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Essential Bus question
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rkharr



Joined: 10 Jan 2006
Posts: 12
Location: Columbia, SC

PostPosted: Fri Jan 31, 2014 11:53 am    Post subject: Essential Bus question Reply with quote

My RV-6 has been flying 12 years now with an electrical system based on the Z diagrams. Now I am assisting my wife complete her RV-7 electrical system. She has chosen to use the VPX Pro unit and wants to incorporate a "backup" source of power for clearances, engine start, and "endurance" (if the VPX box were to quit).
The circuit that we are considering uses a bridge diode that would allow the main battery to supplement the "backup" battery for increased endurance. Since I have not seen this variation before, there must be a "gotcha" that I haven't found. Attached is a picture of the basic circuit. Any suggestions and/or comments would be appreciated.


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Ken
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Kellym



Joined: 10 Jan 2006
Posts: 1705
Location: Sun Lakes AZ

PostPosted: Fri Jan 31, 2014 6:27 pm    Post subject: Essential Bus question Reply with quote

My first question would be why add the complexity of a second electrical
system, when virtually all situations can be handled by either backup
battery for EFIS, ship's battery or just plain old magnetos.

On 1/31/2014 12:53 PM, rkharr wrote:
Quote:


My RV-6 has been flying 12 years now with an electrical system based on the Z diagrams. Now I am assisting my wife complete her RV-7 electrical system. She has chosen to use the VPX Pro unit and wants to incorporate a "backup" source of power for clearances, engine start, and "endurance" (if the VPX box were to quit).
The circuit that we are considering uses a bridge diode that would allow the main battery to supplement the "backup" battery for increased endurance. Since I have not seen this variation before, there must be a "gotcha" that I haven't found. Attached is a picture of the basic circuit. Any suggestions and/or comments would be appreciated.

--------
Ken
RV-6
South Carolina


Read this topic online here:

http://forums.matronics.com/viewtopic.php?p=417953#417953


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nuckolls.bob(at)aeroelect
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PostPosted: Sun Feb 02, 2014 8:13 am    Post subject: Essential Bus question Reply with quote

At 08:25 PM 1/31/2014, you wrote:


My first question would be why add the complexity of a second
electrical system, when virtually all situations . . .

Define "all situations" . . . the term is non-
quantified/qualified. When we're designing a
TC aircraft, EVERY situation needs to be articulated
in the design documents along with the plan-B, C, . . .
or Z that mitigates that situation. Then we have
to go TEST every one of those plans to demonstrate
compliance with design goals.

. . . can be handled by either backup battery for EFIS, ship's
battery or just plain old magnetos.

For OBAM aircraft it's a function of design goals built upon
the pilot's skills, maintenance protocols, airplane capabilities
and anticipated missions. Obviously, the manner in which
one might outfit a Kitfox can depart greatly from the
way you would craft an LAIV-P. At the same time, the
builder of an RV-6 in the Pacific NW (Lots of clouds
all the time) who travels a lot might have a more
sophisticated system than another builder who intends
to use is LAIV only in day VMC but wants the
speed, ability to hop the occasional mountain range
and air conditioning.

This litany of potential "situations" offers
a brief peek into the value of having design
goals synchronized to the end-use.

Production aircraft tend to have cookie-cutter
approaches to system architecture . . . because
the designers can only hypothesize greatest risk
situations for the targeted customer then address
those hypotheses within the framework of the
impediments to creativity imposed by the FARS.

We on the List have a clean sheet of paper
for the beginning of every project. The Z-figures
are intended to offer a sort of "Cliff's Notes"
on architectures that span the spectrum of
possibilities. Some builders have put Z-14
into their 2 place RV's at no small penalty
for cost and weight . . . but find comfort
in not having to go through the very non-
trivial exercise of optimizing their decision.

There ARE LAIV-P aircraft flying with one
battery, one alternator, and backup batteries
sprinkled over the panel and perhaps some
more in the flight bag.

Its unlikely that either builder has tested
available failure response plans against his/her
perceptions of capability in the Plan-B
hardware.

Given the decreasing failure rates of modern
electro-whizzies, it's unlikely that either
of the pilots in the last two examples will
have a 'dark-n-stormy night' story to write
up for Flying Magazine.
Bob . . .


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PostPosted: Sun Feb 02, 2014 8:42 am    Post subject: Essential Bus question Reply with quote

At 01:53 PM 1/31/2014, you wrote:
Quote:


My RV-6 has been flying 12 years now with an electrical system based
on the Z diagrams. Now I am assisting my wife complete her RV-7
electrical system. She has chosen to use the VPX Pro unit and wants
to incorporate a "backup" source of power for clearances, engine
start, and "endurance" (if the VPX box were to quit).

Okay, you're plagued with the same litany of concerns
that arise from lack of confidence in your present
'vision' for how this system should evolve.
Quote:

The circuit that we are considering uses a bridge diode that would
allow the main battery to supplement the "backup" battery for
increased endurance. Since I have not seen this variation before,
there must be a "gotcha" that I haven't found. Attached is a
picture of the basic circuit. Any suggestions and/or comments would
be appreciated.

Read through the posting I made a few minutes ago
and then consider a list of design goals that are
based on . . .

(1) How will this airplane be used? Do you
anticipate long legs of travel at night over
unfriendly terrain?

(2) Are you anticipating more than a tiny
percentage of approaches to landing to be
in IMC?

(3) Do you plan to carry the ultimate in
backup reliability in your flight bag?

http://tinyurl.com/d5mrjgh

This is the stuff I recommend for folks like
me who only rent airplanes . . . but if
it were my airplane, those items would still
be with me. In fact, I've not turned on a
VOR or ADF in 15 years . . . nor have I used
a panel mounted GPS . . . but that's another
story.

