ASTM F2538-07a(2010)
(Practice)Standard Practice for Design and Manufacture of Reciprocating Compression Ignition Engines for Light Sport Aircraft
Standard Practice for Design and Manufacture of Reciprocating Compression Ignition Engines for Light Sport Aircraft
SIGNIFICANCE AND USE
This practice provides designers and manufacturers of engines for light sport aircraft design references and criteria to use in designing and manufacturing engines.
Declaration of compliance is based on testing and documentation during the design and testing or flight-testing of the engine type by the manufacturer or under the manufacturer's guidance.
SCOPE
1.1 This practice covers minimum requirements for the design and manufacture of reciprocating compression ignition engines for light sport aircraft, Visual Flight Rules (VFR) use.
1.2 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.
General Information
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Standards Content (Sample)
NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation: F2538 − 07a (Reapproved 2010)
Standard Practice for
Design and Manufacture of Reciprocating Compression
Ignition Engines for Light Sport Aircraft
This standard is issued under the fixed designation F2538; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 4.2 New Engine Model Designations:
4.2.1 Each new engine model must be qualified in accor-
1.1 This practice covers minimum requirements for the
dance with this practice.
design and manufacture of reciprocating compression ignition
4.2.2 Design or configuration changes that impact the in-
engines for light sport aircraft, Visual Flight Rules (VFR) use.
stallation interface, performance, or operability of the engine
1.2 This standard does not purport to address all of the
require a new engine model designation.
safety concerns, if any, associated with its use. It is the
4.3 Design Changes of Parts—Each design change of a part
responsibility of the user of this standard to establish appro-
or component of an engine model qualified to this practice
priate safety and health practices and determine the applica-
should be evaluated relative to the requirements of this
bility of regulatory limitations prior to use.
practice.
2. Referenced Documents
2.1 RTCA Documents:
5. Data Requirements
RTCA DO-178 Software Considerations in Airborne Sys-
5.1 Retained Data—The following data and information
tems and Equipment Certification
should be retained on file at the manufacturer’s facility for a
RTCA DO-254 Design Assurance Guidance for Airborne
minimum of 18 years after production is discontinued:
Electronic Hardware
5.1.1 Drawings that define the engine configuration,
2.2 FAA Documents:
5.1.2 Material and process specifications referenced in the
FAA AC 33.28–2 Guidance Material 14 CFR 33.28 Recip-
parts drawings, and
rocation Engines, Electrical and Electronic Control Sys-
5.1.3 Engineering analyses and test data prepared for quali-
tems
fication with this practice.
3. Significance and Use
5.2 Delivered Data—The following data should be deliv-
3.1 This practice provides designers and manufacturers of
ered to the airplane manufacturer to support design and
engines for light sport aircraft design references and criteria to
operation of the applicable airplane.
use in designing and manufacturing engines.
5.2.1 An engine performance specification that defines the
engine performance under all anticipated operating environ-
3.2 Declaration of compliance is based on testing and
ments.
documentation during the design and testing or flight-testing of
5.2.2 An installation manual that defines all functional and
the engine type by the manufacturer or under the manufactur-
physical interface requirements of the engine. This should
er’s guidance.
include an engine outline/installation drawing.
4. Engine Model Designation
5.2.3 An operating manual that defines normal and abnor-
4.1 Engine Parts List—A parts list is required for each
mal operating procedures and any applicable operating limita-
engine model qualified in accordance with this practice. tions; this manual shall include instructions for use of appro-
priate engine monitoring gauges, electronic or otherwise.
This practice is under the jurisdiction ofASTM Committee F37 on Light Sport 5.2.4 A maintenance manual that defines periodic installed
Aircraft and is the direct responsibility of Subcommittee F37.70 on Cross Cutting.
maintenance, major inspection, overhaul intervals, and any
Current edition approved Dec. 1, 2010. Published March 2011. Originally
other maintenance limitations.
approved in 2007. Last previous edition approved in 2007 as F2538 – 07a. DOI:
5.2.5 If applicable (or if overhauls are authorized by the
10.1520/F2538-07AR10.
