ASTM F2538-07a(2019)
(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
3.1 This practice provides designers and manufacturers of engines for light sport aircraft design references and criteria to use in designing and manufacturing engines.
3.2 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, health, and environmental practices and determine the applicability of regulatory limitations prior to use.
1.3 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
General Information
Relations
Standards Content (Sample)
This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: F2538 − 07a (Reapproved 2019)
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 3.2 Declaration of compliance is based on testing and
documentation during the design and testing or flight-testing of
1.1 This practice covers minimum requirements for the
the engine type by the manufacturer or under the manufactur-
design and manufacture of reciprocating compression ignition
er’s guidance.
engines for light sport aircraft, Visual Flight Rules (VFR) use.
1.2 This standard does not purport to address all of the
4. Engine Model Designation
safety concerns, if any, associated with its use. It is the
4.1 Engine Parts List—A parts list is required for each
responsibility of the user of this standard to establish appro-
engine model qualified in accordance with this practice.
priate safety, health, and environmental practices and deter-
mine the applicability of regulatory limitations prior to use.
4.2 New Engine Model Designations:
1.3 This international standard was developed in accor-
4.2.1 Each new engine model must be qualified in accor-
dance with internationally recognized principles on standard-
dance with this practice.
ization established in the Decision on Principles for the
4.2.2 Design or configuration changes that impact the in-
Development of International Standards, Guides and Recom-
stallation interface, performance, or operability of the engine
mendations issued by the World Trade Organization Technical
require a new engine model designation.
Barriers to Trade (TBT) Committee.
4.3 Design Changes of Parts—Each design change of a part
or component of an engine model qualified to this practice
2. Referenced Documents
should be evaluated relative to the requirements of this
practice.
2.1 RTCA Documents:
RTCA DO-178 Software Considerations in Airborne Sys-
tems and Equipment Certification 5. Data Requirements
RTCA DO-254 Design Assurance Guidance for Airborne
5.1 Retained Data—The following data and information
Electronic Hardware
should be retained on file at the manufacturer’s facility for a
2.2 FAA Document:
minimum of 18 years after production is discontinued:
FAA AC 33.28-2 Guidance Material for 14 CFR 33.28,
5.1.1 Drawings that define the engine configuration,
Reciprocating Engine, Electrical and Electronic Control
5.1.2 Material and process specifications referenced in the
Systems
parts drawings, and
5.1.3 Engineering analyses and test data prepared for quali-
3. Significance and Use
fication with this practice.
3.1 This practice provides designers and manufacturers of
5.2 Delivered Data—The following data should be deliv-
engines for light sport aircraft design references and criteria to
ered to the airplane manufacturer to support design and
use in designing and manufacturing engines.
operation of the applicable airplane.
5.2.1 An engine performance specification that defines the
engine performance under all anticipated operating environ-
This practice is under the jurisdiction ofASTM Committee F37 on Light Sport
ments.
Aircraft and is the direct responsibility of Subcommittee F37.70 on Cross Cutting.
5.2.2 An installation manual that defines all functional and
Current edition approved Jan. 1, 2019. Published January 2019. Originally
physical interface requirements of the engine. This should
approved in 2007. Last previous edition approved in 2010 as F2538–07a (2010).
include an engine outline/installation drawing.
DOI: 10.1520/F2538–07AR19.
Available from RTCA, Inc., 1150 18th NW, Suite 910, Washington, DC 20036,
5.2.3 An operating manual that defines normal and abnor-
www.rtca.org.
mal operating procedures and any applicable operating limita-
Available from U.S. Department of Transportation, Federal Aviation
tions; this manual shall include instructions for use of appro-
Administration, 800 Independence Avenue, SW, Washington, DC 20591, http://
www.faa.gov. priate engine monitoring gauges, electronic or otherwise.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F2538 − 07a (2019)
5.2.4 A maintenance manual that defines periodic installed be established for the lowest lubricity fuel that will be
maintenance, major inspection, overhaul intervals, and any encountered in service. This may be demonstrated during the
other maintenance limitations. qualification tests in Section 7 or by other means such as fuel
5.2.5 If applicable (or if overhauls are authorized by the system/component bench tests.
manufacturer), an overhaul manual that provides instruction
6.7.2 Filtering—Thetypeanddegreeoffuelandairfiltering
for disassembling the engine to replace or repair, or both, parts necessary to prevent obstruction of air or fuel flow must be
as required to return the engine to airworthy condition that is
specified.
safe for operation until the next major overhaul. 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. Design Criteria lines are required, their provision must be documented in the
installation manual.
6.1 Materials—The materials used in the engine must be
adequate for the intended design conditions of the engine.
6.8 Lubrication System:
6.8.1 The lubrication system of the engine must be designed
6.2 Fire Prevention—The design and construction of the
and constructed so that it will function properly in all flight
engine and the materials used must minimize the probability of
attitudes and atmospheric conditions in which the engine is
the occurrence and spread of fire by:
expected to operate. In wet sump engines, this requirement
6.2.1 Using fire-resistant lines, fittings, and other compo-
must be met when only one-half of the maximum lubricant
nents that contain a flammable liquid when supplied with the
supply is in the engine.
engine, and
6.8.2 The lubrication system of the engine must be designed
6.2.2 Shielding or locating components to safeguard against
and constructed to allow installing a means of cooling the
the ignition of leaking flammable fluid.
lubricant if required.
6.3 Engine Cooling—The engine design must include pro-
6.8.3 The crankcase engines must be vented to the atmo-
visionsforcooling;theinstallationmanualmustspecifyengine
spheretoprecludeleakageofoilfromexcessivepressureinthe
and component temperature limitations.
crankcase. This venting must have a means to prevent the
6.4 Engine Mounting—Attach points on the engine must blockage of the vent by ice.
have data for the correct design of mounting structures to the
6.9 Vibration General—The engine must be designed and
airframe. The maximum allowable limit and ultimate loads for
constructed to function throughout its normal operating range
the engine mounting attachments and related structure must be
of crankshaft rotational speeds and engine powers without
specified.
inducing excessive stress in any of the engine parts.
6.5 Ignition—Reliable combustion must be achieved in all 6.9.1 The engine must have a crankshaft vibration survey to
flight and atmospheric conditions in which the engine is determinetorsionalandbendingcharacteristicsfromidlespeed
expected to operate. 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
consumption shall be determined.
6.6.1 Essentially Single Fault Tolerance—The EEC should
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
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