm start and climbs through
88.76 °C at 14:02:32 UTC to reach 3minutes later (time line 3270 - 3090 = 180
seconds) about 105 °C
- Gearbox oil temperature: Roughly follows the engine oil temperature at a lower level
- Propeller speed: At time line 3380 – 3360 the propeller self-test takes place (indicated
by two distinctive 1900 rpm “humps” while the power lever is at idle (0%)
- Power lever position: After start up and taxi variations, the power lever remains at idle
(0%) during the propeller self-test (time line 3380 – 3320) and is then advanced to full
power for takeoff and initial climb for a duration of about 30 seconds, first power
reduction occurs at 14:02:45 UTC
- Engine oil level: From about 50mm at startup during some fluctuations during the
ground run, the oil level settles to about 35mm during the climb
- Combined engine status: At time line 3370 the status changes to D4 hex (= 11010100
bin), this means the self-test switched from ECU-A to ECU-B. At 14:02:30 the engine
status 1C hex (= 00011100 bin) drops to 12 hex (= 00001100 bin) which means the
squat switch (bit #4, weight on wheels) has been released indicating that the aircraft
was airborne at that time (see appendix “12.2.1 Combined Engine Status” for details)
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Live View
Since AE300-Wizard version 1.1.0.xxx a functionality called “Live View” is available which
allows to view and to record EECU internal signals in real time. Live View can be used both
online and offline to analyze engine tests. It is available in both “Maintenance” and “Qualified
Maintenance” operating mode as well as in the “offline analysis” mode without a CAN
adapter.
Since AE300-Wizard version 1.2.0.xxx the live view files are compressed and encrypted with
a name of the form “LiveView_YYYYMMDD.ae3” or “LiveView_Config_YYYYMMDD.ae3”
while prior to version 1.2.0.xxx the files were saved in XML format and a name of the form
“LiveView_YYYYMMDD.xml” or “LiveView_Config_YYYYMMDD.xml”.
Since AE300-Wizard version 1.3.4.xxx it is possible to record up to 74 signals per ECU. Hint:
The maximum number of signals that can be recorded at once depends on the performance
of the used PC.
Per ECU (half) are 12 CAN bus signals (of the above mentioned 74 signals) permanent
available.
8.3.1 Live View – Online Analysis and Recording
With this functionality, a selectable set (“recording set”) of EECU internal signals can be
sampled at adjustable intervals (0.1 – 3 s) and recorded for later analysis. At the same time,
all or a selectable subset (“display set”) of the recorded signals can be monitored online
while recording in the background.
Live View can be operated in one of two modes:
8.3.1.1 Live View – Standard Mode
In “standard mode” the user can select a set of up to nearly 50 selectable signals per ECU.
The selected set for ECU-A can be different from the set for ECU-B thus allowing a total of
nearly 100 different signals to be selected per recording session.
Please keep in mind though, that the real time clocks (RTC) of the two ECUs are not
synchronized, therefore if you select signals from both ECUs, there can be a timing offset
between the signals from ECU-A and ECU-B.
This offset could be determined by comparison of the two RTC read outs on the bottom of
the “engine data” display:
In this example, a signal change seen by both ECUs at the same point in time will be
displayed by ECU-A with a timestamp differing from the timestamp on ECU-B by 3 seconds.
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Steps:
1) Connect to ECU
2) Select «Live View» tab
3) Select sample interval (default = 0.1s)
4) Select up to 52 signals per ECU, e.g., ECU-A:
- Battery voltage
- Boost pressure actuator (BPA) duty cycle
- Boost pressure
- Boost pressure set point
- Coolant temperature
- Coolant temperature, rate of change
5) Press Record Live View button
6) Select the set of signals for real time display (Note: the “recording set” had been
determined by “Step 3) and signals in the “recording set” but not in the “display set”
are still recorded for later analysis):
- Battery voltage
- Boost pressure actuator (BPA) duty cycle
- Boost pressure
- Boost pressure set point
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Steps continued:
7) Press the “Record” button to start recording session:
8) Select a file name
9) Click on the Save button
10) Measurement runs from left to right:
- Actual signal values
- Graphical display of signal values over time
11) Click on point of signal to display timestamp, name and value
12) Press “Stop” button to stop recording session:
The data (Live View recording) saved during the session can be found on the PC-system in
the folder:
“My Documents\Austro Engine\AE300-Wizard\LiveView”
e.g., under the name “LiveView_YYYYMMDD.ae3” as selected in Step 8).
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8.3.1.2 Live View – Expert Mode
The expert mode of Live View provides access to 158 internal ECU signals. To be able to
distinguish between similar sounding signals (i.e., there are 11 signals available concerning
the boost pressure measurement) when talking to supporting experts, each signal in the list
also carries an abbreviated “codename” which can be used to identify the signal in question.
