SDS EM-6 EFI ECU

[rv6ejguy]

Mike, yes, I'll be at Reno supporting the many racers running SDS this year. Will be good to see you again.

[rv6ejguy]

It's been a while since we updated this thread.

We are currently working on the new panel mount programmers which will be compatible with both EM-5 and EM-6 ECUs. Most of the design for one is done now and some parts have already started the production process while others will go to prototyping next week. Code is already written for these to interface.

Given the great positive feedback we've received from potential and past customers, I think you'll like what we designed.

I anticipate release of the first design in October if all goes well. The second design will hopefully be in production in Dec.

I can't say much more than that until we are closer to release.

[rmartingt]

Originally Posted by rv6ejguy

It's been a while since we updated this thread.

We are currently working on the new panel mount programmers which will be compatible with both EM-5 and EM-6 ECUs. Most of the design for one is done now and some parts have already started the production process while others will go to prototyping next week. Code is already written for these to interface.

Why two different programmers?

Also, would you advise just waiting a month or two on ordering a full system at this point? I'm definitely not in an urgent need for it and can afford the wait; I'll find other parts to work on.

[rv6ejguy]

We wanted to give our customers more choices which will fit their panel space. Research showed this to be a big deal. There are a lot a new builds with glass and still a lot of retrofits in some older aircraft with steam.

The programmers will be EM-5 compatible and released well before the EM-6 ECU becomes available. We want customers to have it's advantages sooner rather than later.

If you can wait, you'll have both choices.

[pr1malr8ge]

Any pics of the new controller?

[rv6ejguy]

Our usual procedure is to wait until we have all the hardware in hand and working before we release photos.

The face was approved for production last week so that's in process now. That usually takes around 4 weeks.

Prototype enclosure CNC machining will start next week.

Should have proto PCBs by this Friday.

[rv6ejguy]

Production keypads for Design 1 will be shipped Oct. 10th. Proto PCBs are being tested now. Proto enclosure machining was delayed 2 weeks while the machine shop replaced one mill with a new 4 axis machine. These should be done mid next week to test fit.

We hope to release final sizes and photos in mid Oct. once testing is completed. If all goes well, we should be able to release some in early Nov.

Design 2 work will begin in mid October.

[rv6ejguy]

Ok, many folks have been waiting to see what the new EM-6 programmers will look like for some time. As always, things take longer to do than you plan.

We looked at many different sizes and types of displays over the last year and were heading towards a large touch screen early on. Bought some screens and CPUs to dabble with but in listening to feedback from customers, they kept telling us to keep it small- they didn't have a lot of panel space to put something big with their large glass displays. Listening to our customers has served us well in the last few years as we have developed the features most wanted- cylinder trim, LOP timing advance, easier to mount injectors etc.

I did a big evaluation here on VAF, downloading over 40 photos of modern RV panels and came to the conclusion we really did need something different than what we were working on. I saw the only place many people had vacant panel space was above the center stack, in the dead space near the top of the panel arch.

We also evaluated the function vs wow factor of touch screens for these devices. Once programming is completed, most people don't use the programmer so much any more, outside of cylinder trim, the LOP switch, gauge modes and maybe looking at a fault code once in a while. We therefore discarded the big, square TFT display and went for the smallest practical display and keypad we could make to fit the maximum number of glass panels. A couple months lost but I think this design will fit modern panels much better and make more people happy.

Here is what we came up with for Design1.



This will be 6.25 X 1.47 inches to fit the normal stack width. Total box depth is less than 2 inches, allow around 4 inches with data cable exits. It will have a blue background LCD (not green as in the photo above) with white alphanumerics to match the recent look of the CPI-2 display which people really liked. The shape and colors fit better with Garmin, Dynon/AFS and MGL glass as we saw in Mike Kellems' CPI-2 post a couple weeks ago.

We also listened to customers who said we should eliminate as many external switches as possible. So we've made the programmer select switch to access either ECU, integral with the keypad as well as the LOP switch with dedicated keys and status LEDs similar to the CPI-2. We've also fitted the check engine light (now called Fault) in the programmer face to eliminate that external light and wiring.

