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Fwd: [Bearhawk] Pacer progress
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user9253



Joined: 28 Mar 2008
Posts: 1920
Location: Riley TWP Michigan

PostPosted: Sun Jun 21, 2015 5:27 pm    Post subject: Re: Fwd: [Bearhawk] Pacer progress Reply with quote

Quote:
I understand that you do not recommend a Master Switch because it is a single point of failure for the electrical system. In that case, how would the system be configured to do away with a Master Switch?

I have never heard anyone recommend not having a master switch. There needs to be some way to shut off power.
Many have recommended not having an avionics switch, which is an unnecessary single point of failure.
Joe


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PostPosted: Sun Jun 21, 2015 5:30 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

Quote:
I'm extending a few of the head set jack. The PM300 calls for shielded wires. Do I need to add shielding at the splice? Something like metal foil then shrink tube?

No . . . in fact, shielding of headset and microphone
wires is of little if any demonstrable benefit. Shielding
breaks certain form of noise propagation that doesn't
exist behind modern panels . . . and few legacy panels.
You could wire headsets with bare, twisted pair and microphonee
with twisted trios (assuming a PTT wire) and save yourself
a lot of fuss with shielding.

But if you choose to extend already sheiled wires, a simple
splice between signal and shield conductors is fine. You
don't need to add a shielding 'cocoon'. We often take
shielded wires through connectors with separate pins
carrying the shield(s) . . . with perhaps as much as
3" of the vulnerable wire running 'unshielded' through
the connector . . . not a problem.


Bob . . . [quote][b]


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PostPosted: Sun Jun 21, 2015 5:41 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

Okay….now I understand. Was not comprehending how you could NOT have a Master Switch. So without an avionics, switch, you have to individually switch on or off all electronics once the master switch is turned on.

M. Haught
Quote:
On Jun 21, 2015, at 8:27 PM, user9253 <fransew(at)gmail.com> wrote:




> I understand that you do not recommend a Master Switch because it is a single point of failure for the electrical system. In that case, how would the system be configured to do away with a Master Switch?

I have never heard anyone recommend not having a master switch. There needs to be some way to shut off power.
Many have recommended not having an avionics switch, which is an unnecessary single point of failure.
Joe

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PostPosted: Sun Jun 21, 2015 6:07 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

On 6/21/2015 8:00 PM, Robert L. Nuckolls, III wrote:

Quote:


  Starter contactor right next to the battery contactor?

  Forgive me, I thought we were at the planning stages.
  The drawing you offered was not a wiring diagram but
  a rough architecture . . . not unlike the Z-figures
  in the book. Building a wiring diagram around an
  architecture drawing takes some time, conversation
  and thought.  The wire book with understanding gleaned
  from a team of guys who have been there done that goes
  a long way toward putting grins on your flying-fuzz when
  they sign off on your rebuild. You were already at the
  top of the ski jump . . . a bit late to be getting input
  from the coaches.


  Bob . . .
As I said in my follow on post after Mark, I AM trying to do my planning.  I am new at this and don't have Mark's experience with other machinery, so I need all the help I can get.  I have a set of the same contactors, and was planning on installing them as Mark has.  What is the problem with the starter contactor right next to the battery contactor?  Other than a vague idea of what I want on the panel, I have not a clue as to how to get to the point of "putting grins on the flying-fuzz when they sign off on my rebuild"?   But that is my purpose. 

So....how do we arrive at the wire book?  What do I need to do to bring this process along get the "coaches" engaged? 

M. Haught


Quote:

Quote:



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PostPosted: Sun Jun 21, 2015 6:24 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

At 02:38 PM 6/21/2015, you wrote:
Quote:
Bob -

Mark’s system is well beyond “opportunities for consideration” ……but I am following his path th on my PA22-20 project, so want to learn from what Mark has done, and get your input on designing a system for my project. Hence, I asked him to post what he has done. From his postings, and the responses from you and the group, I hope to learn what to do differently, as well as what to copy.