Steps:
1) Connect to ECU
2) Select «Live View» tab
3) Check “Expert Mode”
4) Select sample interval (default = 0.1s)
5) Select up to 52 signals per ECU
- 158 non-standard signals are available
- e.g., raw sensor voltages can be monitored
- individual sensors of redundant sets can be monitored (i.e. power lever adjustment)
- contents of status or error registers
- status of internal state machines
6) Press the Record Live View button
7) … continue as explained in section “8.3.1.1 Live View – Standard Mode”
8.3.1.3 Live View – Aux Signal
This functionality is provided for escalated maintenance situations where remote support by
an Austro Engine expert may require access to auxiliary signals which have no name
assigned and are not part of the list of 158 signals defined in the AE300-Wizard.
Application of this functionality is outside of the scope of this user guide and is meant to be
used only under the guidance of an Austro Engine design engineer.
8.3.2
Live View – Online Analysis using Pre-Defined Measurements
To help with standard maintenance tasks, 5 pre-defined signal sets have been developed for
the following situations:
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Boost-pressure test (e.g., after repairs of the turbo charger or air intake system)
Power lever test (e.g., to aid with power lever sensor adjustments)
Propeller self-test (e.g., to troubleshoot self-test problems, or after governor
replacement)
Rail-Pressure test (e.g., to troubleshoot problems in the high-pressure fuel system)
Ca-Cr-Angle-Test (e.g., to troubleshoot problems with the timing chain)
Steps:
1) Connect to ECU
2) Select «Live View» tab
3) Select desired “Pre-Defined Measurement” (i.e., “Boost-Pressure-Test”) from a dropdown list
4) Select sample interval (default = 0.1s)
5) Relevant signals per ECU are selected automatically
6) Press Record Live View button
7) … continue as explained in section “8.3.1.1 Live View – Standard Mode” on page 60.
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Live View – Online Analysis Using User-Defined Measurements
This Live View mode of operation is very similar to the previous “Pre-Defined Measurement”
chapter – but here a “LiveView-Config”, pre-defined by the user or another maintenance
support organization, is used to automatically set the mode of operation (standard/user),
sample-interval and set of signals.
Steps:
1) Connect to ECU
2) Select «Live View» tab
3) Press Load LiveView-Config button
4) Select a file name
5) Click on Open button
6) Up to 52 pre-defined signals per ECU, the required mode (standard/expert) and the
sample interval are set automatically
7) Press Record Live View button
8) … continue as explained in section “8.3.1.1 Live View – Standard Mode”
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8.3.4 Live View – Offline Analysis
Live View data saved during a previous recording session can be analyzed offline, without
the need for a USB/CAN adapter. Also, this Live View mode of operation allows a user to
define and save a “LiveView-Config” which can be used as input configuration for “PreDefined Measurement” explained above.
8.3.4.1 Live View – Defining and Saving a “LiveView-Config”
Here a user can define, save and reuse his or her own “LiveView-Config” which defines mode
of operation (standard/user), sample interval and signal sets for recurring measurements.
Steps:
1) Enter “offline” mode by running the AE300-Wizard without CAN adapter
2) Go to «Live View» tab
3) Select desired sample interval and mode (47 standard or 158 expert signals)
4) Select up to 52 desired signals
per ECU
5) Press Save LiveView-Config button
6) Select a file name
7) Click on the Save button
The resulting “LiveView-Config” file can be found on the PC system in the folder:
“My Documents\Austro Engine\AE300-Wizard\LiveView”
e.g. under the name “LiveView_Config_YYYYMMDD.ae3” as selected in Step 6).
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8.3.4.2 Live View – Importing Live View Recordings
Live View recordings saved during previous sessions can be analyzed offline using the
AE300-Wizard without a CAN adapter, by a maintenance technician at the office or by an
Austro Engine expert in case of escalated situations.
Steps:
1) Enter “offline” mode by running the AE300-Wizard without CAN adapter
2) Go to «Live View» tab
3) Press Load Live View Recording button
4) Select new (“Wizard files” = default) or
old (“Xml files”) format of life view recording
5) Select file name (e.g. LifeView_YYYYMMDD.ae3 or LifeView_YYYYMMDD.xml)
6) Press the Open button
7) The “Live View” windows pops up
8) Analyze the recording as explained in section “8.3.4.3 Live View – Analyzing Live View
Recordings”
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8.3.4.3 Live View – Analyzing Live View Recordings
Live View recordings imported as explained above can be analyzed very similar to the offline
analysis of Data Logger recordings.
Steps:
1) Perform steps 1) – 7) of section “8.3.4.2 Live View – Importing Live View Recordings”
to access the “Live View” window displaying the recording
2) Only the first (top) signal of the recorded signal set is displayed automatically
3) Use navigation bar to find the section of interest
Move left/right time axis
Move up/down signal axis
Zoom in/out time axis
Zoom in/out signal axis
4) Select additional signals to be displayed (out of the list of recorded signals)
5) Click on points of interest to display sample value, time stamp, signal name
6) The left () or right (→) arrow keys on the keyboard may be used to move the
selected point left or right by one sample per each key press for accurate positioning.
