RV Power Systems

Composite Design

Complete Pre-Wired Power Systems for RVs

Composite Design introduced the first pre-wired power panel for experimental aircraft in 1994. Since then we have sold over 2,000 power systems installed in aircraft around the world. Our product line has expanded to include wiring harnesses and various electrical control systems which have proven to be indispensable options for many builders.
Available late summer 2006 will be a complete line of electrical systems for Van's Aircraft models RV6 through RV10. The wiring systems are modular in design with the basic systems including all airframe, engine power and control circuits. This is possible by our comprehensive, plug and play design that is well thought out by RV builders and experienced aircraft wiring technicians. The result is a well documented system that is very complete, easy to install and work with.
The basic system includes switch panel, breaker panel, starter and master solenoid assemblies, and various hardware, as well as prebuilt plug and play cabling for the engine compartment, air frame and basic engine instruments. Very few terminations are finished by the installer and they are carefully documented, not to mention that the tools are included. Avionics wiring is terminated in one connector that provides all power and control signals for the stack. The actual radio wiring is not provided but we provide the complimentary connector set and diagrams for your radio shop.

The Engine power cable carries the basic instrumentation but also provides connections for Left and Right magnetos, Alternator field, Alternator fault, Keep Alive +12V, Master and Starter solenoids as well as the Main 12 volt supply to the A/C bus bars inside the breaker panel.

Standard engine instrument wiring is part of the basic harness including Oil Pressure, Fuel pressure Oil Temp, Fuel flow, Left & Right fuel levels, RPM and Manifold pressure. There are built in spare circuits that allow for flexibility with the instrumentation. The optional Expanded instrumentation cable includes (6) EGT, (6) CHT, TIT, OAT, Ammeter and additional spares.
The airframe harness plugs into the breaker panel and "breaks out" along the way down the sides of the fuselage at several points to connect to the fuel probes, wing lighting wires, stall sensor, flap and trim motors as well as connections to the sticks for grip mounted buttons (PTT, A/P, trim,...

Switch Control Panel

The Switch Panel controls the functions in the breaker panel. It has internal lighting and simply plugs into the breaker panel.

The Breaker Panel is the hub of all aircraft electrical activities. Signals, power and controls from the various aircraft systems are routed through this assembly. Several jumper and routing options are available via clearly marked and documented terminals inside the panel. This allows for a certain degree of personalization in the design of each aircraft without the headaches of rewiring. Included in the breaker panel are the bus bars and breakers as well as control relays, radio bus filtration, options for an essential electrical backup, three axis trim control system, anninciator wiring with test functions, Radio and Panel dimmer controls and internal lighting for the panel face plate.

Breaker Panel

The through firewall connectors are metal with multi turn bayonet locking rings drilled for safety wire. All of the other major connectors used are Amp CPC series bayonet lock assemblies. The majority of the cables are loomed for durability and neatness, gold & silver pins are used in all plug in connectors. Complete, readable documentation will be provided as well as detailed connection schedules for various user options allowed for in the system design.

Pre-wired engine instrumentation packages are another option. The basic system is six inches square and include RPM, MAP, Oil Pressure, Fuel Pressure, Oil Temp, Volts, Hobbs, Left & Right fuel Levels. This package employs high quality UMA gauges that are easy to read and internally illuminated. Other instrument packages include Dynon engine monitor and Electronics International MVP-50.

All instrumentation options are sold as packages that include instruments, senders, probes, and applicable support hardware as well as the instrument and aircraft cabling. Note that the cabling is also plug and play down to all pre labeled wire terminals and connectors. Pressure senders are all mounted to a machined manifold that is bolted to the firewall for easy and proper connections of both wires and hoses. Temperature, RPM and other probes are provided and selected to suit both engine type and instrument option. A complete parts list is included for reference to all probes and senders as well as any required calibration routines if a replacement issue should occur.
The only extensive wiring needed in addition to this system would be the avionics "stack". Since the harness system provides power, PTT, A/P control, etc. to the "stack", system simulators will be available on a loan basis for use by avionics shops to complete the plug and play system.

