Autopilot EFIS/One & EFIS/Lite Installation Manual 06/15/04 Copyright blue mountain avionics, inc. 2004 1.0C DRAFT Page 1 of 20
Revision History Release History 1.0 Draft Release of Autopilot Install Guide MT 06/17/2003 1.1 Update of draft to include new Servo (Rev3) MT 09/01/2003 2.0 Final hardware release GR 03/01/2004 2.1 Tuning examples GR 06/15/2004 Page 2 of 20
Table of Contents Limited Warranty...4 Responsibilities of Buyer...4 Exclusions...4 Overview...5 Important Safety Information...5 Autopilot System Components...6 Rev 2 Servo...6 Rev 3 Servo (currently shipping)...6 Open Frame Servo & Cables...8 Autopilot Controller...10 Electrical Connections...12 Power...12 EFIS/One Processor to Autopilot Interconnect...12 Servo Interconnect Cables...12 Autopilot Disconnect...12 Servo Mounting...13 Autopilot Controller Mounting...14 Autopilot Servo Dimensions Rev 3 Servo....15 Software Configuration and Initial Testing....17 Physical Dimensions and Operation Limits...22 Cable Specifications...23 Open Frame Servo (Rev 1)...23 Closed Frame Servo (Rev 2)...24 Closed Frame Servo (Rev 3)...25 Notes:...26 1.0C DRAFT Page 3 of 20
Limited Warranty Blue Mountain Avionics LLC (hereinafter referred to as BMA ) provides the following limited warranty. If you should have any questions, please contact the avionics dealer that sold you the BMA product or contact BMA directly. If during the one (1) year period from the date of original shipment from BMA, your BMA Product is found on authorized inspection to have a defect in material or workmanship, BMA or an authorized representative will repair such defect or replace the defective unit without charge for parts or labor. Routine maintenance work and the results of normal wear are not covered by this warranty except as noted. BMA reserves the right to utilize reconditioned subassemblies as warranty replacements in the repair of the product. In the event BMA determines that the unit cannot be repaired, BMA will replace the defective unit with either the same model product or one that is reasonably equivalent. At BMA s discretion, replacement units or repaired units may include software or hardware updates and revisions that alter some characteristics of the product. Should warranty service be required, the warranty period will be extended by the number of days that elapse between the date a defect is reported and the date that the repaired unit is returned. BMA assumes no responsibility for payment of any repair services performed by third parties including removal of the unit from the aircraft, inspection, packaging, handling, or installation unless such services are authorized in advance and in writing by BMA. BMA reserves the right to make changes, upgrades, and improvements to its products without incurring any obligation to install such changes, upgrades, and improvements in previously manufactured products. If during the warranty period, title to the aircraft in which the product is installed is transferred the remainder of the warranty may be transferred to the new owner by notifying BMA in writing of the transaction. Such notification must include complete address information for the original owner and the new owner as well as the N number and serial number of the aircraft and the serial number of the BMA product. Please contact BMA directly if you have any questions regarding the BMA limited warranty. This limited warranty is the only warranty which BMA makes with respect to your BMA Products. BMA disclaims all other warranties relating to the product including warranties of merchantability and fitness for a particular use. In any event, BMA shall not be liable for any incidental or consequential damages. Some states do not allow the exclusion or limitation of incidental or consequential damages and some states do not allow limitations on how long an implied warranty may last; therefore, the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights. You may also have other rights that vary from state to state. In the event any of the provisions of this warranty are found by statute or by applicable administrative or judicial entity to be unenforceable, the remaining provisions shall remain in force. Responsibilities of Buyer Please read the Pilot s Guide of your BMA Product and the equipment to which it is connected. The information provided in your Pilot s Guide covers operation and safety precautions. This warranty does NOT cover expenses incurred due to a lack of understanding of the functioning of the product when it is operating as designed. In order for BMA to provide proper warranty service, you may be required to: Supply proof of purchase documents, permit BMA or an authorized representative to provide the applicable warranty service during normal business hours, retain and provide to BMA (upon request) any documentation