Okay, the skeleton wire-book I published for Mark
is the baseline document for doing the best we know
how to do for your project.
Quote:


For example: I have the same contactors for my project, (one for starter that is not continuous, and one form Battery that IS continuous)) coupled with a Bendix ignition switch with a “Start” position to do away with the box / push button system that was originally under the pilot’s seat.Mark used a Master Switch for his syster - I understand that you do not recommend a Master Switch because it is a single point of failure for the electrical system. In that case, how would the system be configured to do away with a Master Switch? Would the entire electrical system be activated from the ignition switch going to a L/R or Both Mag position? I am hoping this will generate a very productive discussion that results in an electrical system design that I can get “approved” for my project with a minimum of problems with the FAA, and yet, have an up to date system with modern components.

Understand. But the 'master switch' discussion was
NOT about the DC Power Master switch, clearly shown
in the baseline wirebook. What you don't find is
an avionics master switch . . . which was birthed
from poor understanding of the physics. All those
NAVCOM 300's we killed at Cessna were NOT spike-bit
by starters . . . starters do not generate spikes
of radio killing proportions . . . and RTCA knows
it. In fact, the legacy 'spike test' conducted under
DO-160 contains very little energy . . . about the
equivalent of a gnat sneeze compared to say, alternator
runaways . . .

The radios were being killed by soggy batteries
allowing engine cranking to drag the bus down to
6-7 volts combined with transistors of the era
being exceedingly vulnerable to a phenomenon
called 'second breakdown'. Conditions imposed on
our NC300's prompted the unhappy event on dozens
of radios on delivery aircraft. The AV Master switch
was a knee-jerk band-aid . . . the value of which
disappeared a few years after we started putting
them in airplanes.

See http://tinyurl.com/q5uzw78

If you find an 'avionics master' mentioned in ANY
installation manual for avionics, I'd like to know
who published it. For the past 40 years, EVERY company
I've contacted about that feature had to confess,
"We don't think it's needed either . . . it's just
that everybody has been doing it for decades . . ."

ANY piece of hardware qualified to DO-160 can easily
stand off the ravages of everything the aircraft bus
can throw at it. Starter spikes don't exist . . . I've
tracked the elusive starter-spike on everything from
C150 to BeechJets . . . they are not there.

Start with the draft wirebook. Craft your questions
based on the existence or absence of some feature
about which you need more understanding. As the
educational process moves forward, we'll edit
those drawings to match the best-we-know-how-to-do
for your project.

For Mark, we're limited to combing out a few big
tangles . . . his system is pretty much cast in
concrete.


Bob . . . [quote][b]


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PostPosted: Sun Jun 21, 2015 7:34 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

Quote:
For example: I have the same contactors for my project, (one for starter that is not continuous, and one form Battery that IS continuous))

Okay, the contactor of choice for starter
duty looks more like this . . .



These devices have been common to the automotive
industry for decades and feature low area, high
pressure contacts much more suited to withstanding
starter inrush currents due to their higher closing
pressures and low mass to minimize bounce.

Location of choice is on the firewall where the
BAT terminal of hte contactor becomes the distribution
point for bringing battery+ wire to the bus.

Although, mounting under the seat is only
slightly inconvenient. But I DO recommend
the alternative form factor . . . it's much
better suited to task and will have diode
suppression built in.




Bob . . . [quote][b]


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PostPosted: Sun Jun 21, 2015 7:56 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

Great article, provides me with the first goals for my system, and a very good understanding of the logic. I have already been studying the wire book pages. Will print out each one and start making note and additions of my specific components, plus compare them to the original schematic.
Question one is: you seemed skeptical about mounting the two contractors side by side right at the battery as Mark did. Why is that not desirable and what are the problems?
M. Haught
Sent from my iPad

On Junhttps://www.flypadmount.com 21, 2015, at 9:23 PM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
[quote]
Okay, the skeleton wire-book I published for Mark
is the baseline document for doing the best we know
how to do for your project.
Quote:


See http://tinyurl.com/q5uzw78



Start with the draft wirebook. Craft your questions
based on the existence or absence of some feature
about which you need more understanding. As the
educational process moves forward, we'll edit
those drawings to match the best-we-know-how-to-do
for your project.