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Live View – Working with Austro Engine Support
As indicated in section “11.1.4 Fourth Step (optional) – Live View recordings or Screenshots”
it might be required to use the Live View functionality to supply additional information when
working with Austro Engine “After Sales” support.
8.3.5.1 “LiveView-Config” Files
Configuration files may be sent to the local service center by the Austro Engine
representative with the request to import it into the AE300-Wizard to collect data from
special measurements.
Steps:
1) A configuration file has been received by email or download
2) The “LiveView-Config” file is normally named similar to this example:
“LiveView_Config_20101108 _OEVPI-RH_LP-Test.ae3”
3) This file should be copied into the default Live View folder:
“My Documents\Austro Engine\AE300-Wizard\LiveView”
4) The configuration can then be imported into the AE300-Wizard as explained in
chapter “8.3.3 Live View – Online Analysis Using User-Defined Measurements” on
page 65.
8.3.5.2 Live View Data saved during Measurements
Recordings saved during applicable Live View sessions can optionally be sent to Austro
Engine “After Sales” support.
Steps:
1) Perform a Live View recording session and save the resulting data as explained in
chapter “8.3.1 Live View – Online Analysis and Recording”,
2) The default storage location for the recorded data is:
“My Documents\Austro Engine\AE300-Wizard\LiveView”,
3) The default name of the data file is for example: “LiveView_20091123.ae3”,
4) It is highly recommended to use additional descriptions for the file name like:
“LiveView_YYYYMMDD_AircraftRegistration-EngineSide_ProblemShort.ae3”,
5) Since version 1.2.0.xxx the AE300-Wizard stores all files (“Wizard files”) in a
compressed and encrypted format (“.ae3”) which reduces the size of Live View
recordings dramatically (to about 1/10th of the previous format), and
6) Because of the smaller file size and the encryption used for privacy of the data, the
Live View recordings may be sent by email to the Austro Engine “After Sales”
organization. Therefore, FTP transfers are not required anymore and may be used as
a backup option or under special circumstances.
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IQA Codes
To be able to work with IQA codes a USB/CAN-adapter with a “Qualified Maintenance”
license has to be connected (see chapter “3.2.2 USB/CAN Adapter” on page 15) BEFORE
starting the AE300-Wizard. This will unlock the «IQA» tab:
9.1.1 Overview
Ideally all injectors produced should always inject the same quantity of fuel when a certain
energizing time and a given rail pressure is applied. But during the manufacturing process
mechanical and electrical tolerances of the injectors produced are unavoidable.
When testing a sample of injectors coming off the manufacturing line different injectors will
show different injection quantities while applying the same rail pressure and energizing
timing during each test. Usually, these variations are high at low rail pressures and short
energizing times and less pronounced at high rail pressures.
In the case of the AE300 engine using 4 injectors the variation for low injection quantities
would cause rough idling while the variations for high injection quantities would impact the
maximum power developed by 2% – 3%.
As the AE300 engine uses more than one injection per compression stroke (= per injection
event at TDC) the ECU has to be able to control the injection quantity to very tight
tolerances. This will result in a smooth idle and prevent torque pulses especially at higher
power settings.
The manufacturer of the injectors tests and marks each injector with a set of adjustment
values, the “Injector Quantity Adjustment” code. This IQA code consists of 6 alphanumeric
positions and is printed on the injector housing. It tells the ECU how to adjust its injection
map so a specific injector will produce the injection quantity and timing intended by the ECU.
For smooth running and predictable engine power the AE300 EECU must know the injection
behavior of each individual injector (indicated by its IQA code) for each cylinder position.
The AE300-Wizard’s IQA functions described below support the maintenance organizations in
their documentation, installation, trouble shooting and repair tasks.
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9.1.2 Reading IQA Codes
This allows to see the IQA codes currently stored and used by the EECU.
Steps:
1) Enter “Qualified Maintenance” mode
2) Select «IQA» tab
3) Click on Read ALL Cylinders button
The IQA codes for a cylinder must be identical for ECU A and ECU B
If the IQA codes for a cylinder do not agree, the values will be displayed in RED
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9.1.3 Saving IQA Codes
For documentation purposes or to be able to reuse the IQA codes (e.g. in case of EECU
replacement) it is recommended to save the IQA codes read from an EECU into a file.
Since AE300-Wizard version 1.2.0.xxx the IQA data files are compressed and encrypted with
a name of the form “IQA_eng-serial_YYYYMMDDhhmmss.ae3” while prior to version
1.2.0.xxx the files where saved in XML format and a name of the form
“IQA_eng-serial_YYYYMMDDhhmmss.xml”.