of the installation of the product in your aircraft, provide BMA with all pertinent information regarding the symptoms, failure, or defect initiating the request for warranty service. Exclusions This warranty does not cover the following; failures that are the result of improper installation, maintenance, or repair, failures that result from neglect, abnormal acceleration or deceleration, shock, modification, accidental damage, theft, vandalism, or exposure to extremes in temperature or relative humidity, radio frequency interference generated by equipment operated in violation of applicable FCC rules. All product or material returned to BMA must be properly packed and labeled with a Returned Material Authorization (RMA) number. Page 4 of 20
Overview The EFIS/One Autopilot is an all digital, self calibrating, two axis Autopilot system designed specifically for the EFIS/One. The Autopilot kit includes two servos, one controller and necessary cables. Each servo incorporates the latest in small, high torque mini DC motors, a high quality gearbox, a high resolution position encoder and a magnetic clutch all enclosed in an aircraft quality housing. From within the EFIS/One system, the Autopilot can be used to: Track any selected course using a Course Bug on the EHSI Track any selected heading using a Heading Bug on the EHSI Track and fly a GPS flight plan from the EFIS/One built-in GPS receiver Track an external NAV receiver signal for the selected VOR radial Track a Localizer and Glideslope signal from an external NAV receiver Climb or Descend at a given climb or descent rate Climb or Descend at a given indicated airspeed Fly to and hold a specific altitude. The blue mountain autopilot system uses the internal sensors to precisely detect aircraft movement in all three axes. Other internal sensors for airspeed and altitude also play a role in the function and operation of the Autopilot providing the best dynamic performance possible. Important Safety Information Please read this document thoroughly before installing your Autopilot system. If you have any doubt or questions, do not hesitate to get help, either by calling Blue Mountain Avionics or by obtaining the help of a qualified A&P mechanic or avionics technician. Incorrect installation could lead to unpredictable results and possible loss of aircraft control. Under no circumstance should the operation of the aircraft s control system be limited or restricted by the attachment of the Autopilot motors to the control system. Under no circumstance should the Autopilot s servo arm move more than 60 degrees in either direction from a central or neutral position. Move the aircraft s control system to maximum deflection in either direction to ensure that the servo arm does not move more than 120 degrees from full deflection in one direction to full deflection in the other. Under no circumstance should the Autopilot s servo arm be able to go over center. Your aircraft s control limitation should also limit the maximum travel possible on the servo arm which must not get close to going over center. When the aircraft s controls are in the neutral position, the servo arms must also be in their neutral position, perpendicular to the connecting push rods and at the center of travel for the servo arm. Under no circumstance operate the Autopilot without a Master Autopilot power switch. Turning off the power is different from the disengage signal which is a software disconnect. If your EFIS/One has failed or stopped processing the disengage signal will not work. Turning off the Master Autopilot power switch removes power from the servo clutches, controller and motors, thereby preventing it from controlling the aircraft. 1.0C DRAFT Page 5 of 20
Autopilot System Components The EFIS/One Autopilot system consists of the Autopilot software, which is contained and functions within the EFIS/One, the Autopilot Controller, two Autopilot Servos and associated interconnect wiring harnesses. Rev 2 Servo Rev 3 Servo (currently shipping) Page 6 of 20
The EFIS/One Autopilot system contains two Autopilot servos -- one for aileron control and one for elevator control. Each Autopilot system contains two 15 cables which connect the Autopilot motors to the Autopilot controller. Please use an avionics shop to properly remove pins from the connectors or to shorten the cable. The cable is a straight through cable. The newer Rev3 servos are connected with a DB9 cable. 1.0C DRAFT Page 7 of 20
Open Frame Servo & Cables The first generations of the Autopilot servos (rev 1) were installed in an open frame mount. Other than the enclosure, these servos are identical to the current production model. The open frame servo is connected to the Autopilot controller using the cable shown below. Servo (Rev 1). Servo Cable Connections for Rev 1 Servo Page 8 of 20
