RV-7/8/10 Roll Kit Installation Instructions - Dynon Avionics

Autopilot Servo Installation GuideRV7, RV8, RV10 RollThis product is not approved for installation in type certificated aircraftDocument 101046-003, Revision FJanuary, 2013Copyright © 2009-2013 by Dynon Avionics, Inc.Permission to print this this manual is granted to third parties

DYNON AVIONICSSERVO MOUNTING INSTRUCTIONS – RV-7/8/10 RIGHT WINGROLL KITKit ContentsDynon Part # QTY Part Description100836-000 2 Large Male Rod End100870-000 1 RV7,8,9,10 Right Roll Bracket100872-000 1 RV7,8,9,10 Right Support Bracket100966-008 1 Aluminum Pushrod Tube - 3.0"100975-002 2 AN315-4R Jam Nut100976-011 2 AN365-1032A Nylon Insert Locknut100977-000 2 AN970-3 Large Flat Washer100978-003 7 AN960-10 Small Flat Washer100979-002 3 MS35333-39 #10 Internal Star Washer100981-000 3 AN3H-3A Bolt - 3/8"100981-005 1 AN3H-10A Bolt - 1"100981-012 1 AN3H-17A Bolt - 1 7/8"100982-004 1 Aluminum Spacer - 0.875"The RV-7/8/10 right wing roll servo mounting kit includes a right wing mounting bracket, rightwing support bracket, pushrod linkage, and most of the required fasteners to mount the servo andproperly link it to the aircraft control system. All Dynon-supplied parts are illustrated in dark grey todistinguish them from existing aircraft hardware. The lower bell crank support bracket must beremoved to install the supplied servo mounting bracket. Fasteners used to secure the existingbrackets will be re-used to install the new Dynon brackets. It is up to the installer to determine ifthese fasteners are suitable for re-use (not available from Dynon). With the mounting bracketsloosened/removed it is an ideal time to drill the aileron bell crank bracket per the dimensions in theillustration.The brackets that will replace the existing aircraft brackets are made of 4130 steel and plated perQQP416 CAD - Type II Class II Yellow. They have been designed to meet or exceed the originalbrackets in strength and corrosion resistance. Install the Dynon-supplied lower servo mountingbracket in place with the previously removed original fasteners and install the vertical bolt as it wasin the original installation.With the bracket in place, install the 2 AN3H-3A bolts, MS35333-39 star washers, and AN960-10flat washers to secure the servo to the bracket per the drawing, noting the orientation of the servooutput arm. All AN bolts supplied by Dynon have drilled heads for use with safety wire.Servo Mounting Instructions – RV-7/8/10 Roll Kit 2101046-003 Rev F

DYNON AVIONICSInstall the support bracket to the other side of the servo using the same bolt stack-up. Secure it tothe upper bell crank support bracket using the existing fastener. With the servo in place, torque allfasteners back to original installation specifications and add safety wire where needed.With the servo installed, the linkage needs to be assembled. Refer to the illustration and followproper rod end installation techniques. Screw at least half of the threads on each rod end into thepush rod. To prevent the possibility of the servo arm going over-center, the servo armmust not travel more than a total of +/-60º from neutral throughout the control system's range oftravel. The linkage should be installed as close to the Dynon recommendation as possible, aschanges will affect geometry. Dynon suggests installing the linkage at the outer-most hole of theservo arm. Changing this location will affect servo torque output, servo arm travel, control surfaceresolution, and the amount of force required to shear the safety screw, and should only be changedif the installer has an understanding of these implications. See the diagram on the following pagewhich illustrates the linear travel and available force for each mount point on standard-arm servos.Thread both large rod ends with jam nuts into the supplied 3.0" tube. Standard mounting of thelinkage to the servo arm will include the AN3H-10A bolt, AN970-3 large diameter flat washer (forcapturing the rod end bearing), 2 AN960-10 flat washers on each side of the servo arm itself, andthe AN365-1032A lock nut. The other end of the linkage will require the same type of stack-up, withthe addition of the 0.875" spacer and longer AN3H-17A bolt to secure to the drilled aileron bellcrank bracket.The distance between the servo arm and the control system attachment point must allow for theangle between the servo arm and the push rod to be at approximately 90º when the controls are atneutral. Use the adjustability in the rod ends to achieve this, and then tighten the jam nuts to lockthe rod ends in place. Installers should always keep in mind the range of motion of the servo. Totalservo arm travel is limited, but verify the arm/linkage do not interfere with anything during the fullmotion of the control stick. The built in control stops of the aircraft will limit the servo arm travelwhen installed correctly. We recommend the use of the optional Range of Motion Limiting Bracket,supplied with the servo to eliminate the chance of the servo arm going over-center. This bracketshould not be used as a normal stop; the aircraft's built-in stops should always be the primary rangelimit.Your servo(s) and AP74/76 (if ordered) came with a CD containing the latest documentation for allDynon products (also available at dynonavionics.com). Please read through that documentation tounderstand the wiring and configuration process for your Autopilot system. We also maintain acollaborative set of this documentation, which is often updated with new information by bothDynon and fellow builders. Visit wiki.dynonavionics.com to view and contribute to the latestversion of these documents.You can also visit forum.dynonavionics.com to discuss and share installation notes, pictures, andsuggestions with other builders.Neglecting to properly install and/or use Dynon autopilot hardware mayresult in failures which could cause loss of aircraft control resulting inaircraft damage, personal injury or death.Servo Mounting Instructions – RV-7/8/10 Roll Kit 3101046-003 Rev F