Steps:
1) Enter “Qualified Maintenance” mode
2) Select «IQA» tab
3) Click on Read ALL Cylinders button
4) Click on Save ECU IQA data to file button
5) Select a file name
6) Press the Save button
The resulting IQA data file contains in addition to the IQA data the ID information (engine
and ECU serial numbers, revisions etc.) as well. It can be found on the PC system in the
folder:
“My Documents\Austro Engine\AE300-Wizard\IQA_File”
e.g. under the name “IQA_eng-serial_YYYYMMDDhhmmss.ae3” as selected in Step 5).
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9.1.4 Entering IQA Codes
When a new injector has to be installed, the IQA data of this injector has to be entered at
the corresponding cylinder position.
Example: New injector with IQA code 5PP83S to be installed into cylinder 3
1) Enter “Qualified Maintenance” mode
2) Select «IQA» tab
3) Click on Read ALL Cylinders button
4) Position mouse cursor into input field of “Cyl. 3” and enter IQA code (5PP83S)
5) Click on Write Cyl. 3 button
6) Click on Read ALL Cylinders button for verification
“Checksum O.K.” indicates, that the IQA code (5PP83S) has been entered correctly
If the checksum is not O.K. the IQA code might have been misread or misspelled
7) Click on Save ECU IQA data to file for documentation (see “9.1.3 Saving IQA
Codes”)
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Scanning Injector IQA Codes
As explained in chapter “9.1.4 Overview” it is important to update the IQA code stored within
the EECU if an injector has to be replaced.
Manually entering the new IQA code has to be performed as described in chapter “9.1.4
Entering IQA Codes” on page 73. The typeface used to print the IQA code onto the injector
housing makes it hard to distinguish between letters like “1” and “I” or “8” and “B” etc.
especially under adverse lighting conditions or if the injector has already been installed in its
place. Because of that, reading errors can happen and the erroneous IQA code (secured by
checksum and range check) will be refused by the ECU.
Therefore a 2-dimensional DataMatrix code has also been printed on the injector housing
which besides some other data contains the IQA code in machine readable form.
1) DataMatrix code
2) IQA Code
A special handheld scanner is available from Austro Engine, which has been programmed for
this situation (size, contrast, and lighting) and will scan the DataMatrix field, extract the IQA
code from the data stream read and send the resulting 6 letters/numbers via USB to the PC
system running the AE300-Wizard.
-
The scanner connects to a USB port of the PC system and behaves like a keyboard
connected via USB (no device driver installation required)
Position the mouse cursor into the required IQA input field of the AE300-Wizard
The scanner has to be placed about 10 cm over the DataMatrix field to be scanned, it
emits a red laser aiming dot to help with positioning
Press the scan button and reposition the scanner until it lights up green and makes a
beeping sound while vibrating in your hand to indicate a successful scan.
See chapter “3.2.3 USB DataMatrix Scanner” on page 15 for ordering information
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EECU Replacement
When replacing an EECU the stored IQA codes have to be downloaded from the “old” EECU
before removing it from the aircraft. It is recommended to perform this download earlier,
before any problems arise and to save this downloaded IQA data file as described in chapter
“9.1.3 Saving IQA Codes” for archiving and documentation purposes.
Forgetting this step before installing the new EECU will result in additional work for the
mechanic. To gain access to the injectors to be able to read or scan the IQA codes directly
from the installed injectors, the turbo charger and the injector cover of the engine has to be
removed and reinstalled (see “Maintenance Manual AE 300”, document number E4.08.04).
After installing the new EECU, the following steps must be performed to write the IQA codes
saved from the previous EECU into the newly installed EECU:
1) Enter “Qualified Maintenance” mode
2) Select “IQA” tab
3) Click on Read ALL Cylinders button
-
A brand new, initialized EECU must show the IQA code “AAAAAE”. This IQA code
indicates an adjustment value of “0” to the EECU including a correct checksum.
○ If the new EECU shows a “real” IQA code, chances are, the EECU has been
initialized with the IQA codes on file at Austro Engine for this engine serial number.
○ If the new EECU shows a “not set” in the IQA code fields, the EECU must be
initialized by Austro Engine before it can be used on an engine.
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4) Load the IQA data file saved from the previous EECU
5) Click on Load IQA data from file button
6) Select “Wizard files” or “XML” format
7) Select filename
8) Click on Open button
9) The IQA data read in from the file will be filled into the input fields
10) Click on Write ALL Cylinders button
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After the new IQA codes have been written, they will be automatically read back for
verification:
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EECU Software Update
To allow EECU software updates to be performed in the field by qualified maintenance
personnel, the AE300-Wizard includes this functionality required for “Field Loadable
Software” (as it is defined by the certifying authorities) starting with version 1.2.0.xxx.
Only trained, qualified maintenance personnel shall update EECU software in the field as it is
critical to understand the upgrade process and to decide, if the upgrade process has
completed successfully and the engine may be released into service. Under no circumstances
an engine shall be released with just a partial or unsuccessful software update.