(4) Are your skill sets going to be honed
to the levels necessary for low risk
implementation of the hardware you plan to install?
It's entirely possible to have an airplane
decked out to the window-sills with goodies
only to have A pilot become the weak link
in the chain.

http://tinyurl.com/kb2zr8m

I've flown with pilots who were quite proud
of all those dials, switches and knobs on
the panel who never flew more IFR than to
keep their ticket current. The greatest
risk for bending their airplane was not
rooted failure of hardware.

Keep in mind that 2x the hardware is 2x
the probability of failure. Got some more
batteries scattered around the airplane
. . . guess what . . . now you're running
a clinic for batteries upon which you believe
you're building a 'dependable' system.

Commodity items like batteries are like house plants.
Just because you have two of them does not mitigate
the need for knowledgeable preventative
maintenance but it DOES double the maintenance
$time$.

So before we spend a lot of time refining
the work-arounds for hypothesized failures,
let's look at the big picture and size the
solutions to realistic risks having the
greatest probability of presentation.

Then you're ready to sift solutions for those
having the lowest cost of ownership, weight
penalties on the aircraft and taxation of
your skill sets.
Bob . . .


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PostPosted: Sun Feb 02, 2014 9:32 am    Post subject: Essential Bus question Reply with quote

I would just add a simple Brown out 7ah Alarm battery/Aux bus charged thru a Schottky diode and maybe a resistor is very simple & cheap to do. A lot of equipment now comes with multiple diode isolated power inputs making it easy.
This allows flight plan entry and clearance requests before start up without draining the main battery, keeps the GPS/NAV/COM and EFIS from rebooting when cranking the engine, and provides maybe 20-30 minutes of extra time to get back on the ground.
Weight/cost is about $35 and 5 lbs. cheaper than a factory backup, which only powers one item.

Tim


Quote:
On Feb 2, 2014, at 8:39 AM, "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com> wrote:



At 01:53 PM 1/31/2014, you wrote:
>
>
> My RV-6 has been flying 12 years now with an electrical system based on the Z diagrams. Now I am assisting my wife complete her RV-7 electrical system. She has chosen to use the VPX Pro unit and wants to incorporate a "backup" source of power for clearances, engine start, and "endurance" (if the VPX box were to quit).

Okay, you're plagued with the same litany of concerns
that arise from lack of confidence in your present
'vision' for how this system should evolve.
>
> The circuit that we are considering uses a bridge diode that would allow the main battery to supplement the "backup" battery for increased endurance. Since I have not seen this variation before, there must be a "gotcha" that I haven't found. Attached is a picture of the basic circuit. Any suggestions and/or comments would be appreciated.

Read through the posting I made a few minutes ago
and then consider a list of design goals that are
based on . . .

(1) How will this airplane be used? Do you
anticipate long legs of travel at night over
unfriendly terrain?

(2) Are you anticipating more than a tiny
percentage of approaches to landing to be
in IMC?

(3) Do you plan to carry the ultimate in
backup reliability in your flight bag?

http://tinyurl.com/d5mrjgh

This is the stuff I recommend for folks like
me who only rent airplanes . . . but if
it were my airplane, those items would still
be with me. In fact, I've not turned on a
VOR or ADF in 15 years . . . nor have I used
a panel mounted GPS . . . but that's another
story.

(4) Are your skill sets going to be honed
to the levels necessary for low risk
implementation of the hardware you plan to install?
It's entirely possible to have an airplane
decked out to the window-sills with goodies
only to have A pilot become the weak link
in the chain.

http://tinyurl.com/kb2zr8m

I've flown with pilots who were quite proud
of all those dials, switches and knobs on
the panel who never flew more IFR than to
keep their ticket current. The greatest
risk for bending their airplane was not
rooted failure of hardware.

Keep in mind that 2x the hardware is 2x
the probability of failure. Got some more
batteries scattered around the airplane
. . . guess what . . . now you're running
a clinic for batteries upon which you believe
you're building a 'dependable' system.

Commodity items like batteries are like house plants.
Just because you have two of them does not mitigate
the need for knowledgeable preventative
maintenance but it DOES double the maintenance
$time$.

So before we spend a lot of time refining
the work-arounds for hypothesized failures,
let's look at the big picture and size the
solutions to realistic risks having the
greatest probability of presentation.

Then you're ready to sift solutions for those
having the lowest cost of ownership, weight
penalties on the aircraft and taxation of
your skill sets.


Bob . . .






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PostPosted: Sun Feb 02, 2014 10:47 am    Post subject: Essential Bus question Reply with quote

At 11:31 AM 2/2/2014, you wrote:
Quote:


I would just add a simple Brown out 7ah Alarm battery/Aux bus
charged thru a Schottky diode and maybe a resistor is very simple &
cheap to do. A lot of equipment now comes with multiple diode
isolated power inputs making it easy.
This allows flight plan entry and clearance requests before start up
without draining the main battery, keeps the GPS/NAV/COM and EFIS
from rebooting when cranking the engine, and provides maybe 20-30
minutes of extra time to get back on the ground.
Weight/cost is about $35 and 5 lbs. cheaper than a factory backup,
which only powers one item.

Tim

Good data points. Let us consider the premises
underlying the evolution of Figure Z-07

http://tinyurl.com/my9u3ud

this shows a two battery/single alternator system
for an electrically dependent engine. This
exercise in 'electron gazing' grew out of Fred's
project already fitted with a EXP-Bus. I could
see a way to accommodate Fred's initial design
goals for two batteries with a simple mod to
the EXP-Bus . . . but I could see an alternative
to Z-19 evolving from the deliberations . . .
hence Z-07.

Off in the distance, I think I see a single-battery
variant of this architecture but that's possible
only after we get real energy requirements data
. . . and further refine the operating philosophy
for the system. Tim's words raise useful questions
that go directly to deliberations for sizing risks
in a single-battery design.

Where is it written or demonstrated that having
the ship's processors 'reboot' is a bad thing?
Under what operating scenarios is it useful/necessary
minimize the time between the glass being awake
and reaching the end of the runway just prior
to engine run-up?

