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  #101  
Old 03-09-2018, 06:40 AM
rv6ejguy's Avatar
rv6ejguy rv6ejguy is offline
 
Join Date: Mar 2005
Location: Calgary, Canada
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As a result of the thermal testing, we're re-designing the coil driver circuit with different components and modifying the board with extra heat sinking capacity. Things were getting a bit hotter than we were comfortable with at max duty cycle.

Some of the new components are already being tested with more to follow on the weekend.

A second prototype board will soon follow. It's an unfortunate delay but this has to be right before production begins.
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Ross Farnham, Calgary, Alberta
Turbo Subaru EJ22, Marcotte M-300, IVO, RV6A C-GVZX flying from CYBW since 2003- 424.4 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi.htm


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  #102  
Old 03-09-2018, 06:47 AM
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maniago maniago is offline
 
Join Date: Aug 2014
Location: Bowie MD
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Quote:
Originally Posted by rv6ejguy View Post
As a result of the thermal testing, we're re-designing the coil driver circuit with different components and modifying the board with extra heat sinking capacity. Things were getting a bit hotter than we were comfortable with at max duty cycle.

Some of the new components are already being tested with more to follow on the weekend.

A second prototype board will soon follow. It's an unfortunate delay but this has to be right before production begins.
DIRFT! Do it right (the) first time.....
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Mani
MustangII (FoldingWing) "FirewallFwd&sundries": IO360B1E,RSA,C2YR-BF/F7666-2,Superior sump,James; 2xHXr,MiniX,EIS,480,327,240,SL30,Navworx; SteamAlt,AS,VSI
Don't be a hater; I'm a cousin with thin wings!
N251Y (res)
Dec2017
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  #103  
Old 03-10-2018, 03:42 PM
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rv6ejguy rv6ejguy is offline
 
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Location: Calgary, Canada
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Running the new circuit today and we're seeing about a third of the temperature at nearly triple the duty cycle as when running the previous test. We're happy with this now and will modify the PCB design to take these new parts. Onwards to further testing next week.
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Ross Farnham, Calgary, Alberta
Turbo Subaru EJ22, Marcotte M-300, IVO, RV6A C-GVZX flying from CYBW since 2003- 424.4 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi.htm


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  #104  
Old 03-10-2018, 06:45 PM
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maniago maniago is offline
 
Join Date: Aug 2014
Location: Bowie MD
Posts: 608
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Quote:
Originally Posted by rv6ejguy View Post
Running the new circuit today and we're seeing about a third of the temperature at nearly triple the duty cycle as when running the previous test. We're happy with this now and will modify the PCB design to take these new parts. Onwards to further testing next week.
Pffft. No IR pics.........then it didnt happen! LOL

Nice work Ross. Keep truckin'.
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Mani
MustangII (FoldingWing) "FirewallFwd&sundries": IO360B1E,RSA,C2YR-BF/F7666-2,Superior sump,James; 2xHXr,MiniX,EIS,480,327,240,SL30,Navworx; SteamAlt,AS,VSI
Don't be a hater; I'm a cousin with thin wings!
N251Y (res)
Dec2017
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  #105  
Old 03-11-2018, 10:21 AM
Chkaharyer99 Chkaharyer99 is offline
 
Join Date: Oct 2011
Location: Pilot Hill, CA
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Quote:
Originally Posted by rv6ejguy View Post
We can make the CPI2 face plate dimensions available now to anyone who needs it for laying out their panels.
Ross,

Please send me a copy.

I’d also like more details about your blind mount option. Pictures?
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Last edited by Chkaharyer99 : 03-11-2018 at 05:32 PM. Reason: correct spelling
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  #106  
Old 03-13-2018, 06:42 PM
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rv6ejguy rv6ejguy is offline
 
Join Date: Mar 2005
Location: Calgary, Canada
Posts: 4,714
Default Battery Mount

Finally got the prototype backup battery mount done for the CPI2.