Bob . . .
Quote:

[b]


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PostPosted: Sun Jun 21, 2015 8:18 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

Sent from my iPad

On Jun 21, 2015, at 10:32 PM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
[quote]
Quote:
For example: I have the same contactors for my project, (one for starter that is not continuous, and one form Battery that IS continuous))

Okay, the contactor of choice for starter
duty looks more like this . . .



These devices have been common to the automotive
industry for decades and feature low area, high
pressure contacts much more suited to withstanding
starter inrush currents due to their higher closing
pressures and low mass to minimize bounce.

Location of choice is on the firewall where the
BAT terminal of hte contactor becomes the distribution
point for bringing battery+ wire to the bus.

Although, mounting under the seat is only
slightly inconvenient. But I DO recommend
the alternative form factor . . . it's much
better suited to task and will have diode
suppression built in.




Bob . . .
Quote:


[b]


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PostPosted: Sun Jun 21, 2015 8:22 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

Okay.....found one the B&C site plus located your article on the use of diodes. The B & C has diode built in and is PMA. Grounds from mounting surface.
Thanks!
M. Haught

Sent from my iPad

On Jun 21, 2015, at 10:32 PM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
[quote]
Quote:
For example: I have the same contactors for my project, (one for starter that is not continuous, and one form Battery that IS continuous))

Okay, the contactor of choice for starter
duty looks more like this . . .



Quote:


[b]


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PostPosted: Mon Jun 22, 2015 5:46 am    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

At 08:41 PM 6/21/2015, you wrote:
Quote:
--> AeroElectric-List message posted by: "H. Marvin Haught" <handainc(at)madisoncounty.net>

Okay….now I understand. Was not comprehending how you could NOT have a Master Switch. So without an avionics, switch, you have to individually switch on or off all electronics once the master switch is turned on.

as you do with any appliance that is not
intended to be operated 100% of the time.
The core idea to be considered is whether
or not there is value in making sure any
particular device is OFF during any particular
phase of aircraft operation . . .

The Avionics Master was created based on the
notion that radios were prone to go belly up
due to supposed spikes from the starter . . .
which turned out to be brown-out events and
not spikes.

Adding the switch reduced the risk of pilots
killing radios that were not well crafted to
withstand the brown-out event . . . a condition
that disappeared from the marketplace a few
years after the avionics master became deeply
entrenched in the aviator's psyche.

Some still argue that it's useful to reduce
loads on the battery while cranking . . . again
a condition built on the performance of marginal
batteries miserably maintained.

If you're SVLA battery is watched as closely
as you check your tires, oil, brake fluid,
fuel and nicks on the prop, then there's no
reason to 'relieve' cranking loads. The
avionics are a tiny fraction of cranking loads
and insignificant in the grand energy calculus.


Bob . . . [quote][b]


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PostPosted: Mon Jun 22, 2015 6:10 am    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

And with having only a comm radio (Icom) and a transponder (Sandia), and a panel mount for an iPad, there is only 3 items to be added to the before start up checklist.  The Pacer I flew (now the one Mark is rebuilding) had no avionics master, radios are already a part of my checklist habit. 

What regulator do you recommend - I had installed a Zefftronics on the old Pacer due to a chronic problem with the old Ford Type regulator.  Could never get one to last more than 6 or 8 months.  Bought the first 2 from aircraft supply stores (read pricy) and the last two from auto supply stores,( read crappy rebuilds) , which I suspect was also the problem with the aircraft supply units, just with 3 times the markup.  The Zefftronics made the charging system trouble free with gel cell batteries lasting 5 years, and only changing  them because of their age or accidentally leaving the master switch on in sub zero temps,  killing the battery.  But generally, I took very good care of my batteries.  The Zeftronics is now over $350. 