I recall some stories about the Blue-Mountain
systems (hard drives?) taking perhaps 90
seconds to wake up . . . but when was the
last time you were ready to check mags less
than, say 3-4 minutes after engine startup?

I've reviewed as many of the airports I've
visited that I can remember. I cannot recall
any departure where engine run-up was accomplished
for before the oil was warmed up a bit and I
had taxied from parking to the run-up stand,
certainly 4 minutes, sometimes 10. I think
it took 15 minutes to get out of KCI once.

. . . the check list belongs to YOU . . . you
can adjust sequences of events to fit hardware.

Let us consider "draining the main battery"
for the purposes of gathering the ATIS data
and getting a clearance delivery. Suppose the
e-bus runs 5A and the exercise takes 3 minutes.
12v x 5a x 60s x 3m = 10,800 watt-seconds.
Cranking the engine 12v x 200a x 10s = 24,000
watt-seconds. What does the battery hold?
12v x 5a x 60s x 120m = 432,000 watt-seconds.

Okay, you used up 34,800 watt-seconds before
the engine was lit for 35K/432K or 8 percent
of the battery's capacity. If you're targeting
80% of new capacity for banishing your battery
to kiddie-car duty, then the last flight
will tax the battery to 10% of available
capacity.

The above analysis is a first order estimate
and does not take into account vagaries of
temperature and internal impedances of the
battery but it's in the right church if not
in the right pew.

Whats is the return on investment for 5 more
pounds of battery and two batteries to maintain
instead of one?

The value of this . . . or even more detailed
analysis presumes that you KNOW what the
drains are and what the battery's capabilities
are after accounting for aforementioned
vagaries AND targeted end of life decisions.
Bob . . .


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PostPosted: Sun Feb 02, 2014 2:34 pm    Post subject: Essential Bus question Reply with quote

my comments in larger font...

-Jeff
From: "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com>
To: aeroelectric-list(at)matronics.com
Sent: Sunday, February 2, 2014 10:47 AM
Subject: Re: Essential Bus question


--> AeroElectric-List message posted by: "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)>

At 11:31 AM 2/2/2014, you wrote:
Quote:
--> AeroElectric-List message posted by: Tim Andres <tim2542(at)sbcglobal.net (tim2542(at)sbcglobal.net)>

I would just add a simple Brown out 7ah Alarm battery/Aux bus charged thru a Schottky diode and maybe a resistor is very simple & cheap to do. A lot of equipment now comes with multiple diode isolated power inputs making it easy.
This allows flight plan entry and clearance requests before start up without draining the main battery, keeps the GPS/NAV/COM and EFIS from rebooting when cranking the engine, and provides maybe 20-30 minutes of extra time to get back on the ground.
Weight/cost is about $35 and 5 lbs. cheaper than a factory backup, which only powers one item.

Tim

Good data points. Let us consider the premises
underlying the evolution of Figure Z-07

http://tinyurl.com/my9u3ud

this shows a two battery/single alternator system
for an electrically dependent engine. This
exercise in 'electron gazing' grew out of Fred's
project already fitted with a EXP-Bus. I could
see a way to accommodate Fred's initial design
goals for two batteries with a simple mod to
the EXP-Bus . . . but I could see an alternative
to Z-19 evolving from the deliberations . . .
hence Z-07.

Off in the distance, I think I see a single-battery
variant of this architecture but that's possible
only after we get real energy requirements data
. . . and further refine the operating philosophy
for the system. Tim's words raise useful questions
that go directly to deliberations for sizing risks
in a single-battery design.

Where is it written or demonstrated that having
the ship's processors 'reboot' is a bad thing?

OK, let me write it here:
Watching the Garmin 430 in my Cherokee re-boot after engine start is very inconvenient. Is it catastrophic? No. Are there work-arounds? Certainly. It's just a pain in the (at)ss. In an experimental w/ all glass, it would be even more annoying.

Now that I'm designing the electrical system for my RV-7A, I'm certainly want a design where that does not happen. This is one of the reasons people like us build our own airplanes - we get to engineer-out those little annoyances that we just have to put up with in certified airplanes.
Under what operating scenarios is it useful/necessary
minimize the time between the glass being awake
and reaching the end of the runway just prior
to engine run-up?

I recall some stories about the Blue-Mountain
systems (hard drives?) taking perhaps 90
seconds to wake up . . . but when was the
last time you were ready to check mags less
than, say 3-4 minutes after engine startup?

  I've reviewed as many of the airports I've
visited that I can remember. I cannot recall
any departure where engine run-up was accomplished
for before the oil was warmed up a bit and I
  had taxied from parking to the run-up stand,
certainly 4 minutes, sometimes 10. I think
it took 15 minutes to get out of KCI once.

All true but, there are also thousands of quiet little airports where you can depart as quickly as you want to

  . . . the check list belongs to YOU . . . you
can adjust sequences of events to fit hardware.

Let us consider "draining the main battery"
for the purposes of gathering the ATIS data
and getting a clearance delivery. Suppose the
e-bus runs 5A and the exercise takes 3 minutes.
12v x 5a x 60s x 3m = 10,800 watt-seconds.
Cranking the engine 12v x 200a x 10s = 24,000
watt-seconds. What does the battery hold?
12v x 5a x 60s x 120m = 432,000 watt-seconds.

Okay, you used up 34,800 watt-seconds before
the engine was lit for 35K/432K or 8 percent
of the battery's capacity. If you're targeting
80% of new capacity for banishing your battery
to kiddie-car duty, then the last flight
will tax the battery to 10% of available
capacity.

The above analysis is a first order estimate
and does not take into account vagaries of
temperature and internal impedances of the
battery but it's in the right church if not
in the right pew.

Whats is the return on investment for 5 more
pounds of battery and two batteries to maintain
instead of one?

