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  #11  
Old 09-26-2021, 03:25 PM
Bob Y Bob Y is offline
 
Join Date: Jul 2017
Location: Piedmont, SC
Posts: 287
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Well, don’t know how many occurrences are required to call something a pandemic, or how many countries to call it a global pandemic, but when I flew on Friday, I had the EXACT same issue - no fuel pump #2 and no green light. Diagnosed the problem today and the same root cause - poor contact at the HIC connector. Mine too was on pin #8. Wiggling the connector would cause the pump and light to operate intermittently. Noting would fail #1 pump, which was reassuring.

After disconnecting the connector from the HIC board, I removed the shell around the connector. Steinair used heat shrink around the wire bundle where it went into the connector shell to make a nice neat package. When I cut the shrink tube loose and reinstalled the connector, like magic, the pump started running. I was able to pull on #8 pin and cause intermittent misoperation. And there is discoloration on the female pin. After using a pin probe to gently push the segments of the female pin together for a tighter fit on the male pin, adding a wire tie several inches away from the connector and reinstalling without the heat shrink, I was no longer able to cause a failure by wiggling. So, the strain of the heat shrink in the outer pin is my conclusion for my failure.

And as a side note, this is the third time I’ve needed to remove the avionics bay cover since completion. I am so glad I modified the fiberglass canopy shroud to expose those otherwise hidden screws.

And yes, Scott, I will contact Support tomorrow with my findings.
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N569TT first flight 2/9/2020
#121047

Last edited by Bob Y : 09-28-2021 at 04:36 AM.
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  #12  
Old 09-27-2021, 12:51 AM
PEB PEB is offline
 
Join Date: Mar 2018
Location: Denmark
Posts: 20
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I have not informed Van's about this.

Quote:
Originally Posted by rv9builder View Post
Rob and PEB,

Did you contact Van's about this? If so, what were their thoughts or suggestions?
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RV-12iS
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  #13  
Old 09-27-2021, 02:49 PM
Bob Y Bob Y is offline
 
Join Date: Jul 2017
Location: Piedmont, SC
Posts: 287
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Apparently there have been multiple reports of this failure, as Vanís Support indicated an SB is in works to address it.
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N569TT first flight 2/9/2020
#121047
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  #14  
Old 09-27-2021, 10:58 PM
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rcarsey rcarsey is offline
 
Join Date: Jul 2012
Location: North Brunswick, NJ
Posts: 270
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I can confirm that a SB is in the works. I've already performed it, which took about 1 full airport-day (that's a day where you try doing a 1 hour job and it turns into 6 hours as other builders/pilots stop by to see what you're doing).

I won't go into the details, as its still a draft.. but I felt like it was straight-forward and easy for a builder to retrofit.. and maybe adds 5-10 minutes of work for someone still in the process of building.

I tried redesigning the board myself (shown below), but given the real estate constraints (its surrounded things that can't really move.. the firewall, the ECU, the instrument panel fan), I had trouble breaking out the Pump 2 wires (pins 7&8) into its own Molex Mega Fit connector. I did fit a 6 and 2 pin Megafit connectors onto the board, but the D-Sub connector is covering up the HIC Module mounting holes.. so it won't work. Theres just not enough room.

I also wanted to replace Mega Fit with Deutsch DTP connectors (same as the fusebox's regulator connectors which can carry up to 25A). However, they are gigantic and there's definitely no way to squeeze them into the existing footprint.

Now that I see PEB's idea -- removing Mega Fit and soldering a pigtail right onto the board, along with changing the type of connector.. AND securing that connector to Van's proposed strain relief bracket.. that may be the way to go.

PEB: What connector did you use? I like the convenience of having 1 connector, but I still may want to use two connectors to eliminate a single point of failure.
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  #15  
Old 09-28-2021, 11:46 AM
PEB PEB is offline
 
Join Date: Mar 2018
Location: Denmark
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Quote:
Originally Posted by rcarsey View Post
Now that I see PEB's idea -- removing Mega Fit and soldering a pigtail right onto the board, along with changing the type of connector.. AND securing that connector to Van's proposed strain relief bracket.. that may be the way to go.

PEB: What connector did you use? I like the convenience of having 1 connector, but I still may want to use two connectors to eliminate a single point of failure.
I used automotive connectors from an Audi. They have VW part numbers.

Female connector: 3B0 937 741

The male consist of 2 parts: 3B0 937 713 and 3B0 979 714

Female pins 2.5 mm2 square: 000 979 225 E
Male pins 2.5 mm2 square: 000 979 226 E

You can find the parts on eBay.

If you want 2 connectors you can use 191 972 714 and 1J0 972 704.
Male pins: 000 979 219 E
Female pins: 000 979 225 E
(google the part numbers to see pictures)
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Last edited by PEB : 09-28-2021 at 11:53 AM.
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  #16  
Old 09-29-2021, 06:12 AM
jcboon jcboon is offline
 
Join Date: Aug 2013
Location: Amsterdam
Posts: 42
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Amazing coincidence. Yesterday I had the same experience with my fuel pump quiting (after 11 minutes). Switch light went off, and pressure dropped to 44.2. No signs of this happening in earlier flights. Great video.

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  #17  
Old 09-29-2021, 12:08 PM
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rcarsey rcarsey is offline
 
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Location: North Brunswick, NJ
Posts: 270
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I'm unsure if I posted snapshots of my Fuel PSI vs Fuel Flow in this or other forums, but that's about what I saw. I'll post a couple below. Its normal to see a slight drop in pressure as flow goes up.. maybe about 0.5psi from idle to full-power

Unless I happened to look down and see the light out, or notice < ~45psi, there is no way to tell - no alerts, engine sound change, etc.

Now that I'm all fixed up with Van's draft Service Bulletin, I may experiment with changing the Fuel PSI warning (yellow) level in the G3X. I'm careful to document any settings change in my Avionics Logbook when I deviate from Van's standard configs.. and I suspect the exact cut-off number will vary slightly from aircraft to aircraft..or pump assembly to pump assembly.
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  #18  
Old 09-29-2021, 01:03 PM
Bob Y Bob Y is offline
 
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Location: Piedmont, SC
Posts: 287
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Vanís eliminated the upper and lower yellow caution fuel pressure ranges in the last firmware update.
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N569TT first flight 2/9/2020
#121047
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