I see now that I should have been following the list closer, as many of these things have likely been discussed on here.  My plate has stayed too full as of late, and now these topics are front an foremost in what I need to accomplish. 

M. Haught

On 6/22/2015 8:45 AM, Robert L. Nuckolls, III wrote:

Quote:
At 08:41 PM 6/21/2015, you wrote:
Quote:
--> AeroElectric-List message posted by: "H. Marvin Haught" <handainc(at)madisoncounty.net> (handainc(at)madisoncounty.net)

Okay….now I understand.  Was not comprehending how you could NOT have a Master Switch.  So without an avionics, switch, you have to individually switch on or off all electronics once the master switch is turned on. 

  as you do with any appliance that is not
  intended to be operated 100% of the time.
  The core idea to be considered is whether
  or not there is value in making sure any
  particular device is OFF during any particular
  phase of aircraft operation . . .

  The Avionics Master was created based on the
  notion that radios were prone to go belly up
  due to supposed spikes from the starter . . .
  which turned out to be brown-out events and
  not spikes.

  Adding the switch reduced the risk of pilots
  killing radios that were not well crafted to
  withstand the brown-out event . . . a condition
  that disappeared from the marketplace a few
  years after the avionics master became deeply
  entrenched in the aviator's psyche.

  Some still argue that it's useful to reduce
  loads on the battery while cranking . . . again
  a condition built on the performance of marginal
  batteries miserably maintained.

  If you're SVLA battery is watched as closely
  as you check your tires, oil, brake fluid,
  fuel and nicks on the prop, then there's no
  reason to 'relieve' cranking loads. The
  avionics are a tiny fraction of cranking loads
  and insignificant in the grand energy calculus.


  Bob . . .
Quote:



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PostPosted: Mon Jun 22, 2015 7:19 am    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

At 10:54 PM 6/21/2015, you wrote:

Quote:
Great article, provides me with the first goals for my system, and a very good understanding of the logic. I have already been studying the wire book pages. Will print out each one and start making note and additions of my specific components, plus compare them to the original schematic.

bingo!

Quote:
Question one is: you seemed skeptical about mounting the two contractors side by side right at the battery as Mark did. Why is that not desirable and what are the problems?

Okay, from the perspective of a clean-piece-of-paper
installation on a homebuilt aircraft, we try to
position items in the airplane to minimize numbers
and lengths of wires. The first goal is battery
contactor next to battery, starter contactor next
to the starter.

In the case of your refurb, the original battery
and starter controls were crew operated switches
one the seat stringer under the pilot's knees
and the battery was under the passenger's seat.
It's not illogical to REPLACE those switches
with contators located more or less in the same
locations as the original switches.

I would write my proposed 337 up to move the
starter contactor to the firewall but if you
wanted to utilize as much of the factory stock
architecture as possible . . . locating
the contactors like Mark did is perfectly
logical. The style of starter contactor
problematic . . . while the Lamar 'works',
upgrading it's technology will improve service
life an reduce risk of sticking the contactor.

By the way, what starter are you contemplating
for this airplane?