The value of this . . . or even more detailed
analysis presumes that you KNOW what the
drains are and what the battery's capabilities
  are after accounting for aforementioned
vagaries AND targe> http://foru - List Contribution Web Site -


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PostPosted: Sun Feb 02, 2014 3:39 pm    Post subject: Essential Bus question Reply with quote

OK, let me write it here:

Watching the Garmin 430 in my Cherokee re-boot after engine start is
very inconvenient.

Stop-watch that for me some time. I'd really
like to have a number on this widely discussed
but never quantified driver of design goals.

Is it catastrophic? No. Are there work-arounds? Certainly. It's
just a pain in the (at)ss.
In an experimental w/all glass, it would be even more annoying.

Now that I'm designing the electrical system for my RV-7A, I'm
certainly want a design
where that does not happen. This is one of the reasons people like
us build our own
airplanes - we get to engineer-out those little annoyances that we just have to
put up with in certified airplanes.

Then by all means do so. It's your airplane and your
design goals. The question wasn't whether or not you
wanted to do a particular thing, it was an invitation
explore why you wanted to do it . . . hopefully for reasons
firmly of your own choosing and not 'just because'
hangar lore and legacy traditions dictated it.

Brownout batteries have been discussed her on the list often
for several years an even illustrated one approach
in Z-10/8

http://tinyurl.com/7ro5yuc
All true but, there are also thousands of quiet little airports where you can
depart as quickly as you want to

Yup . . . there are. If a significant percentage
of your departures are so expeditious that
boot time on the glass becomes an impediment,
then you have an element of fact that drives
a different design goal.

I'm trying head off any notions that just because
one is considering a glass cockpit that a brownout
battery is recommended . . . it comes with a price in
weight and costs of ownership that may add little
or no value.

Bob . . .


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PostPosted: Sun Feb 02, 2014 4:14 pm    Post subject: Essential Bus question Reply with quote

Not to argue your points Bob, and I agree simple is often better, but I would just add that I don't want to wait 20 seconds for the screens to reboot after engine start as my engine data is there also and I want see oil pressure etc right away.
And I much prefer to enter a lengthy flight plan with the prop off as my attention will be focused inside the plane, I'll admit on occasion I've looked up from the panel and discovered the plane moving. My flight plan will then be lost when I then crank the engine, unless I save it to memory, which I won't unless I'm using it again.
And sometimes I take off with a hot engine, I'd rather not sit with the already hot engine running in the summer heat while I enter several waypoints in the Garmin.
To me it's worth the 5lbs for the convenience, and the cost is easily overcome in fuel not burned.
The beauty of EAB, built what you want, then live with your decisions.
Tim
Quote:
On Feb 2, 2014, at 10:47 AM, "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com> wrote:



At 11:31 AM 2/2/2014, you wrote:
>
>
> I would just add a simple Brown out 7ah Alarm battery/Aux bus charged thru a Schottky diode and maybe a resistor is very simple & cheap to do. A lot of equipment now comes with multiple diode isolated power inputs making it easy.
> This allows flight plan entry and clearance requests before start up without draining the main battery, keeps the GPS/NAV/COM and EFIS from rebooting when cranking the engine, and provides maybe 20-30 minutes of extra time to get back on the ground.
> Weight/cost is about $35 and 5 lbs. cheaper than a factory backup, which only powers one item.
>
> Tim

Good data points. Let us consider the premises
underlying the evolution of Figure Z-07

http://tinyurl.com/my9u3ud

this shows a two battery/single alternator system
for an electrically dependent engine. This
exercise in 'electron gazing' grew out of Fred's
project already fitted with a EXP-Bus. I could
see a way to accommodate Fred's initial design
goals for two batteries with a simple mod to
the EXP-Bus . . . but I could see an alternative
to Z-19 evolving from the deliberations . . .
hence Z-07.

Off in the distance, I think I see a single-battery
variant of this architecture but that's possible
only after we get real energy requirements data
. . . and further refine the operating philosophy
for the system. Tim's words raise useful questions
that go directly to deliberations for sizing risks
in a single-battery design.

Where is it written or demonstrated that having
the ship's processors 'reboot' is a bad thing?
Under what operating scenarios is it useful/necessary
minimize the time between the glass being awake
and reaching the end of the runway just prior
to engine run-up?

I recall some stories about the Blue-Mountain
systems (hard drives?) taking perhaps 90
seconds to wake up . . . but when was the
last time you were ready to check mags less
than, say 3-4 minutes after engine startup?

I've reviewed as many of the airports I've
visited that I can remember. I cannot recall
any departure where engine run-up was accomplished
for before the oil was warmed up a bit and I
had taxied from parking to the run-up stand,
certainly 4 minutes, sometimes 10. I think
it took 15 minutes to get out of KCI once.

. . . the check list belongs to YOU . . . you
can adjust sequences of events to fit hardware.

Let us consider "draining the main battery"
for the purposes of gathering the ATIS data
and getting a clearance delivery. Suppose the
e-bus runs 5A and the exercise takes 3 minutes.
12v x 5a x 60s x 3m = 10,800 watt-seconds.
Cranking the engine 12v x 200a x 10s = 24,000
watt-seconds. What does the battery hold?
12v x 5a x 60s x 120m = 432,000 watt-seconds.

Okay, you used up 34,800 watt-seconds before
the engine was lit for 35K/432K or 8 percent
of the battery's capacity. If you're targeting
80% of new capacity for banishing your battery
to kiddie-car duty, then the last flight
will tax the battery to 10% of available
capacity.

The above analysis is a first order estimate
and does not take into account vagaries of
temperature and internal impedances of the
battery but it's in the right church if not
in the right pew.

Whats is the return on investment for 5 more
pounds of battery and two batteries to maintain
instead of one?

The value of this . . . or even more detailed
analysis presumes that you KNOW what the
drains are and what the battery's capabilities
are after accounting for aforementioned
vagaries AND targeted end of life decisions.


Bob . . .