The AE300-Wizard performs pre and post update checks as well as automatic retries to help
and guide the maintenance technician through the update process and final decision making.
Both the new EECU software and update instructions for the AE300-Wizard are contained in
a single file, called “Flash Container (FCT)”. This FCT file will be distributed to the field
organization to update their aircraft’s engines using the AE300-Wizard.
Which FCT and SW version is compatible with which engine type and EECU HW-revision can
be found in the latest revision of Austro Engine AE300 service bulletin MSB-E4-003/rev.
10.1 FCT Naming Convention up to Baseline 25
Up to ECU-SW baseline 25 the following naming conventions are used for the FCT file:
“E4FCT_rr_VCxx_t_yy_ds.ae3” (e.g., E4FCT_01_VC33_0_07_25.ae3)
○ E4FCT
○ rr
○ VCxx
○ t
○ yy
○ ds
○ ae3
Flash container for E4 or E4P engine
Revision of flash container (e.g., “01”)
Major revision of ECU SW (e.g., “VC33”)
Engine type (e.g., “0” for E4-B/DA42, “1” for E4-A/DA40)
Minor revision of ECU SW (e.g., “07”)
Data set revision of ECU SW (“e.g., “25”)
Extension of AE300-Wizard files (compressed and encrypted)
10.2 FCT Naming Convention starting with Baseline 26
Since ECU-SW baseline 26 (VC33_x(P)_07_26) and (VC33_x(P)_07_26-01) the applicable 8
ECU-SW variants for engine type E4-A, E4-B, E4-C and E4P-C dependent on the installed
EECU-HW revision have been combined into ONLY ONE “extended” flash container:
ExtE4FCT_rr_VCxx_yy_ds.ae3 (e.g., ExtE4FCT_00_VC33_07_26.ae3)
This flash container can only be used with AE300 Wizard V1.3.18.450 or later and will allow
the AE300 Wizard to read the engine type and HW-version of the connected EECU and to
select the applicable SW-variant.
○ ExtE4FCT
○ rr
○ VCxx
○ yy
○ ds
○ ae3
Extended flash container for E4 or E4P engine
Revision of flash container (e.g., “00”)
Major revision of ECU SW (e.g., “VC33”)
Minor revision of ECU SW (e.g., “07”)
Data set revision of ECU SW (“e.g., “26”)
Extension of AE300-Wizard files (compressed and encrypted)
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10.3 Minimum Requirements
The following items are required to perform field updates of the EECU software:
- Full installation of AE300-Wizard version V1.3.18.450 or higher.
- CAN-USB Adapter QM” to unlock “Qualified maintenance mode”, see chapter “3.2.2
USB/CAN Adapter” for ordering information.
- The FCT file for the engine type to be updated e.g., “E4FCT_01_VC33_0_07_25.ae3” for
an E4-B (DA42 A/C) data set revisions up to 25 (minimum data set revision is 16).
- Or Extended FCT if updating to ECU-SW baseline 26 or higher.
10.4 Overview of the Software Update Process
The EECU software update process consists of the following phases which are performed by
using the AE300-Wizard «Update SW» tab:
-
-
-
Set up the aircraft for a diagnosis session as described in chapter “6.3.2 Engine not
Running” on page 21.
The estimated time to perform the update depends on the flash container (FCT) type. If
the FCT includes only new SW configuration data, the update time will be about 5
minutes per engine including the required operator’s actions (pure data transfer time is
about 1 minute).
If the flash container (FCT) involves the complete ECU SW (e.g. when upgrading from
VC33.6 to VC33.7) the update time will be about 8 minutes per engine including the
required operator’s actions (pure data transfer time is about 4 min).
Connect the AE300-Wizard to the CAN bus of the engine to be updated.
Load the desired (usually the latest) flash container (FCT or ExtFCT) file into the AE300Wizard.
The AE300-Wizard will then use the information from the FCT or ExtFCT to check if it is
possible to update the EECU with this specific flash container.
The AE300-Wizard checks required items to accept the software update. Relevant items
are, the engine type (i.e., E4-A or E4-B), the HW version, the SW version, and the
Wizard version in use.
If any of these checks reveal an unsupported configuration, the AE300-Wizard will
inform the maintenance technician about it and will abort the update session. There is
no option to allow an operator to force an update erroneously or willingly.
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The update can only be performed on a stopped engine; therefore the AE300-Wizard
will check for “aircraft on ground” and a stopped engine before allowing an update.
If the checks show a supported configuration, the actual software update process will
commence.
In the “Flash progress information” field, the AE300-Wizard informs the maintenance
technician about the steps of the update process:
○ Step 1: To document the engine situation before the attempted software update an
engine log will automatically be saved under the name:
“Flash_Autosave_Engine_Log_YYYYMMDD_hhmmss.ae3”.
○ Step 2: ECU-A will be updated.
○ Step 3: ECU-B will be updated.
○ Step 4: The fault code memories (FCMs) of both ECUs will be checked for flash
memory errors.