Bob . . . [quote][b]


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PostPosted: Mon Jun 22, 2015 8:26 am    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

Well, this discussion is progressing nicely! I spent the evening trying to decide if I am going to invest in a lightweight starter and alternator, or save several hundred dollars and use the serviceable original starter and generators that I have one had (have 3 or 4 of each, all in good working order). Since this airplane is to resell, I think at this point, I am going to opt to use the original equipment. This whole exercise is to turn a project in which I have money tied up into cash, while getting hours toward my mechanic’s license (have tried to sell it for 3 or 4 years as a project with absolutely NO interest, even at give away prices). I am treading water while waiting to see if the medical reform passes and is put into effect. If so, my keeper project is another Pacer that will end up experimental…..very little will be left of the original fuselage, new wing with a different airfoil, fuselage extension, and otherwise, pretty much your dream project on big tires. Only 2 seat with large cargo space, built as lightly as possible.
So your clean piece of paper installation will be the next step in project evolution, but for now, I want the experience of doing the 337, and hopefully, getting it approved fairly easily because it will be a valuable experience in the work I hope to do as a licensed mechanic in my retirement world. So I like your second and third paragraph as if fits what I am trying to do, as well as being compatible with my thinking process. I think the architecture choices should be driven by feedback from active mechanics as to the prevalent mind set of FAA inspectors - closed minds as to changes in architecture when reviewing 337’s in the approval process, or receptive with logical support, professional wire book and presentation. If the former, Mark’s approach wins out - if the latter, firewall location of the starter contactor.

I have the continuous duty Lamar contactor being delivered today, but the starter contactor was back ordered, so I canceled that order. Will likely order the B&C starter contactor at $45 unless you have better and or cheaper alternative, and will do the same for the Battery contactor.

M. Haught
Quote:
On Jun 22, 2015, at 10:17 AM, Robert L. Nuckolls, III <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:
At 10:54 PM 6/21/2015, you wrote:
Quote:
Great article, provides me with the first goals for my system, and a very good understanding of the logic. I have already been studying the wire book pages. Will print out each one and start making note and additions of my specific components, plus compare them to the original schematic.
bingo!
Quote:
Question one is: you seemed skeptical about mounting the two contractors side by side right at the battery as Mark did. Why is that not desirable and what are the problems?
Okay, from the perspective of a clean-piece-of-paper installation on a homebuilt aircraft, we try to position items in the airplane to minimize numbers and lengths of wires. The first goal is battery contactor next to battery, starter contactor next to the starter. In the case of your refurb, the original battery and starter controls were crew operated switches one the seat stringer under the pilot's knees and the battery was under the passenger's seat. It's not illogical to REPLACE those switches with contators located more or less in the same locations as the original switches. I would write my proposed 337 up to move the starter contactor to the firewall but if you wanted to utilize as much of the factory stock architecture as possible . . . locating the contactors like Mark did is perfectly logical. The style of starter contactor problematic . . . while the Lamar 'works', upgrading it's technology will improve service life an reduce risk of sticking the contactor. By the way, what starter are you contemplating for this airplane?
Bob . . .
Quote:


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PostPosted: Mon Jun 22, 2015 9:19 am    Post subject: Re: Fwd: [Bearhawk] Pacer progress Reply with quote

Panel is almost ready to instal. Dimmer pot for the Ei hardware should be here today. Head set jacks extended. A few zip ties remain. On the subject of stuck starter solenoids. On my list of pros and cons for locating the starter contactor under the seat... How easy is it to get at if I need to whack it with something or disconnect it from the battery? Deciding the trade off... More wire up the firewall to a solenoid location accessible with the cowl open. Or deal with pulling the seat.

Marv and I spoke yesterday about the avionics master. When the PM3000 and the Sandia transponder was installed. The avionics guy told Marv and I to pull the breakers for them before starting the engine. Don't recall the reason. If the battery is nearly dead, low voltage....start contactor just asking to be stuck. Or brown out. A good battery shouldn't pull down below 10.8 volts under a load. What if it does due to poor health or some other reason. Being in the middle of now where. Many many times waiting for the temperature to reach 25 below zero before the first flight. Decided the avionics master is a good thing for me.
Some of the other decisions I made... Perhaps due to drain bramage....but. Decided to go with the Ei amp shunt on the alternator. I'd rather know if the field voltage reduces as the battery charge state comes up after starting. Or to discover the ampherage is greater than normal, indicating a possible battery problem. Monitor the battery health with the voltage meter.