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Kellym



Joined: 10 Jan 2006
Posts: 1705
Location: Sun Lakes AZ

PostPosted: Sun Feb 02, 2014 4:14 pm    Post subject: Essential Bus question Reply with quote

Virtually all glass have their own light weight backup batteries so do
not have startup brown out issues unless no backup battery is installed.
I see very little value in being able to turn on GPS prior to start.
While one needs engine instrumentation prior to and during start, one
does not need avionics on.
Of course newer avionics that allow faster input of flight plans than
the 430 help, if that is the reason for turning on 430 before start.

On 2/2/2014 4:39 PM, Robert L. Nuckolls, III wrote:
Quote:


Brownout batteries have been discussed her on the list often
for several years an even illustrated one approach
in Z-10/8

http://tinyurl.com/7ro5yuc
All true but, there are also thousands of quiet little airports where
you can
depart as quickly as you want to

Yup . . . there are. If a significant percentage
of your departures are so expeditious that
boot time on the glass becomes an impediment,
then you have an element of fact that drives
a different design goal.

I'm trying head off any notions that just because
one is considering a glass cockpit that a brownout
battery is recommended . . . it comes with a price in
weight and costs of ownership that may add little
or no value.

Bob . . .




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PostPosted: Sun Feb 02, 2014 5:11 pm    Post subject: Essential Bus question Reply with quote

At 06:14 PM 2/2/2014, you wrote:
Quote:


Not to argue your points Bob, and I agree simple is often better,
but I would just add that I don't want to wait 20 seconds for the
screens to reboot after engine start as my engine data is there also
and I want see oil pressure etc right away.

Yeah . . . that's an old saw that has been around
since the Curtis Jenny . . . when sheared oil pump
shafts were relatively common . . . along with a
host of other ills associated with vintage engines.

I've never encountered a pilot who's oil pump died
at startup. I've flown lots of airplanes in cold
weather that didn't show any pressure for 30-45
seconds after start.

Quote:
And I much prefer to enter a lengthy flight plan with the prop off
as my attention will be focused inside the plane, I'll admit on
occasion I've looked up from the panel and discovered the plane
moving. My flight plan will then be lost when I then crank the
engine, unless I save it to memory, which I won't unless I'm using it again.

Quote:
And sometimes I take off with a hot engine, I'd rather not sit with
the already hot engine running in the summer heat while I enter
several waypoints in the Garmin.

You mean its stored waypoints go away during
reboot?

Quote:

To me it's worth the 5lbs for the convenience, and the cost is
easily overcome in fuel not burned.
The beauty of EAB, built what you want, then live with your decisions.

Absolutely. But why 5#? What did Eric decide about
his brown-out eliminator? Perhaps we still need
to refine the electronic bus-booster idea . . . it
weights a few ounces and has no periodic maintenance
requirements. Of course, a battery used only for
brownout protection can be run until it dies . . .
as long as the pilot doesn't included it in his/her
calculations for battery only endurance.
Bob . . .


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rickofudall



Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA

PostPosted: Mon Feb 03, 2014 5:28 am    Post subject: Essential Bus question Reply with quote

Bob, There is more than inconvenience to not having engine instruments if you fly with a Rotax. Unlike the LyConosaurs, these engines are so tight, the wear limit on a piston is only .0015" and a standard new fit is .0000" to .0009", that to lose oil pressure is catastrophic within seconds. The example that I saw in school was an engine that the owner had hooked the oil hoses up backward. On first start up the engine ran for less than 10 seconds before it threw a rod and blew a big hole in the engine case.

Rick Girard

On Sun, Feb 2, 2014 at 7:10 PM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
Quote:
--> AeroElectric-List message posted by: "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)>


At 06:14 PM 2/2/2014, you wrote:

Quote:
--> AeroElectric-List message posted by: Tim Andres <tim2542(at)sbcglobal.net (tim2542(at)sbcglobal.net)>


Not to argue your points Bob, and I agree simple is often better, but I would just add that I don't want to wait 20 seconds for the screens to reboot after engine start as my engine data is there also and I want see oil pressure etc right away.


   Yeah . . . that's an old saw that has been around
   since the Curtis Jenny . . . when sheared oil pump
   shafts were relatively common . . . along with a
   host of other ills associated with vintage engines.

   I've never encountered a pilot who's oil pump died
   at startup. I've flown lots of airplanes in cold
   weather that didn't show any pressure for 30-45
   seconds after start.

Quote:
And I much prefer to enter a lengthy flight plan with the prop off as my attention will be focused inside the plane, I'll admit on occasion I've looked up from the panel and discovered the plane moving. My flight plan will then be lost when I then crank the engine, unless I save it to memory, which I won't unless I'm using it again.
And sometimes I take off with a hot engine, I'd rather not sit with the already hot engine running in the summer heat while I enter several waypoints in the Garmin.


   You mean its stored waypoints go away during
   reboot?

Quote:

To me it's worth the 5lbs for the convenience, and the cost is easily overcome in fuel not burned.
The beauty of EAB, built what you want, then live with your decisions.


  Absolutely. But why 5#? What did Eric decide about
  his brown-out eliminator? Perhaps we still need
  to refine the electronic bus-booster idea . . . it
  weights a few ounces and has no periodic maintenance
  requirements. Of course, a battery used only for
  brownout protection can be run until it dies . . .
  as long as the pilot doesn't included it in his/her
  calculations for battery only endurance.


  Bob . . .

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PostPosted: Mon Feb 03, 2014 10:51 am    Post subject: Essential Bus question Reply with quote

At 07:27 AM 2/3/2014, you wrote:
Quote:
Bob, There is more than inconvenience to not having engine
instruments if you fly with a Rotax. Unlike the LyConosaurs, these
engines are so tight, the wear limit on a piston is only .0015" and
a standard new fit is .0000" to .0009", that to lose oil pressure is
catastrophic within seconds. The example that I saw in school was an
engine that the owner had hooked the oil hoses up backward. On first
start up the engine ran for less than 10 seconds before it threw a
rod and blew a big hole in the engine case.