DYNON AVIONICSWiring OverviewThe following diagram provides an overview of the autopilot-specific wiring installation. For thecomplete set of wiring and configuration instructions, please see the latest Installation Guide foryour Dynon EFIS product. For a SkyView system please reference the Autopilot ServoInstallation, Configuration, and Calibration chapter of your SkyView System Installation guide.For EFIS-D10A, EFIS-D100 or FlightDEK-D180 please reference the Autopilot Installation andConfiguration chapter of each respective Installation GuideUse 22 AWG wire for SkyNetand Disengage signals.D10A/D100/D180D25CONNECTORN/AN/A54SKYVIEWD9CONNECTOR4861WHT/BLUWHT/GRNBLUGRNWht/BluWht/GrnBlueGreenTwisted PairAircraft Power (10-30V)Pilot-accessibleServo PowerSwitch/BreakerUse appropriate wire gauge forservo power based on currentconsumption and length of wire runWiresRedServo 1Power (10-30V)Pilot-accessibleDisengage/CWS button(Normally open, momentary)Usually mounted to the stickTwisted PairAircraft GNDBlackGreenBlueYellowGroundSkyView Network 1 A or DSAB ASkyView Network 1 B or DSAB BDisengageAircraft GNDWht/Grn SkyView Network Data 2 A *Wht/Blu SkyView Network Data 2 B *Optional resistor fordetecting brokendisengage lines5 kohmServo Current Draw at 12V(halve the current values for 24V systems)SV32Powered but disengaged: 0.1 ampsEngaged and holding, 100% torque: 0.80 ampsEngaged and moving, 100% torque: 1.33 ampsSV42Powered but disengaged: 0.1 ampsEngaged and holding, 100% torque: 1.11 ampsEngaged and moving, 100% torque: 2.03 ampsSV52Powered but disengaged: 0.1 ampsEngaged and holding, 100% torque: 1.52 ampsEngaged and moving, 100% torque: 2.80 ampsTwisted PairPitch and Roll Servosare wired identically, and canshare wiring for convenience atany point along the run.Aircraft GND*NOT USED FOR D10A/D100/D180Servo 2WiresRed Power (10-30V)Black GroundGreen SkyView Network 1 A or DSAB ABlue SkyView Network 1 B or DSAB BYellow DisengageWht/Grn SkyView Network Data 2 A *Wht/Blu SkyView Network Data 2 B *Servo Mounting Instructions – RV-7/8/10 Roll Kit 4101046-003 Rev F

DYNON AVIONICSServo DimensionsUse the following dimensions (in inches) for reference when planning and implementing yourinstallation.Long-arm variants(not needed in mostinstallations)havelinkage mount holesat 1.5”, 1.75”, and2.0”LSV32 2.17”SV42 3.10”SV52 4.02”Weight2 lb3 lb4 lbServo Mounting Instructions – RV-7/8/10 Roll Kit 5101046-003 Rev F

DYNON AVIONICSLinkage mount position force and travelThe diagram below illustrates the maximum travel and force available at each linkage mountingpoint. As can be seen, the closer you mount the linkage to the shaft, the more force the servo candeliver. However, this also means the travel of the arm is shorter. Again, ensure that the servo arm isnowhere near going over-center throughout the entire range of the control system.Position A should be used in most RV-7/8/10 roll installations. Modify mount position withcaution and take all precautions to ensure that a near over center condition cannot occurStandard ArmMax Linear TravelA: 2.6”, B: 2.2”, C: 1.8”Max Force @ 100% TorqueSV32 - A: 24lb, B: 29lb, C: 36lbThe autopilot safety shear screw should NEVER be removed or adjusted during thisoperation. If the shear screw has broken and needs replacement, there is specificdocumentation available for this purpose at http://docs.dynonavionics.com.Mounting DrawingsThe following pages provide detailed views of the mounting and assembly of the servo andthis kit.Servo Mounting Instructions – RV-7/8/10 Roll Kit 6101046-003 Rev F

DYNON AVIONICSServo Mounting Instructions – RV-7/8/10 Roll Kit 7101046-003 Rev F

DYNON AVIONICSServo Mounting Instructions – RV-7/8/10 Roll Kit 8101046-003 Rev F

DYNON AVIONICSServo Mounting Instructions – RV-7/8/10 Roll Kit 9101046-003 Rev F

DYNON AVIONICSServo Mounting Instructions – RV-7/8/10 Roll Kit 10101046-003 Rev F