Contact Composite Design
copyright 1997-2010, Custom Internet Pages


Composite Design introduced the first pre-wired power panel for experimental aircraft in 1994. Since then we have sold over 2,000 power systems installed in aircraft around the world. Our product line has expanded to include wiring harnesses and various electrical control systems which have proven to be indispensable options for many builders. Available late summer 2006 will be a complete line of electrical systems for Van's Aircraft models RV6 through RV10. The wiring systems are modular in design with the basic systems including all airframe, engine power and control circuits. This is possible by our comprehensive, plug and play design that is well thought out by RV builders and experienced aircraft wiring technicians. The result is a well documented system that is very complete, easy to install and work with. The basic system includes switch panel, breaker panel, starter and master solenoid assemblies, and various hardware, as well as prebuilt plug and play cabling for the engine compartment, air frame and basic engine instruments. Very few terminations are finished by the installer and they are carefully documented, not to mention that the tools are included. Avionics wiring is terminated in one connector that provides all power and control signals for the stack. The actual radio wiring is not provided but we provide the complimentary connector set and diagrams for your radio shop.
The Engine power cable carries the basic instrumentation but also provides connections for Left and Right magnetos, Alternator field, Alternator fault, Keep Alive +12V, Master and Starter solenoids as well as the Main 12 volt supply to the A/C bus bars inside the breaker panel.
Standard engine instrument wiring is part of the basic harness including Oil Pressure, Fuel pressure Oil Temp, Fuel flow, Left & Right fuel levels, RPM and Manifold pressure. There are built in spare circuits that allow for flexibility with the instrumentation. The optional Expanded instrumentation cable includes (6) EGT, (6) CHT, TIT, OAT, Ammeter and additional spares. The airframe harness plugs into the breaker panel and "breaks out" along the way down the sides of the fuselage at several points to connect to the fuel probes, wing lighting wires, stall sensor, flap and trim motors as well as connections to the sticks for grip mounted buttons (PTT, A/P, trim,...

Switch Control Panel		The Switch Panel controls the functions in the breaker panel. It has internal lighting and simply plugs into the breaker panel. The Breaker Panel is the hub of all aircraft electrical activities. Signals, power and controls from the various aircraft systems are routed through this assembly. Several jumper and routing options are available via clearly marked and documented terminals inside the panel. This allows for a certain degree of personalization in the design of each aircraft without the headaches of rewiring. Included in the breaker panel are the bus bars and breakers as well as control relays, radio bus filtration, options for an essential electrical backup, three axis trim control system, anninciator wiring with test functions, Radio and Panel dimmer controls and internal lighting for the panel face plate.
Breaker Panel

The through firewall connectors are metal with multi turn bayonet locking rings drilled for safety wire. All of the other major connectors used are Amp CPC series bayonet lock assemblies. The majority of the cables are loomed for durability and neatness, gold & silver pins are used in all plug in connectors. Complete, readable documentation will be provided as well as detailed connection schedules for various user options allowed for in the system design.
Pre-wired engine instrumentation packages are another option. The basic system is six inches square and include RPM, MAP, Oil Pressure, Fuel Pressure, Oil Temp, Volts, Hobbs, Left & Right fuel Levels. This package employs high quality UMA gauges that are easy to read and internally illuminated. Other instrument packages include Dynon engine monitor and Electronics International MVP-50.
All instrumentation options are sold as packages that include instruments, senders, probes, and applicable support hardware as well as the instrument and aircraft cabling. Note that the cabling is also plug and play down to all pre labeled wire terminals and connectors. Pressure senders are all mounted to a machined manifold that is bolted to the firewall for easy and proper connections of both wires and hoses. Temperature, RPM and other probes are provided and selected to suit both engine type and instrument option. A complete parts list is included for reference to all probes and senders as well as any required calibration routines if a replacement issue should occur. The only extensive wiring needed in addition to this system would be the avionics "stack". Since the harness system provides power, PTT, A/P control, etc. to the "stack", system simulators will be available on a loan basis for use by avionics shops to complete the plug and play system.

Contact Composite Design copyright 1997-2010, Custom Internet Pages