Back in the day, the oil pressure gage was the same
device on grandpa's Ferguson tractor . . . a pressure
gage plumbed to the engine with a small diameter
tube.

In cold weather, the 50W oil would turn to road
tar in the tubing and delay accurate readings of
the gage by many seconds.

If I had an engine so critically vulnerable to
low oil pressure, then I'd add a pressure switch
as close as practical to the engine plumbed in
with any transducer intended to drive electronics.

10 seconds to destruct because the oil pressure
was absent on THAT start? Broke a rod because the
piston fits got tight? I'm skeptical. Pistons
seizing up progressively in the bores will
load up the engine until it stalls.

I worked a Rotax 912 accident that the owner tried to
blame on an electrical issue with ignition. I proved
the ignition system to be intact . . . but in the
accident narrative, the owner had taxied around for
30+ minutes 'getting the feel of the airplane' before
he decided to take off. On climb out the engine
slowly lost power . . . as if somebody was closing
the throttle. He descended into the trees, destroyed
the airplane and received a back injury. I told my
client attorney that they should do a teardown
of the engine and inspect cylinders for signs of
seizing due to overheat. Whether engine seizes
due to poor oil, air or water flow, the behavior is
the same.

I'll bet that engine had been in trouble for some
time and only decided to give up the ghost on that start-
event. It probably would have shelled out pretty
soon whether it had oil pressure or not.
Bob . . .


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rickofudall



Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA

PostPosted: Mon Feb 03, 2014 12:58 pm    Post subject: Essential Bus question Reply with quote

Bob, As one Rotax mechanic I know put it quite succinctly, "The worst enemy of the Rotax 912 is their owners". As for the blown up engine I saw, the school I attended was taught by the owner of the Rotax North American distributorship. I cannot fathom why he would make up such a story. If the owner had followed the manual, prelubed the engine, and then burped the oil system (the 912 has a dry sump oiling system that has no scavenge pump but instead relies upon blow by to pressurize the crankcase and push the oil out) he'd never have had a problem.


Rick
do not archive

On Mon, Feb 3, 2014 at 12:50 PM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
Quote:
--> AeroElectric-List message posted by: "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)>


At 07:27 AM 2/3/2014, you wrote:
Quote:
Bob, There is more than inconvenience to not having engine instruments if you fly with a Rotax. Unlike the LyConosaurs, these engines are so tight, the wear limit on a piston is only .0015" and a standard new fit is .0000" to .0009", that to lose oil pressure is catastrophic within seconds. The example that I saw in school was an engine that the owner had hooked the oil hoses up backward. On first start up the engine ran for less than 10 seconds before it threw a rod and blew a big hole in the engine case.



  Back in the day, the oil pressure gage was the same
  device on grandpa's Ferguson tractor . . . a pressure
  gage plumbed to the engine with a small diameter
  tube.

  In cold weather, the 50W oil would turn to road
  tar in the tubing and delay accurate readings of
  the gage by many seconds.

  If I had an engine so critically vulnerable to
  low oil pressure, then I'd add a pressure switch
  as close as practical to the engine plumbed in
  with any transducer intended to drive electronics.

  10 seconds to destruct because the oil pressure
  was absent on THAT start? Broke a rod because the
  piston fits got tight? I'm skeptical. Pistons
  seizing up progressively in the bores will
  load up the engine until it stalls.

  I worked a Rotax 912 accident that the owner tried to
  blame on an electrical issue with ignition. I proved
  the ignition system to be intact . . . but in the
  accident narrative, the owner had taxied around for
  30+ minutes 'getting the feel of the airplane' before
  he decided to take off. On climb out the engine
  slowly lost power . . . as if somebody was closing
  the throttle. He descended into the trees, destroyed
  the airplane and received a back injury. I told my
  client attorney that they should do a teardown
  of the engine and inspect cylinders for signs of
  seizing due to overheat. Whether engine seizes
  due to poor oil, air or water flow, the behavior is
  the same.

  I'll bet that engine had been in trouble for some
  time and only decided to give up the ghost on that start-
  event. It probably would have shelled out pretty
  soon whether it had oil pressure or not.


  Bob . . .  

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PostPosted: Mon Feb 03, 2014 5:26 pm    Post subject: Essential Bus question Reply with quote

At 02:57 PM 2/3/2014, you wrote:
Quote:
Bob, As one Rotax mechanic I know put it quite succinctly, "The
worst enemy of the Rotax 912 is their owners".
As for the blown up engine I saw, the school I attended was taught
by the owner of the Rotax North American distributorship. I cannot
fathom why he would make up such a story. If the owner had followed
the manual, prelubed the engine, and then burped the oil system (the
912 has a dry sump oiling system that has no scavenge pump but
instead relies upon blow by to pressurize the crankcase and push the
oil out) he'd never have had a problem.

But a broken rod in 10 seconds? Rod failures
tend to be the byproduct of hammering of the
end cap after the bearing is worn . . . a process
that takes hours. To break the rod with the
torque offered by a seized bearing that
lacked lubrication for 10 seconds doesn't
fit with the physics. You cited tight fits
for the pistons and segued to a broken
rod.

To be sure, we don't have the benefit of
failure analysis on the subject engine
but using what appears to be capitalization
of outlier event to re-enforce a perfectly
reasonable caution to be certain of engine
lubrication smells of "teaching by
sensationalism." This sort of teaching is core
to many the useless if not expensive
ol' mechanic's tales that plague our
community.

I'm not calling him a liar . . . but I am
skeptical based on the cause/effect cited.
Bob . . .