○ Step 5: The maintenance technician will be informed about success or failure of the
update process and whether or not the engine is in a serviceable condition. Also,
the number of error entries per ECU prior to the software update and the name of
the “Autosave_Engine_Log” will be provided.
○ Step 6: After completion or abort of a software update process an automatically
compiled log file of the update process will be saved in the folder:
“My Documents\Austro Engine\AE300-Wizard\Flash” with the name:
“FlashLog_EECU-Serial-number_YYYYMMDD_hhmmss.ae3”.
-
○ Step 7: If the update was successful the fault code memories of both ECUs will be
cleared, the ECUs disconnected from the AE300-Wizard and restarted for further
use.
A successful completion of the update process will be indicated by a green message.
Unsuccessful completion or abort of the process will be indicated by a red message.
Only if both ECUs have been updated successfully, the engine is serviceable!
This is important, because if one ECU has been updated while the other one still contains the
older software revision or no working software at all (e.g. because of a power failure or
disconnected cable during the programming session), the engine in question will still start up
and run on one ECU, but because of the loss of redundancy it does not conform to the type
certificate anymore and has to be considered unserviceable.
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10.5 Detailed Steps of the Software Update Process
The EECU software update process consists of the following steps which are performed by
using the AE300-Wizard «Update SW» tab.
Before starting the update process, the flash container file (FCT) received should be copied
into the standard folder holding software update related files.
For example:
Copy: “E4FCT_01_VC33_0_07_25.ae3” (for baseline 25 on E4-B)
or “ExtE4FCT_00_VC33_07_26.ae3” (for baseline 26 and higher, all engine types)
To:
“My Documents\Austro Engine\AE300-Wizard\Flash”
Steps:
1)
2)
3)
Set up the aircraft for a diagnosis session as described in chapter “6.3.2 Engine not
Running” on page 21 – estimated time to perform the update is about 5 or 8
minutes per engine including the required operator’s actions (pure data transfer
time is about 1 min) depending on the type of the flash container (FCT) (see
chapter “10.4 Overview of the Software Update Process” on page 79).
Connect to the ECU
Select «Update SW» tab
4)
Click on Load Flash Container button
4)
Select FCT file
5)
Press Open b
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6) When selecting an “Extended Flash Container” for an upgrade to baseline 26 or
higher, the following message box will present the only applicable selection for the
current engine type and EECU-HW revision found by the Wizard (e.g., E4-A on HWRev AE):
6a) Select engine type
6b) Press Next
7) The next message box verifies the intended configuration to be updated:
8) After verifying the pre-flash conditions specified in the FCT or ExtFCT, the actual
update process will start, and the progress will be shown in the “Flash progress
information” field:
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9) After a successful software update the following GREEN MESSAGE BOX will be
shown:
-
Note the name of the “Flash_Autosave_Engine_Log_YYYYMMDD_hhmmss.ae3”
-
In case of an unsuccessful update (RED MESSAGE BOX) continue with step 9a.
9a) If the information in the RED MESSAGE BOX after an unsuccessful software update
suggests a retry of the update process – continue with section “10.7 Software
Update Retry” on page 86.
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9b) If the information in the RED MESSAGE BOX after an unsuccessful software update
asks to call “Austro Engine After Sales” for support – please do so and do not
release the engine in question back to service.
10) Reconnect to EECU
11) Save an engine log as described in section “8.2.1 Engine Log File” on page 41 for
documentation purposes.
12) Use the checklist provided in the “Maintenance Manual AE300” to complete the update
process and to make sure, both ECUs have been updated to the same software
revision and both ECUs are functional.
ECU-A and ECU-B must have identical software revisions after the update!
11) Disconnect from ECU and return engine into service
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10.6 Documentation of Software Update Process
To document the successful software update, the following three files are required:
1. Engine data (i.e., serial, HW and SW versions) before the software update:
This is contained in the automatically saved engine log file presented in step 9)
above:
In “My Documents\Austro Engine\AE300-Wizard\Engine_Log”
as “Flash_Autosave_Engine_Log_YYYYMMDD_hhmmss.ae3”
2. Logfile of the software update process:
In “My Documents\Austro Engine\AE300-Wizard\Flash”
as “FlashLog_EECU-Serial-number_YYYYMMDD_hhmmss.ae3”
3. Engine data (i.e., serial, HW and SW revisions) after the software update
It is contained in the engine log file to be saved during step 9) above:
In “My Documents\Austro Engine\AE300-Wizard\Engine_Log”
as “Engine_Log_YYYYMMDD.ae3”
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10.7 Software Update Retry
In most cases after an abort or unsuccessful completion of a software update attempt due to
operator intervention, unexpected event, or verification failure – a manual retry of the
software update process is possible.
The AE300-Wizard will try to establish connection to at least one ECU channel to perform the
pre-flash condition checks and after having determined, that a previous flash operation has
failed, will offer the maintenance technician the option of a new software update.
