X-Virus-Scanned: clean according to Sophos on Logan.com Return-Path: Received: from [64.4.51.81] (HELO hotmail.com) by logan.com (CommuniGate Pro SMTP 4.3.4) with ESMTP id 990161 for flyrotary@lancaironline.net; Thu, 09 Jun 2005 14:43:58 -0400 Received-SPF: pass receiver=logan.com; client-ip=64.4.51.81; envelope-from=lors01@msn.com Received: from mail pickup service by hotmail.com with Microsoft SMTPSVC; Thu, 9 Jun 2005 11:43:10 -0700 Message-ID: Received: from 64.4.51.220 by BAY107-DAV9.phx.gbl with DAV; Thu, 09 Jun 2005 18:43:10 +0000 X-Originating-IP: [64.4.51.220] X-Originating-Email: [lors01@msn.com] X-Sender: lors01@msn.com From: "Tracy Crook" To: "Rotary motors in aircraft" References: Subject: Re: [FlyRotary] Re: EC2 Urgent AD Date: Thu, 9 Jun 2005 14:43:02 -0400 MIME-Version: 1.0 Content-Type: multipart/mixed; boundary="----=_NextPart_000_0014_01C56D01.89DEEBD0" X-Priority: 3 X-MSMail-Priority: Normal X-Mailer: MSN 9 X-MimeOLE: Produced By MSN MimeOLE V9.10.0011.1703 Seal-Send-Time: Thu, 9 Jun 2005 14:43:02 -0400 X-OriginalArrivalTime: 09 Jun 2005 18:43:10.0975 (UTC) FILETIME=[15F778F0:01C56D23] This is a multi-part message in MIME format. ------=_NextPart_000_0014_01C56D01.89DEEBD0 Content-Type: multipart/alternative; boundary="----=_NextPart_001_0015_01C56D01.89DEEBD0" ------=_NextPart_001_0015_01C56D01.89DEEBD0 Content-Type: text/plain; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable I was researching the failure on John Slades EC2 and found some = disturbing things. =20 The input power filter uses a choke which is the only single failure = point in the EC2. The part was originally specified to be so over rated = rated such that failure could only be caused by physical damage to the = part. If an overload occurred sufficient to fail this part, the circuit = traces on the board would fail long before the part would. This was the = rationale for the basic design approach. Don't want to get into a = discussion of why separate chokes are not used. =20 At some point the manufacturing facility substituted a different part = with same inductance but lower current rating. It was still over rated = and sufficient for any foreseeable situation so it was considered OK. Still later, the board maker substituted an even lower rated part that = looks almost identical to the previously substituted part. I was not = informed of this change. The unit will function normally with this = part but it has no extra margin for safety in the event of miswire, = shorted output, etc. I was able to duplicate the failure John Slade had = by shorting 1 or more ignition driver outputs to ground or 12V input = power. The original design intent was to allow this condition without = failure of the choke. Point of this message is to announce an AD (airworthiness directive) to = inspect and verify the type of choke used on your EC2. Attached to this = message is a picture of the three types of chokes used. The left is the = originally specified part. The center part is an acceptable substitute = part. The right hand part is the unacceptable choke. If you have this = part, do not fly the aircraft until it has been replaced. In addition = to the visual difference, you can determine which part by measuring the = resistance. The bad part has a resistance over 10 ohms. The correct = parts are much lower in resistance. We will replace the part for you for no charge except shipping cost as = specified in the warranty. This is a simple through-hole soldered part = that is relatively easy to replace. If you are qualified to replace the = part yourself, we will send the correct part at no cost. Tracy Crook ------=_NextPart_001_0015_01C56D01.89DEEBD0 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable

I was researching the failure on John Slades EC2 and = found some=20 disturbing things.

The input power filter uses a choke which is the only single = failure point=20 in the EC2. The part was originally specified to be so over=20 rated rated such that failure could only be caused by physical = damage to=20 the part. If an overload occurred sufficient to fail this part, = the=20 circuit traces on the board would fail long before the part would. = This=20 was the rationale for the basic design approach. Don't want to get = into a=20 discussion of why separate chokes are not used.

At some point the manufacturing facility substituted a different = part with=20 same inductance but lower current rating. It was still over rated = and=20 sufficient for any foreseeable situation so it was considered = OK.

Still later, the board maker substituted an even lower = rated part=20 that looks almost identical to the previously substituted part. I = was not=20 informed of this change. The unit will function normally = with this=20 part but it has no extra margin for safety in the event of miswire, = shorted=20 output, etc. I was able to duplicate the failure John Slade had by = shorting 1 or more ignition driver outputs to ground or 12V input=20 power. The original design intent was to allow this = condition=20 without failure of the choke.

Point of this message is to announce an AD (airworthiness = directive)=20 to inspect and verify the type of choke used on your EC2. = Attached to=20 this message is a picture of the three types of chokes used. The = left is=20 the originally specified part. The center part is an = acceptable=20 substitute part. The right hand part is the unacceptable = choke. If=20 you have this part, do not fly the aircraft until it has been=20 replaced. In addition to the visual difference, you can determine = which=20 part by measuring the resistance. The bad part has a resistance = over 10=20 ohms. The correct parts are much lower in resistance.

We will replace the part for you for no charge except shipping cost = as=20 specified in the warranty. This is a simple through-hole=20 soldered part that is relatively easy to replace. If you are=20 qualified to replace the part yourself, we will send the correct=20 part at no cost.

Tracy Crook

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