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rickofudall



Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA

PostPosted: Mon Feb 03, 2014 6:24 pm    Post subject: Essential Bus question Reply with quote

Bob, You also have to take into account that unlike the LyCo's, the Rotax has a five piece crank that is pressed together with nothing but the pressure of the fit to keep it together and aligned. I would imagine the trail of tears would include a piston seizure that causes the crank to come out of alignment which not only destroys a bearing or two, but gives the various crank sections a chance to beat upon each other. The reason for the multipiece crank is so that it can be made shorter by reducing the clearance between the side of the rod, see picture. With so little clearance between the rod and the adjacent crank web the twisted, misaligned crank now has a chance to really start beating on the rods, the piston skirts, and any pieces that have come loose. Of course the Rotax engineers have reduced clearances between the rotating assembly and the case halves to shave off more weight and by now the bearings are not only being twisted out of their seats but the case webs are being hammered, too. Well, that's about all I can conjecture about the cause and effect trail, but you get the idea. Rotax engines are just a different animal.
Rick
do not archive



On Mon, Feb 3, 2014 at 7:25 PM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
Quote:
--> AeroElectric-List message posted by: "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)>


At 02:57 PM 2/3/2014, you wrote:
Quote:
Bob, As one Rotax mechanic I know put it quite succinctly, "The worst enemy of the Rotax 912 is their owners".
As for the blown up engine I saw, the school I attended was taught by the owner of the Rotax North American distributorship. I cannot fathom why he would make up such a story. If the owner had followed the manual, prelubed the engine, and then burped the oil system (the 912 has a dry sump oiling system that has no scavenge pump but instead relies upon blow by to pressurize the crankcase and push the oil out) he'd never have had a problem.


 But a broken rod in 10 seconds? Rod failures
 tend to be the byproduct of hammering of the
 end cap after the bearing is worn . . . a process
 that takes hours. To break the rod with the
 torque offered by a seized bearing that
 lacked lubrication for 10 seconds doesn't
 fit with the physics. You cited tight fits
 for the pistons and segued to a broken
 rod.

 To be sure, we don't have the benefit of
 failure analysis on the subject engine
 but using what appears to be capitalization
 of outlier event to re-enforce a perfectly
 reasonable caution to be certain of engine
 lubrication smells of "teaching by
 sensationalism." This sort of teaching is core
 to many the useless if not expensive
 ol' mechanic's tales that plague our
 community.

 I'm not calling him a liar . . . but I am
 skeptical based on the cause/effect cited.


  Bob . . .

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PostPosted: Mon Feb 03, 2014 7:08 pm    Post subject: Essential Bus question Reply with quote

I think the multi piece crank is needed when they use one piece rods with roller bearings. Still hard to imagine a 10 sec failure. An oil change now becomes a major event in the life of your engine!
Tim

[quote] On Feb 3, 2014, at 6:23 PM, Richard Girard <aslsa.rng(at)gmail.com> wrote:

Bob, You also have to take into account that unlike the LyCo's, the Rotax has a five piece crank that is pressed together with nothing but the pressure of the fit to keep it together and aligned. I would imagine the trail of tears would include a piston seizure that causes the crank to come out of alignment which not only destroys a bearing or two, but gives the various crank sections a chance to beat upon each other. The reason for the multipiece crank is so that it can be made shorter by reducing the clearance between the side of the rod, see picture. With so little clearance between the rod and the adjacent crank web the twisted, misaligned crank now has a chance to really start beating on the rods, the piston skirts, and any pieces that have come loose. Of course the Rotax engineers have reduced clearances between the rotating assembly and the case halves to shave off more weight and by now the bearings are not only being twisted out of their seats but the case webs are being hammered, too.
Well, that's about all I can conjecture about the cause and effect trail, but you get the idea. Rotax engines are just a different animal.

Rick
do not archive


> On Mon, Feb 3, 2014 at 7:25 PM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com> wrote:
>
>
> At 02:57 PM 2/3/2014, you wrote:
>> Bob, As one Rotax mechanic I know put it quite succinctly, "The worst enemy of the Rotax 912 is their owners".
>> As for the blown up engine I saw, the school I attended was taught by the owner of the Rotax North American distributorship. I cannot fathom why he would make up such a story. If the owner had followed the manual, prelubed the engine, and then burped the oil system (the 912 has a dry sump oiling system that has no scavenge pump but instead relies upon blow by to pressurize the crankcase and push the oil out) he'd never have had a problem.
>
> But a broken rod in 10 seconds? Rod failures
> tend to be the byproduct of hammering of the
> end cap after the bearing is worn . . . a process
> that takes hours. To break the rod with the
> torque offered by a seized bearing that
> lacked lubrication for 10 seconds doesn't
> fit with the physics. You cited tight fits
> for the pistons and segued to a broken
> rod.
>
> To be sure, we don't have the benefit of
> failure analysis on the subject engine
> but using what appears to be capitalization
> of outlier event to re-enforce a perfectly
> reasonable caution to be certain of engine
> lubrication smells of "teaching by
> sensationalism." This sort of teaching is core
> to many the useless if not expensive
> ol' mechanic's tales that plague our
> community.
>
> I'm not calling him a liar . . . but I am
> skeptical based on the cause/effect cited.
>
>
>
> Bob . . .
>
> =========================>> -List" target="_blank">http://www.matronics.com/Navigator?AeroElectric-List
> =========================>> http://forums.matronics.com
> =========================>> le, List Admin.
> ="_blank">http://www.matronics.com/contribution
> =========================>


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PostPosted: Tue Feb 04, 2014 5:33 am    Post subject: Essential Bus question Reply with quote

You also have to take into account that unlike the LyCo's, the Rotax has a five piece crank that is pressed together with nothing but the pressure of the fit to keep it together and aligned. I would imagine the trail of tears would include a piston seizure that causes the crank to come out of alignment which not only destroys a bearing or two, but gives the various crank sections a chance to beat upon each other. The reason for the multipiece crank is so that it can be made shorter by reducing the clearance between the side of the rod, see picture. With so little clearance between the rod and the adjacent crank web the twisted, misaligned crank now has a chance to really start beating on the rods, the piston skirts, and any pieces that have come loose. Of course the Rotax engineers have reduced clearances between the rotating assembly and the case halves to shave off more weight and by now the bearings are not only being twisted out of their seats but the case webs are being hammered, too.
Quote:
Quote:
Quote:
I find this scenerio to be highly unlikely! If this were the case, then I would wager that there would be cases of this type of failure during normal operation, due to the stress and vibration created during high power running.