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PostPosted: Tue Jun 23, 2015 5:30 pm    Post subject: Fwd: [Bearhawk] Pacer progress Reply with quote

At 12:19 PM 6/22/2015, you wrote:
--> AeroElectric-List message posted by: "mmoyle" <moylemc(at)gmail.com>

Panel is almost ready to instal. Dimmer pot for the Ei hardware should be here today. Head set jacks extended. A few zip ties remain. On the subject of stuck starter solenoids. On my list of pros and cons for locating the starter contactor under the seat... How easy is it to get at if I need to whack it with something or disconnect it from the battery?

Normally, shuts off the battery master to stop the fault . . . so that it can be dealt with in a relaxed manner.
Deciding the trade off... More wire up the firewall to a solenoid location accessible with the cowl open. Or deal with pulling the seat.

Ideally, one chooses a starter contactor designed to minimize the sticking phenomenon . . . THEN one also MAINTAINS the battery in a condition that (1) provides design-goal-driven endurance requirements from which the happy condition (2) arises: Risks for starter contactor sticking are significantly reduced.

Marv and I spoke yesterday about the avionics master. When the PM3000 and the Sandia transponder was installed. The avionics guy told Marv and I to pull the breakers for them before starting the engine. Don't recall the reason.

I'll bet he doesn't have one . . . beyond the notion that 'everybody does it' . . .
Further, pulling a breaker is not accepted operational practice . . . you won't find that behavior in any TC aircraft POH. If shutting a thing OFF for cranking operations is a good thing to do . . . then the reason is probably NOT something you want to spend money on.

If the battery is nearly dead, low voltage....start contactor just asking to be stuck. Or brown out. A good battery shouldn't pull down below 10.8 volts under a load. What if it does due to poor health or some other reason. Being in the middle of now where. Many many times waiting for the temperature to reach 25 below zero before the first flight. Decided the avionics master is a good thing for me.

BINGO! Routine preventative maintenance of the battery is the time honored, demonstrated recipe for comfortable completion of missions to PREDICTABLE compliance with design goals while minimizing miseries. There is NO GOOD REASON to be "in the middle of nowhere" with a soggy battery . . . there are lots of bad reasons . . . mostly founded in the owner/operators's less than responsible attitudes toward battery maintenance.
Being short on fuel 'in the middle of nowhere' would get you many raised eyebrows around a table of suds and pizzas . . . sadly, being caught in-the-wild with a soggy battery is all too often simply attributed to 'bad luck'.
I suggest that it is easy to make it NOT so . . .


Bob . . . [quote][b]


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addseo1115



Joined: 26 May 2015
Posts: 2

PostPosted: Wed Jun 24, 2015 2:28 am    Post subject: Re: Fwd: [Bearhawk] Pacer progress Reply with quote

I have enjoyed with your posts.
Useful posts here.
Nice to be here.


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mmoyle



Joined: 15 Jun 2015
Posts: 10
Location: Platinum, Alaska

PostPosted: Wed Jun 24, 2015 8:05 pm    Post subject: Re: Fwd: [Bearhawk] Pacer progress Reply with quote

No smoke..... Every thing functions.... Haven't powered up the radio yet. I'd like to have an antenna connected before closing the breaker.... Marv gifted me The Bob's book. Arrived in the mail today. Another manual to digest.... Thank you Marv and Bob. When I get to the Bearhawk harness I will be better edge-you-ma-kate'd. One odd thing I found today. Have installed a dimmer rheostat for the Ei components. The engine monitor dims nicely.....thing is the Ei USB power supply is opposite. It gets bright as the engine monitor gets dim??. Don't know if I made a mistake...some ting Wong? One question I've asked on the shortwing and Bearhawk group.... No answer. Hour meter. The Ei engine monitor is programmed with the actual total time on the aircraft. Do I need a separate hour meter? Not having fresh trout for dinner......

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