If the AE300-Wizard is not able to establish connection to any of the ECUs, then it will not
offer any option to continue or retry the update but will ask the operator to contact Austro
Engine “After Sales” department for help.
Steps:
1) Set up the aircraft for a diagnosis session as described in chapter “6.3.2 Engine not
Running” – estimated time to perform the update is about 5 or 8 minutes per engine
including the required operator’s actions (pure data transfer time is about 1 or 4 min)
depending on the type of flash container (FCT).
2) Connect to ECU
3) Select «Update SW» tab
4) Click on Load Flash Container button
4) Select FCT file
5) Press Open button
6) Click on Yes for a software update retry (“Did a previous flash operation fail …”)
7) Continue with Step 6) of section “10.5 Detailed Steps of the Software Update
Process”.
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10.8 Error Handling during Software Updates
The AE300-Wizard uses several methods to ensure successful completion of the update
process or to guide the maintenance technician through situations of unsuccessful attempts
or aborts.
10.8.1 Pre-Flash Conditions
As indicated in chapter “10.4 Overview of the Software Update Process” on page 79, a set of
parameters (“pre-flash conditions”) will be checked by the AE300-Wizard to match the
loaded flash container with the engine it is connected to. If a mismatch is detected, the
AE300-Wizard will report the type of mismatch (e.g., wrong engine type or revision
incompatibilities) and will abort the attempted update session. For example, trying to flash
E4-B software onto E4-A engine:
Another set of conditions is used to check the general situation of the engine (e.g. engine
stopped, aircraft on ground, battery voltage high enough, etc.) before commencing or
aborting the update session. For example, battery voltage is too low:
10.8.2 Automatic Retries
A hierarchy of retries has been implemented to ensure robustness for the connection to the
EECU, the data transfers and the programming of the ECU flash memory. If the retries
remain unsuccessful, the update process will be aborted, the maintenance technician
informed about the reason of the abort and a restart of the update process will be
suggested.
- In case of loss or disruption of the CAN connection, automatic retries attempt to reestablish the physical and/or logical connection (“Connect ECU”) to the EECU.
- If the loss of connection lasts too long and a time-out occurs, manual reconnection by
the maintenance technician is required. After a manual reconnect, the AE300-Wizard will
then continue or restart the update process depending on the given situation.
- In case of data transfer failures (e.g., due to electrical interference, cabling or connector
problems) up to 3 attempts to resend the data will be performed before an abort.
- For flash memory erasure or programming problems, up to 3 retries will be attempted.
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10.8.3 Aborts
The reasons for an abort can be grouped into three areas and the AE300-Wizard will report
the reason for the specific abort to the maintenance technician and will suggest the next
step.
- Not meeting all the pre flash conditions will lead to an abort without even attempting
the software update session.
The maintenance technician can abort at any time by clicking on the Cancel button
during a software update session.
- Unexpected and unrecoverable (by automatic retries) events during the software update
sessions, for instance loss of power in the aircraft, loss of CAN connection or similar
influences, will lead to an abort.
In most of these scenarios, the reason for the abort can be resolved by the maintenance
technician (reestablish power to the aircraft, reconnect the CAN cable, etc.) and a manual
restart of the software update will be successful.
E.g., bus voltage too low:
-
E.g., update process cancelled at user’s request:
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10.8.4 Unsuccessful Completion
After an uninterrupted software update session, the AE300-Wizard will perform a number of
post flash checks (checksums, flash memory related FCM entries, consistency of ECU-A and
ECU–B, etc.) to verify success of the update session on both ECUs.
If these checks reveal any problems or inconsistencies, a RED MESSAGE BOX will inform
the maintenance technician about the detected problem.
Depending on the type of problem detected by the AE300-Wizard, the information in the
message box will either suggest a manual restart of the software update by the maintenance
technician, if this is a viable option, or will ask the technician to call Austro Engine for
support in determining further actions.
If (i.e., after several unsuccessful software update attempts) the EECU is in a state where it
does not respond to queries from the AE300-Wizard anymore and therefore the pre flash
conditions cannot be verified anymore – no further software update attempts will be allowed
by the AE300-Wizard and it will ask the maintenance technician to call Austro Engine for help
to solve the situation.
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10.8.5 Successful Completion
After an uninterrupted software update session, the AE300-Wizard will perform a number of
post flash checks (checksums, flash memory related FCM entries, consistency of ECU-A and
–B, etc.) to verify success of the update session on both ECUs.
If these checks don’t show any problems or inconsistencies, the FCM of both ECUs will be
cleared and a GREEN MESSAGE BOX will inform the maintenance technician about the
successful software update.
Results of a successful software update:
- Before the update, ECU-A contained 1 diagnostic trouble code (DTC)
- Before the update, ECU-B contained 2 DTCs
- The information about those DTCs (Fault Code Memory) has been automatically stored
in an engine log called: “Flash_Autosave_Engine_Log_20101115_161032.ae3” for
later analysis
- After the update, the FCMs of both ECUs have been cleared
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Calling for Support
To get help during fault finding the following steps should be taken when contacting Austro
Engine “After Sales” support for help.
