DA40 2023 starter engaged uncommanded during flight

[N301MJ]

Just declared an emergency and landed at Danville. 33 hrs on this plane.

Was cruise on AP 75% power. G1000 warning bell red annunciator comes on. Persists for about a minute. I start grabbing altitude and heading towards nearest which was about 15nm away.

Issue goes away momentarily.

It comes back on, cockpit starts to smell like burning. Bell continues to go off. Landed safely.

[gyro3816]

Based on you mentioning power setting (fadec), I assume your airplane is an DA40 NG.

[N301MJ]

Yes da40ng 2023 got her in May

[Colin]

Yes, he is flying a DA40NG. The registration is there in his little member-info card.

[Colin]

Good job getting it on the ground. We will all be very interested to hear what they find caused the alarm.

[N301MJ]

Yea I will keep you guys posted. From everyone I've spoken with this is something they haven't seen before.

I was able to replicate the issue after running her idle on ground for 20 minutes, did another ECU run up, went fine, then as I was taxing back I got it again, multiple times. Southtec guys have been great hopefully we can figure more out in the am.

[Boatguy]

Yea I will keep you guys posted. From everyone I've spoken with this is something they haven't seen before.

I was able to replicate the issue after running her idle on ground for 20 minutes, did another ECU run up, went fine, then as I was taxing back I got it again, multiple times. Southtec guys have been great hopefully we can figure more out in the am.

Glad to hear you were able to get down safely.

Sounds like a faulty starter relay, or short in the starter switch or wiring which is triggering the relay. Then the question is what has it done to the starter itself and to the flywheel with which I assume the starter engages.

This is a new plane. If AOG time is significant, I suggest you ask for an extension to your engine warranty.

[N301MJ]

Yea I will keep you guys posted. From everyone I've spoken with this is something they haven't seen before.

I was able to replicate the issue after running her idle on ground for 20 minutes, did another ECU run up, went fine, then as I was taxing back I got it again, multiple times. Southtec guys have been great hopefully we can figure more out in the am.

Glad to hear you were able to get down safely.

Sounds like a faulty starter relay, or short in the starter switch or wiring which is triggering the relay. Then the question is what has it done to the starter itself and to the flywheel with which I assume the starter engages.

This is a new plane. If AOG time is significant, I suggest you ask for an extension to your engine warranty.

Thanks for the suggestions and a few folks I've spoken with have alluded to the same probable sources. Hoping there isn't significant damages. Will update once I know more!

[N301MJ]

Pulled the starter fuse after start, did some tests, didn't get any fumes after 30min on the ground then flew her 85nm to RUQ today. After landing and clearing the runway, the starter annunciator came back on (with the fuse pulled). So the whole situation doesn't make any sense at all. There's obviously something seriously wrong with the wiring/electrical. I pulled the ESS 30amp, pulled her into southtec and called it a day. This airplane has 35 hrs now total. I had another thread about ECU failures in the same aircraft which is what I was investigating in the first place. Also have a faulty left fuel tank sensor. When they sent me photos of the airframe with the wrong decals I should have been more sceptical. The attention to detail just isn't there. I honestly don't trust this airplane at all or remotely feel safe in it. I could have had clients on board or family. What a nightmare. I guess I have to wait a few weeks now to get a better sense of what is going on.

[dmloftus]

I hope your experience is unique and temporary. I have had excellent reliability and great pleasure from my DA40XLS. Glenn's guys are great at Southtec and hope you get to the bottom of this quickly, and most importantly, safely.