Autopilot Controller Connector and Clutch power wires The Autopilot cable must be attached to the servo as follows: Wire K connects to two positions, on opposite sides, on the servo motor. Connect to the servo POSITIVE + by removing the small brass screw. There is a brush and spring below the screw please be careful not to lose it. Loop the second ring terminal on the K wire to the opposite side of the servo and retain with the brass screw. Only install one ring terminal under the screw. Some cables were shipped without the Y end. If you have these, cut off the ring terminal and crimp on a new one that has two wires, one for each brush connection. Repeat the above for the M wire but connect to the motor s negative terminals, one on each side of the motor. Important: the small brown five pin connector is installed onto the servo encoder, with the lip facing the motor, or toward the left in the picture on the previous page. The remaining two wires L and J connect to the servo clutch. The clutch wires are shown as white wires on the previous page. Polarity of these two is not important. The MIL-Spec round connector plugs into the Autopilot controller. 1.0C DRAFT Page 9 of 20
Autopilot Controller The Autopilot controller is shown below. On one end are two connectors to connect the servo cables, the left connector is for the aileron servo and the right for the elevator. The controller measures 4 by 8 by 2 Page 10 of 20
The following picture shows the connections, power and EFIS/One CPU on the opposite end of the controller. Serial port is not currently used. The controller can be mounted in any orientation in the aircraft. All aircraft position sensing is in the EFIS/One processor. Interconnect to EFIS/One CPU Power Cable 1.0C DRAFT Page 11 of 20
Electrical Connections Power Aircraft power from 10-32V is supplied to the Autopilot controller which, in turn, supplies power to each of the servos through the BMA supplied interconnect cables. A 10 Ampere circuit breaker should be used in conjunction with a Master Autopilot switch to supply power to the controller. The black or green wire is ground. Removing power from the controller via AP Master Switch also removes power from the servos and their associate magnetic clutches. Without power, there is no physical link between the servo motor and the controls of your aircraft. Note, there is also an Autopilot disengage option but the disengage option does not remove power from the servos and may not disengage the Autopilot if there has been a malfunction of the EFIS/One system. EFIS/One Processor to Autopilot Interconnect To connect the AP controller to the EFIS/One CPU install the supplied Ethernet Crossover cable into the controller and EFIS/One CPU. If you need a different length cable, these are readily available at most computer stores. If purchasing a cable from a computer store, it must be the crossover type of cable. Standard Ethernet cables will not work. Do not cut, splice or otherwise modify this cable. Servo Interconnect Cables The system is supplied with two servo interconnect cables. One end is connected to the controller and the other to the servo. If you need to change the length of this cable BMA recommends taking it to an avionics shop. An avionics shop will have the correct tools to properly remove the pins, crimp on new pins and reinsert the new pins into the mil spec connector. These cables are very expensive. Replacement cables cost $150 each. Alternatively, this cable can be cut and re-spliced. If you decide to do this, check the cable out after splicing. The cable is wired straight through. Check each pin for proper location and continuity from end to end. Do not use automotive splice connectors. Autopilot Disconnect The EFIS/One processor can be triggered to disconnect the Autopilot via the use of a SPST momentary switch. This switch is connected to ground and to pin 15 of the DB25 Encoder connector on the EFIS/One. To re-engage the Autopilot, press the AP button on the bezel and then press the center concentric knob to select the Autopilot check box. A flashing Autopilot message in the ADI screen indicates that the AP is selected but cannot be engaged due to an exception condition such as, GPS navigation is selected but no waypoint has been entered or External Nav is selected and no valid signal is present from the Nav receiver. Initially use the Heading Bug mode to test the AP. Note: The AP disconnect option signals the EFIS/One processor which in turn turns off the Autopilot. If the EFIS/One has malfunctioned the disconnect feature may not function. In this case, turn off the AP Master Switch which removes power from the AP controller and servos. Page 12 of 20