Touch screens were not an option for this size and shape and many people said they prefer the tactile feeling of membrane switches anyway.

We'll follow in early 2020 with a second programmer choice-Design2, which will be the same size and shape of the present EM-5 aviation programmer (fits in a standard 3 1/8 round hole). This will have the same colors, graphics and functions as Design1 above. Some people do have room for this shape or may want to upgrade from an earlier type programmer to this one at some point and don't want to cut new holes in their panels.

These new programmers will be introduced into the EM-5 lineups as soon as they are in production and older EM-5s can use them if re-flashed with new software.

We did leak some basic dimensions to customers working on panels and response has been really positive with this new shape so I think we may have made a good call.

Thanks to everyone who gave us comments and feedback during the evaluation and design stage. That helped correct our path and come up with something that suits more panels.

[charosenz]

Ross,

Looks great. I for one am somewhat glad touchscreen is not incorporated. Great to see innovation with a high degree of customer input involved.

I would much rather have buttons that are easy to see and find that a touch screen. Best of all you don't have to hunt to find just that right spot on a touch screen to activate a function. I am also glad it is LCD and not LED. I have learn that even the brightest LED get washed out in bright sunlight, but LCD are not affected.

I am sure they will sell well.

Charlie

[GordonV]

Hi Ross,

The Design1 Programmer looks great and I am happy you choose this form factor for all the reasons you gave in your post above.

I hope the programmer LED ?s A/B are extinguished when NOT in the programmer mode and that you make the Fault LED red. Just a small point, I noticed that the bezel on the right is bigger than on the left, I think it would be more beautiful when they are equal. Where will the Mixture knob be?

I know I am way too late to give input for the new EM-6, but here goes anyway.
I would love to see the following features:
Ability to program 3 different ignition/fuel maps, to be chosen via the LOP button.
MAX PWR, the ignition/fuel maps are programmed to give maximum power on the ROP side, staying just outside the red box, but without wasting any more fuel then necessary.
ECON, the ignition/fuel maps are programmed to give ?maximum? power on the LOP side, staying just outside the red box. This power is arbitrarily chosen, but I would choose just below LOP, for instance 25 degrees LOP, resulting in a relatively low speed loss.
ECON +, the ignition/fuel maps are programmed to give the maximum fuel efficiency. This power is also arbitrarily chosen, for instance 75 degrees LOP, resulting in minimum fuel flow, but accepting a much bigger speed loss.
Both Econ settings would be programmed with ROP values above 75% power and/or the ECU would automatically switch to the MAX PWR map when it sees power settings above 75%. This feature would make it literally foolproof, so you always have max power ROP available for take off and go around. Of course the LOP LED on the programmer should follow this auto switching.
Ability to have ?automatic? cylinder fuel trim for all power settings. During test flights we find what individual fuel trim is needed to have the EGT?s peak at the same time for several MAP and RPM combinations. This information is then ?overlaid? on the ignition/fuel map so we get automatic individual fuel trim at these MAP/RPM settings with an interpolation between these points.

The new programmer will sit in a high visibility spot, so when not in program mode it can be used as an annunciator. It can show for instance the chosen power mode MAX PWR, ECON or ECON + and % power and AFR. When there is an anomaly this will be replaced by for instance ECU1 or ECU2, IGN1 or IGN2, FUEL PRESSURE, BUS1 xx V, or BUS2 xx V. The fault codes should be on a separate page. Ideally the white alphanumerics should change color to red or amber or alternatively the whole screen could change color from blue to amber or red. It is important to have a visible change otherwise it will be very easy to miss.
Also I find it important to see not only the LOP LED illuminated but also the power mode annunciation when LOP is chosen, again because a little LED will be overlooked very easily.
As far as the % power is concerned, I know there is no operational need for it and that often it is not very accurate. But with all the data available to the ECU you should be able to calculate a reasonable number and it is nice to have. As far as AFR is concerned, also no operational need, but it is a very nice indicator of your fuel efficiency. I plan on mostly using unleaded fuel so the Oxygen sensor should survive. Give the users some freedom to decide what they want to see on this page and everybody will be happy.

Gordon