Available from RTCA, Inc., 1828 L Street, NW, Suite 805, Washington, DC
manufacturer), an overhaul manual that provides instruction
20036. www.rtca.org
for disassembling the engine to replace or repair, or both, parts
Available from U.S. Department of Transportation, Federal Aviation
as required to return the engine to airworthy condition that is
Administration, 800 Independence Avenue, SW, Washington, DC 20591. www.faa-
.gov safe for operation until the next major overhaul.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F2538 − 07a (2010)
6. Design Criteria 6.7.3 Air Lock—The degree of susceptibility to air in the
fuel supply lines must be established. If return flow or purge
6.1 Materials—The materials used in the engine must be
lines are required, their provision must be documented in the
adequate for the intended design conditions of the engine.
installation manual.
6.2 Fire Prevention—The design and construction of the
6.8 Lubrication System:
engine and the materials used must minimize the probability of
6.8.1 The lubrication system of the engine must be designed
the occurrence and spread of fire by:
and constructed so that it will function properly in all flight
6.2.1 Using fire-resistant lines, fittings, and other compo-
attitudes and atmospheric conditions in which the engine is
nents that contain a flammable liquid when supplied with the
expected to operate. In wet sump engines, this requirement
engine, and
must be met when only one-half of the maximum lubricant
6.2.2 Shielding or locating components to safeguard against
supply is in the engine.
the ignition of leaking flammable fluid.
6.8.2 The lubrication system of the engine must be designed
and constructed to allow installing a means of cooling the
6.3 Engine Cooling—The engine design must include pro-
lubricant if required.
visionsforcooling;theinstallationmanualmustspecifyengine
6.8.3 The crankcase engines must be vented to the atmo-
and component temperature limitations.
spheretoprecludeleakageofoilfromexcessivepressureinthe
6.4 Engine Mounting—Attach points on the engine must
crankcase. This venting must have a means to prevent the
have data for the correct design of mounting structures to the
blockage of the vent by ice.
airframe. The maximum allowable limit and ultimate loads for
6.9 Vibration General—The engine must be designed and
the engine mounting attachments and related structure must be
constructed to function throughout its normal operating range
specified.
of crankshaft rotational speeds and engine powers without
6.5 Ignition—Reliable combustion must be achieved in all inducing excessive stress in any of the engine parts.
flight and atmospheric conditions in which the engine is
6.9.1 The engine must have a crankshaft vibration survey to
expected to operate.
determinetorsionalandbendingcharacteristicsfromidlespeed
up to maximum desired takeoff speed. This survey should be
6.5.1 Limitations on restart at altitude must be established
done with a representative propeller and no hazardous condi-
and documented in the operating manual.
tions would be allowed.
6.5.2 The use of “glow plugs” or other starting aids must be
established (if applicable) and documented in the operating
7. Qualification Tests
manual.
7.1 Calibration Test—Each engine design shall be tested
6.6 Electronic Engine Controllers (EEC):
and the characteristics of engine rated power, speeds, and fuel
6.6.1 Essentially Single Fault Tolerance—The EEC should
consumption shall be determined.
be designed to accommodate single failures of the electrical
7.2 Knocking/Misfire Test—Each engine shall be tested on
circuit. Loss of any single EEC should not cause significant
the lowest cetane number fuel likely to be encountered in
power reduction or engine stoppage.
service. Lack of off-load misfiring or excessive cylinder
6.6.2 The functioning of EECs must not be adversely
pressure due to delayed combustion (knocking), or both, must
affected by the declared environmental conditions of operation
be demonstrated.
by the manufacturer, including temperature and moisture. The
limits to which the system has been qualified shall be docu-
7.3 Durability Testing—Each engine model must be sub-
mented in the installation manual. For protection against
jected to an engine test that will verify durability by one of the
ra
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