Roger


I am using the Free version of SPAMfighter.SPAMfighter has removed 1850 of my spam emails to date.Do you have a slow PC? Try a free scan! [quote][b]


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Eric M. Jones



Joined: 10 Jan 2006
Posts: 565
Location: Massachusetts

PostPosted: Wed Feb 05, 2014 12:48 pm    Post subject: Re: Rotax Crank was Essential Bus question Reply with quote

Quote:
You also have to take into account that unlike the LyCo's, the Rotax has a five piece crank that is pressed together with nothing but the pressure of the fit to keep it together and aligned. I would imagine the trail of tears would include a piston seizure that causes the crank to come out of alignment which not only destroys a bearing or two, but gives the various crank sections a chance to beat upon each other. The reason for the multipiece crank is so that it can be made shorter by reducing the clearance between the side of the rod, see picture. With so little clearance between the rod and the adjacent crank web the twisted, misaligned crank now has a chance to really start beating on the rods, the piston skirts, and any pieces that have come loose. Of course the Rotax engineers have reduced clearances between the rotating assembly and the case halves to shave off more weight and by now the bearings are not only being twisted out of their seats but the case webs are being hammered, too.
I find this scenerio to be highly unlikely! If this were the case, then I would wager that there would be cases of this type of failure during
normal operation, due to the stress and vibration created during high power running. Roger


Let me venture way outside my pay-grade and offer an opinion that the Rotax multipiece crank is in no way an inferior design, and in fact offers lots of advantages:

1) Cost
2) The connecting rods need no end bearing caps, thus they are stronger and lighter.
3) Exceptional resistance to failure from torsional vibration.
4) The ability to use different metals for the various parts.
5) Shorter crank.
6) The ability to use roller bearings. (I have no idea if they actually should or do).

As long as the rod and main bearings are good, the idea that the crank can come apart is simply a distraction. Porsche 4-cam racing engines used a similar design, although they keyed theirs. But Still... Your Mileage May Vary.

Off Topic... Do not Archive


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PostPosted: Fri Feb 07, 2014 2:31 pm    Post subject: Essential Bus question Reply with quote

Sorry about adding to this rather old discussion but I've been away for
awhile.

I finished my RV10 in 2011 which means that I designed my electrical
system and panel around 2008 for a 2009-2010 build.

I have 3 GRT HX EFISs - 2 aimed at the pilot, 1 at the passenger. They
supply synthetic vision, moving map, weather, traffic and a complete
suite of engine stats. No light weight backup batteries can be
configured at the factory with these systems. These screens have no
integral on/off switch. I chose not to add any switches or operable
CBs. They come on with the master and will usually reboot when my IO540
cold starts with a single, fresh PC 680 battery.

The GPS WAAS smarts for this system are supplied by a G430W.

I am a serious traveler with this machine and practically all flight are
on IFR plans. My normal routine for all flights is to file my plan
using Foreflight on an iPad. Whenever at an airport with clearance
delivery, or when departing into IMC conditions, I obtain my clearance
on the ground, before engine start, and enter it into my iPad and then
into my G430. Many times in congested areas, this entry is followed by
no small amount of study. As my aging mind continues to fog over, I'm
finding that the study time grows.

Here's the challenge on G430 based panels; it loses any entered flight
plan when powered off. An engine start that reboots my GRTs, reboots my
G430.

An acute challenge on 430 based panels when used for flights around the
Wash DC area or for flights along Florida's Atlantic coast is that the
G430 does not know what a Victor airway is. These are flights I make
regularly and clearances in these areas typically still include Victor
airways. So in the routine described above, entry into the iPad
generates the necessary waypoints to any Victor airways. Accurate entry
of these waypoints into the G430 is important and there's no way I want
to redo the work.

As Bob would put it, this is the 'kitchen sink' I choose to fly with. I
think it's fantastic and works very very well for me. It's now a well
grooved swing. The inability of some (e.g. Bob, not necessarily you
Kelly but I did choose to respond to your post) to 'get' this
requirement for this pilot, seems to me is just an inability to see past
old school experience or perhaps your current pleasure flying routines.

I have a Z-14 with 2 batts, 2 alts, and 2 buses and I REALLY like it. I
bring up the 'kitchen sink' on one battery, get my clearances, enter
them into my systems, study my departure plan when doing complicated
airspace or low IMC departures and then bring up the 2nd battery bus,
cross link them and start my engine. Everything stays up. Before
takeoff I've learned, per Bob, to de-link the buses and off I go.

Per Bob, I've eliminated any semblance of an avionics bus, extra
switches or CBs. After a few operational adjustments and refinements
(Thanks Bob!), the 'overkill' of a Z-14 has given me exactly what I
think I need.

I need my avionics on before start and I have a big kitchen sink that
takes care of the dishes just like I want them done. So can we please
stop dismissing this approach to equipping and traveling in our very
fine OBAM aircraft within the user fee free ATC system we have? Some
of us do it every day because that's the way we choose to roll.

PS: I've been out of the loop island hopping the Bahamas. Recommend it
highly. What an adjustment flying VFR from place to place! However, I
still used the same procedures because that's what standard procedures
are for.

Bill "It's pretty darn good in the Bahamas" Watson
N215TG
On 2/2/2014 7:14 PM, Kelly McMullen wrote:
Quote:

<kellym(at)aviating.com>

Virtually all glass have their own light weight backup batteries so do
not have startup brown out issues unless no backup battery is installed.
I see very little value in being able to turn on GPS prior to start.
While one needs engine instrumentation prior to and during start, one
does not need avionics on.
Of course newer avionics that allow faster input of flight plans than
the 430 help, if that is the reason for turning on 430 before start.



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