Servo Mounting The servos are supplied with a bell crank arm as standard but a capstan can be provided if required. The standard cables which link the servos to the EFIS/One controller are 15ft in length providing flexibility with mounting options of the servos and the controller. As the builder, you will be required to fabricate a mount to hold each servo that is suitable for your situation. Below are pictures showing how one customer has mounted the servos in a Lancair IV P. Courtesy of Bob Pastusek, Jim and Roz White To attach a push rod to the bell crank arm, first remove the bell crank by using a 5/64th Allen wrench through the small hole in the servo case. Drill the bell crank to the suitable size for the th selected rod end, normally 3/16. Make sure you put the 3/32nd square key back in place and that the set screw is tight if you adjust or remove the bell crank. The above photos show the Rev 2 Servo. 1.0C DRAFT Page 13 of 20
Rev 2 Servo. A bracket should also be fabricated and attached to the motor housing or aircraft to prevent the bell crank arm from sliding out of the end of the motor in the event the set screws come loose. If the bell crank was to come loose and fall out of the end of the servo, it could jam the aircraft s controls causing the pilot to lose control of the aircraft. The two servos are designed to be connected to the aircraft s pitch and roll controls. It is possible just to have one servo and use it to control the aircraft s roll. The system will move the bell crank a maximum of approximately 2.5 inches, 1.25 inches from a center or neutral position. The control surfaces do not have to move very far for the Autopilot to fly the aircraft, so take this into consideration when connecting the servos to the aircraft s control system. When the aircraft s controls are moved to their full travel positions, check that the servo arms move at least 45 degrees but no more than 60 degrees in each direction from center or neutral position. The servo arms must be perpendicular to their push rods when in the neutral position. Autopilot Controller Mounting The controller can be mounted anywhere in the aircraft, although we do supply an interconnect cable from the EFIS/One to AP Controller which is 7 long. Do not cut or splice the interconnect cable. The controller can be mounted in any orientation and is held in place with four 10-32 screws. The controller does not have to be level or in any particular orientation. Page 14 of 20
Autopilot Servo Dimensions Rev 3 Servo. 1.0C DRAFT Page 15 of 20
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Software Configuration and Initial Testing. The Autopilot software is part of the 2.15 and higher releases of the EFIS/One, EFIS/Lite and EFIS/Sport products. To configure the software, simply go to the Setup screen and enter the proper parameters. The Setup screens for the EFIS/Lite EFIS/Sport and EFIS/One look like this: Aileron Setup Looking at the screen above, it s easy to setup your Autopilot. Set the Gain to Positive 40 as shown in the pictures, and start up your EFIS. Here s all you do: 1. Go to the Settings screen and press Set Level so the EFIS thinks it s dead level with your hangar floor. This is especially important for taildraggers! 2. Go to the Settings page and set your Altimeter to 1200 MSL. For safety, the Autopilot will not engage below this altitude. 3. With the Autopilot powered up, spin the Outer Knob to put the Heading Bug on the nose. 4. Go to the AP screen, and choose Heading Bug as your Nav Source, and Engage. 5. The Roll (aileron) servo should click and grab the stick. Page 18 of 20
6. Touch the AP button to dismiss the AP screen, and turn the Heading Bug to the LEFT. 7. The stick should step over LEFT incrementally and get more aggressive over a period of about 60 seconds since the Autopilot is commanding the airframe to move and the airplane isn t responding, but is still sitting in the hangar. 8. If the stick goes the wrong way, go back to Setup and change the Autopilot Aileron Sense to NEGATIVE. 9. Try the above procedure again to make sure you everything is the way you want it. Aileron Gain Setting Once the linkage direction is set properly, we just need to set your gain. This gain is a measure of how much servo movement is required to get a specified amount of roll rate and varies between differing airplane designs. Typical values are: RVs 40 Velocity 75 Cozy 65 Lancair 75 This gain is a measure of initial roll response the RV s shorter wing turns faster, so gets a lower gain. If the AP is turning sluggishly or wandering, turn up the gain. If the stick pumps back and forth about once a second, turn it down! Elevator Setup As for aileron above, Set the Gain to Positive 40 as shown in the pictures, and start up your EFIS. Here s all you do: 1. Go to the Settings screen and press Set Level so the EFIS thinks it s dead level with your hangar floor. This is especially important for taildraggers! Since we re about to test climbs and descents, the Pitch attitude needs to be level for these tests to work. 2. Go to the Settings page and set your Altimeter to 1200 MSL. For safety, the Autopilot will not engage below this altitude. 3. With the Autopilot powered up, go to the AP screen, and select an Altitude to Hold of 5000 feet and Engage. 4. The Pitch (elevator) servo should click and pull the stick back incrementally over a period of about 60 seconds. 1.0C DRAFT Page 19 of 20