11.1 Saving Failure Information
Austro Engine “After Sales” and engineering support asks its customers to assemble the
following failure related data files before calling for support:
11.1.1 First Step – Engine Log
As described in chapter “8.2.1 Engine Log File” on page 41 download the failure data from
fault code memory, engine statistics and ID information from the EECU and save it to the PC.
11.1.2 Second Step – Event Recorder File
As described in chapter “8.2.2 Event Recorder File” on page 42 download the event recorder
data in HexDump format from the EECU and save it to the PC.
11.1.3 Third Step – Data Logger File
As described in chapters “8.2.3 Data Logger File (Full Flight Time)” on page 43 and “8.2.3
Partial Data Logger File (Fraction of Flight Time)” on page 43 download the data from the
EECU and save it to the PC.
11.1.4 Fourth Step (optional) – Live View recordings or Screenshots
Depending on the situation Live View recordings of the failure or screenshots of the
corresponding Wizard page might be helpful and should be included.
11.1.5 Fifth Step (optional) – IQA Data File
In case of problems during injector or EECU replacement activities please also supply the
IQA data files saved before and/or after the replacement activities. See chapter “9.1.3
Saving IQA Codes” on page 72 for a description on how to save IQA data to a file.
11.2 Sending Maintenance Information
The data files assembled above shall be mailed to Austro Engine:
mailto:
phone:
AE300data@austroengine.net
+43 2622 23000 - 2525
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Appendices
12.1 Error Messages of the AE300-Wizard
List TBD
12.2 Details – Freeze Frame
12.2.1 Combined Engine Status
Bit
0
1
2
3
4
5
6
7
Description
1 = engine status “afterrun”
1 = engine status “start”
1 = engine status “normal”
1 = rail pressure governing via metering unit
1 = squat switch depressed (“weight on wheels”) → aircraft on ground
Proposed active ECU (0 = ECU A, 1 = ECU B)
Voter decision (0 = ECU A, 1 = ECU B)
1 = ECU is passive
0 = ECU is active
Table 5
Combined Engine Status
Note:
1) Bit 0 is the least significant bit or the right most position of the bit mask
2) If bit 5 and 6 do not agree (e.g. bit 5 = 1, bit 6 = 0) the pilot has overruled the voter
and manually selected ECU-A to become active.
12.3 Details – Event Recorder
12.3.1 Event Status
Bit
0
1
2
3-7
Description
1 = start of event
0 = end of event
1 = ECU is passive
0 = ECU is active
1 = RAM queue overflow when previous event was appended
0 = RAM queue was OK when previous event was appended
not used
Table 6
Event Status
Note: bit 0 is the least significant bit or the right most position of the bit mask
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12.4 Details – LiveView
12.4.1 Self-Test Timeout Flags (SlfTst_stTOutErr)
Bit
Description
0
1
2
3
4
1 = timeout while waiting for a successful tester intervention (max 1 sec)
not used
not used
1 = timeout while waiting for the ECU switch over for a passive ECU (max 30 sec)
1 = timeout while waiting for the ECU switch over for an active ECU (max 0.5
sec)
1 = timeout when executing the function tests (max 30 sec)
not used
5
6-15
Table 7
Self-Test Timeout Flags
Note: Bit 0 is the least significant bit or the right most position of the bit mask, bit 15 is the
most significant bit or the left most position.
12.4.2 Self-Test Release Condition Flags (SlfTst_stRls)
Bit
Description
0
1 = Release to start self-test is given (this is a summary bit, if all required
conditions are met, it will be set and the self-test will start)
1 = No failure pending (a “0” here would indicate a previous failure status is
preventing the self-test from starting)
1 = bit 5 AND bit 6 are set (to 1)
1 = Request of the pilot to start the self-test is present (i.e. the self-test switch in
the cockpit is being pressed)
1 = Pilot request for this run of self-test (detected by rising edge of self-test
button signal).
0 = Self-test has not been started yet or self-test has been deactivated
1 = Power lever is in low idle position (< 5%)
1 = Prop speed is idle (<1000rpm) AND weight on wheels switch is pressed (=
A/C on ground) AND engine run state is NORMAL (bit 2 of “combined engine
status” must be set, i.e. NOT start, afterrun)
1 = current propeller speed is lower than 800 rpm
0 = current propeller speed is higher than 1000 rpm
1
2
3
4
5
6
7
Table 8
Note 1:
Self-Test Release Condition Flags
Bit 0 is the least significant bit or the right most position of the bit mask, bit 7
is the most significant bit or the left most position.
Note 2:
Since ECU SW version VC33_x_05_12, a gearbox oil temperature below 40° C
will also prevent the self-test from starting.