Only one ATO fuse holder is shown here. Mounting is via six 10-32 countersunk screws. The top strap will be threaded in 2 places to accept 2 more Adel clamps to hold the battery wires securely.

Total weight is a bit under 3 pounds with the battery.
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Ross Farnham, Calgary, Alberta
Turbo Subaru EJ22, Marcotte M-300, IVO, RV6A C-GVZX flying from CYBW since 2003- 424.4 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi.htm


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  #107  
Old 03-13-2018, 06:51 PM
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rv6ejguy rv6ejguy is offline
 
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Location: Calgary, Canada
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Quote:
Originally Posted by Chkaharyer99 View Post
Ross,

Please send me a copy.

I’d also like more details about your blind mount option. Pictures?
The blind mount will dispense with the panel display and you'll have a couple of switches to power up the unit(s). Nothing to really see at this time. We're at least 3 weeks away from machining prototype single and dual board enclosures as we can't do that until the PCB is redesigned.

I'd probably recommend most people who want to blind mount, look at the original CPI, since without the panel display, a lot of the newer features are not available. The CPI is lighter, smaller and less expensive than the CPI2. Plans are to continue to offer both. The CPI appeals to many of the lower hp engine owners (Rotax, Jabiru, VW etc.)

BTW, yesterday Barry completed a severe coil/ board test running at 12,000 rpm for 45 minutes. The new board drivers ran cool but it cooked the coil. I'm guessing few aviation folks will be running at 12K for very long...

Today we were running auto switch over tests and looking at performance at low battery voltages down to around 10V.
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Ross Farnham, Calgary, Alberta
Turbo Subaru EJ22, Marcotte M-300, IVO, RV6A C-GVZX flying from CYBW since 2003- 424.4 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi.htm



Last edited by rv6ejguy : 03-13-2018 at 07:03 PM.
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  #108  
Old 03-14-2018, 07:32 PM
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rv6ejguy rv6ejguy is offline
 
Join Date: Mar 2005
Location: Calgary, Canada
Posts: 4,714
Default Backup Battery Tetsing

We were running backup battery tests with the board and 4 cylinder coil pack running at 2500 rpm powered by the 2.9 AH Powersonic AGM battery we plan to recommend.

Average current draw was 1.18 amps. We ran one coil pack for 1 hr and 15 mins and resting battery voltage was still 11.8V at the end of the test. This was using the regular full coil charge time. We can reduce the charge time about 15% in backup mode to reduce the current draw a bit more with no spark energy issues. Pretty happy with this performance so far.

We'll repeat with 2 coil packs soon.
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Ross Farnham, Calgary, Alberta
Turbo Subaru EJ22, Marcotte M-300, IVO, RV6A C-GVZX flying from CYBW since 2003- 424.4 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi.htm


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  #109  
Old 03-15-2018, 05:42 AM
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rv6ejguy rv6ejguy is offline
 
Join Date: Mar 2005
Location: Calgary, Canada
Posts: 4,714
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Last night we continued testing of the backup battery. We got 109 minutes of stable run time and will do a slight software change to try to get this to 120 mins. Will repeat that test soon to prove it.

We're tweaking software to the battery charging code today based on measurements from testing yesterday.

The new drive circuits are essentially ice cold running at 2500 rpm. Very happy with that change.
__________________

Ross Farnham, Calgary, Alberta
Turbo Subaru EJ22, Marcotte M-300, IVO, RV6A C-GVZX flying from CYBW since 2003- 424.4 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi.htm


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  #110  
Old 03-15-2018, 07:16 AM
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rv6ejguy rv6ejguy is offline
 
Join Date: Mar 2005
Location: Calgary, Canada
Posts: 4,714
Default Controller Face Drawing for Panel Cutout

Here is the link for the CPI2 panel cutout: http://www.sdsefi.com/cpi2panel.pdf
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Ross Farnham, Calgary, Alberta
Turbo Subaru EJ22, Marcotte M-300, IVO, RV6A C-GVZX flying from CYBW since 2003- 424.4 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi.htm


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