5. If the stick moves the wrong way, go back to Setup and change the Autopilot Elevator Sense to NEGATIVE. 6. Try the above procedure again to make sure you are correctly linked up. Elevator Gain Setting Once the linkage direction is set properly, we just need to set your gain. This gain is a measure of how much servo movement is required to get a specified amount of pitch rate and varies between differing airplane designs. Typical values are: RVs 40 Velocity 75 Cozy 65 Lancair 75 This gain is a measure of initial pitch response the RV is shorter coupled and pitches faster, so gets a lower gain. If the AP is hunting is Altitude, turn up the gain. If the stick pumps up and down, turn it down! In-Flight Tuning If you get real close, but not perfect, on your gain settings and want to tweak them inflight, we ve made provision for you. You ll need your keyboard hooked up, and follow this sequence: 1. Touch ESCAPE to go to the command shell 2. Choose Command Shell and touch <enter> 3. Type EFIS APTUNE and touch <enter> The EFIS will come up in AP tuning mode, and you ll notice two additional controls at the bottom of the AP screen: Page 20 of 20
These are the same Gains that you worked with on the Setup screen, and can be adjusted here by highlighting the gain, and turning the Inner Knob as you would any other control in the EFIS. The procedure is to set the gain, engage and fly heading bug, then disengage and tweak the gain, re-engage and fly heading bug until you are happy with the roll performance. Same thing for Altitude Hold, set gain, engage and hold, disengage, tweak gain and try again. Should take just a few tries to get it exactly the way you like. If you get the gain set too high, the stick will pump back and forth about one a second when you engage. If this happens, drop the gain 5 points and you are done. 1.0C DRAFT Page 21 of 20
Physical Dimensions and Operation Limits Autopilot Servo (Rev2): 10 by 2.5 by 2.5, weight, 3.75lbs Autopilot Servo (Rev3): See previous pages for dimensions, weight 3.4lbs Autopilot Controller: 8 by 4 by 2 Power: 10-32v, max current 7A, use 10 Amp CB. Page 22 of 20
Cable Specifications Open Frame Servo (Rev 1) This cable is supplied to connect the Autopilot Controller to the open frame servos. Two are required for each airplane. One end has a Female cannon plug, the other has the Female 5 Pin IDC connector and four (4) open leads. The cable are supplied 15 long, Teflon insulated wire is used. AP Servo Connection Female Cannon DigiKey MS3126F-14-12S Female 5 pin IDC Allied #512-3213 Encoder 1 A #22 Black Encoder 2 B #22 Red Encoder 3 C #22 Green Encoder 4 D #22 Yellow Encoder 5 E #22 White Motor + ( 2 positions ) K #6 Ring terminal, #18 RED Motor (2 positions ) M #6 Ring terminal, #18 BLK Clutch J #18, YELLOW Clutch L #18, YELLOW From left to right the colors shown are: white, yellow, green, red, black. 1.0C DRAFT Page 23 of 20
Closed Frame Servo (Rev 2) The internal cable in the servo is wired as follows. AP Servo Connection Female Cannon DigiKey MS3126F-14-12S Female 5 pin IDC Allied #512-3213 Encoder 1 A #22 Black Encoder 2 B #22 Red Encoder 3 C #22 Green Encoder 4 D #22 Yellow Encoder 5 E #22 White Motor + (2 positions) K #6 Ring terminal, #20 RED Motor (2 positions) M #6 Ring terminal, #20 BLK Clutch J #20, YELLOW Clutch L #20, YELLOW From left to right the colors shown are: white, yellow, green, red, black. The cable from the Rev 2 servo to the AP Controller is wired straight thru as follows: Female Cannon Female Cannon Wire Size. DigiKey MS3126M-14-12S DigiKey MS3126F-14-12S A A #22 Black B B #22 Red C C #22 Green D D #22 Yellow E E #22 White K K #18 RED M M #18 BLACK J J #18, YELLOW L L #18, YELLOW Page 24 of 20
Closed Frame Servo (Rev 3) The internal cable in the servo is wired as follows. AP Servo Connection DB9 Female Female 5 pin IDC Allied #512-3213 Encoder 1 1 #22 Black Encoder 2 2 #22 Red Encoder 3 3 #22 Green Encoder 4 4 #22 Yellow Encoder 5 5 #22 White Motor + (2 positions) 6 #6 Ring terminal, #20 RED Motor (2 positions) 7 #6 Ring terminal, #20 BLK Clutch 8 #20, YELLOW Clutch 9 #20, YELLOW From left to right the colors shown are: white, yellow, green, red, black. The cable from the Rev 3 servo to the AP Controller is wired straight thru as follows: DB9 Male DB9 Female Wire Size 1 1 18 2 2 18 3 3 18 4 4 18 5 5 18 6 6 18 7 7 18 8 8 18 9 9 18 1.0C DRAFT Page 25 of 20
Notes: Page 26 of 20