Rotax 912 iS Engine Cabling

Rotax 912 iS Engine Cabling

The sensors and actuators of the 912iS engine are fitted at factory and connected to the engine wiring harness.
The builder/installer needs to connect the harness to:
- ECU (Control unit)
- FUSE BOX
- Cockpit (switch, instruments, maintenance connection)

The wiring harness consists mainly of two cable looms.  To rout this quite stiff and long cable looms through the fire wall within the limited space in the RV12  took me some effort.

Wiring harness

Fire wall penetration

The main effort are the two HIC (Harness Interface Connectors) which connects the control and monitoring instruments and maintenance ports to the engine.
Following a tip from Rotax I acquired prefabricated cables with the HIC connectors already on.

Connectors as supplied by Rotax

I sent the connectors to a little local company (MLT Maschinen Leitungstechnik GmbH, http://www.mlt.at/ ) 
In return I received cabling of adequate length and size with the HIC connectors on one end. 
Each wire correct labeled. But I intend to replace the yellow slip on labels by heat shrink typ.

HIC connectors in place

Having one side of the connections already done saved me a lot of time.
But to connect the countless number of wires to the different locations including a few d-sub connectors was a tedious work for me. 😅

Engine cabling finished

One of the five DA20 Katana of our flying club Weiße Möwe Wels (http://www.wmw.at/) has been equipped with a 912iS engine recently.
I did the electrical installation exactly the same way as worked out for this airplan by rotax employee.
This includes the EMU (Engine Management Unit) from Stock Flight Systems. www.stockflightsystems.com
To follow this tried and proven path turned out to be a wise decision when I turned on the system for the first time.
A little error I made was corrected quickly. I have had connected a few ground wires to regulator B instead of regulator A.
As soon as I hooked up this wires correctly everthing worked as expected. 😀😂

EMU alive

I hope this success will continue at the day of the first engine start. Fingers crossed!