Rolls-Royce M250-C47 FADEC Familiarization Revision Date August 2015 The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies. Rolls-Royce M250-C47 FADEC NOTICE The information contained herein is intended to provide familiarization on the Rolls-Royce M250 FADEC system. This presentation contains general technical and maintenance information considered current at time of publication. Information in this presentation is not intended to replace or contradict approved maintenance procedures. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization MODEL 250 FADEC Features Reduced Pilot Workload Automatic Starts Hot Start Protection Enhanced NR Governing with Load Anticipation Enhanced Flight Safety Flameout Detection and Auto Re-Light Automatic Overspeed Protection Fault or Exceedance Recording and Enunciation Simplified maintenance Troubleshooting Maintenance Terminal Software Fault Isolation Manual August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Full Authority Digital Engine Control System The FADEC system is essentially a computer which takes signals from sensors in the helicopter & on the engine to precisely schedule fuel flow Elements that make up the FADEC system are: Electronic Control Unit : (ECU) Hydromechanical Unit: (HMU) Turbine Thermocouples: (MGT) Speed Sensors: (NG, NP, NR, all are dual poll) Torque Sensors: (TMOP; 2ea one for aircraft gauge and one for FADEC) Position Sensors: (CP, PLA, WFMV) Inlet Temperature Sensor: (CIT) Pressure Altitude Sensor: (PA, located on ECU) Permanent Magnet Alternator: (PMA) August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C40/47 FADEC Familiarization Fuel Boost Pump Stage CEFA 28VDC NR T1 CP Switches P1 Lights Start Relays N1 Feedback Signals, WFMV, PLA N2 FADEC ECU Pressure Pump Stage Command Signals HMU Metering Unit PMA 28VDC Fuel N1, N2, MGT, Q, Ff August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC System Power and Grounds The FADEC is powered by 28VDC from the following sources: Aircraft 28VDC power bus Engine driven PMA (permanent magnet alternator) PMA is driven from NP gear train Provides power to ECU above 85% NP The FADEC system has four ground straps: ECU to Airframe HMU to turbine fireshield PMA to fireshield/gearbox Gearbox to airframe Integrity of grounds is very important to proper operation of the FADEC August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Automatic Engine Start The Model 250 FADEC controls all engine start sequencing Throttle @ Idle, Starter button depressed Pilot must depress starter button within 60 sec of roll-up to Idle 60 sec starter timer re-sets when light-off is detected or when PLA goes < 9 FADEC introduces fuel @ 10% NG Light-off is detected when NG> 25% and MGT rise of 122C FADEC will disengage starter at 50% NG by opening ground for holding relay FADEC will abort a start: if MGT abort limit of 885C is triggered with NG < 50% 913C if Alt >10,000 ft or if residual MGT prior to start is >82C if Starter 60 sec timer is exceeded with NG < 50% FADEC will automatically cool down engine after a hot start abort Starter remains engaged (for up to 60 sec) when MGT > 148.8C and PLA in cutoff August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Automatic Engine Starting The FADEC monitors NG rate of acceleration to maintain a constant NG acceleration of approximately 2% per sec. acceleration rate changes with OAT (6%/sec @ low OAT) NG rate is the primary reference for the ECU to schedule fuel flow during normal starts but if the MGT monitoring set point is approached, the ECU will automatically switch to MGT monitoring, thus biasing MGT and NG rate of acceleration for fuel flow scheduling to prevent an over temperature MGT Monitoring Mode Change 704C August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Aborted Starts • Aborted Auto Mode Starts at higher ambient temps (>21°C) & altitudes. • Aborts occur during the initial portion of the start where the metering valve has • no authority to reduce fuel flow. Root Cause is too much fuel for given air flow. Min flow is constant in the HMU throughout operating envelope (34 PPH) Air flow (density) changes throughout operating envelope • Fuel introduction versus airflow Fuel introduction is initiated at a fixed NG speed (10%) in auto mode In less dense air, fuel introduction @ min flow may be too much for required fuel/air ratio, thus hot start abort is activated Fuel introduction initiated at a higher NG speed (16%), when lower density air flow conditions exist , will improve fuel/air ratio (alternate start procedure) August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Aborted Starts (NG less than 50%) August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Aborted Starts • Alternate Engine Starting Procedure: Auto/Manual Mode switch in “Auto” position. Throttle in cut-off position (not in Ground Idle). Push and hold Starter Button. When NG reaches 16%, roll throttle to Ground Idle position. The starter should now latch and normal Auto Mode start resumes. • Experience has shown a significant decrease in start MGT and significantly reduced occurrence of aborted starts. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Model 250 FADEC Speed Control • FADEC will control NG speed to: Schedule NG rate of change during start Maintain Idle speed @ 63% NG Limit Maximum NG to 106.5% when PLA is at Fly position Reduce NG acceleration schedule to avoid compressor surge. • FADEC will control NP speed to: Maintain speed at set point for 100% NR Anticipate rotor load change through collective pitch pot for stable NR Adjust NR to 92% for Quiet Cruise Mode August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Model 250 FADEC Overspeed Limiting • The FADEC will Limit NP overspeed by activating the overspeed solenoid in the HMU C47B cut-back Wf to Min Flow (34-49 pph) @ 118.5% resets @ 6% below trip speed • The overspeed test will verify functionality of the O/S solenoid and drivers. The test must have the following parameters in order to operate: PLA 30-40 (ground idle) CP <10 NG between 60 & 66% NP <75% Wf >65 pph (higher altitudes may inhibit O/S Test due to low required Wf at idle) August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Model 250 FADEC Torque & Temperature Limiting • %Q in the ECU of the B407 is not equal to %Q on the Helicopter Indicator The cockpit gage is reading %Q of airframe mounted transducer (100% = 560 lbs/ft) The ECU is reading %Q of engine mounted transducer (100% = 590 lbs/ft) If cockpit gage records an overtorque, it may not affect the engine. Divide gage Q% by 1.0535 to get engine Q% and convert to lbs/ft to determine maintenance • FADEC will Limit the MGT Run Temperature with NG >50% C47B @ 905.5C August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Model 250 FADEC Settings Item Ground Idle NG RPM 100% NG RPM 100% NP RPM 100% PTO RPM 100% NR RPM NG overspeed trip NP overspeed trip 100% Q (Ft/Lbs) 100% Q (psi TMOP) Q Limiter (%Q) MGT Start Limiter MGT Start Abort (Res MGT<82) MGT Start Abort (Res MGT>82) MGT Run Limiter August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication C47B 63% 51,000 32,183 6,317 413 110% 118.5% 590 96.3 Not Limited 704C 885C 913C 905C Rolls-Royce M250-C47 HMU Familiarization FADEC Hydromechanical Unit (HMU) Basic Operation The Hydro-Mechanical Unit receives signals from the ECU which meters fuel flow via a stepper motor connected to the metering valve. The HMU incorporates feedback potentiometers that tell the ECU the positions of the metering valve & Power Lever Angle (PLA) PLA pot August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication WF pot Rolls-Royce M250-C47 HMU Familiarization • Two Stage Fuel Pump • Manual Mode Section • Flat Plate Metering Valve Manual Mode Solenoid • Stepper Motor controlled in Auto Mode • Throttle Controlled in Manual Mode • De-energized open • Pressurizing Valve • Opens @ 150 psi • Ensures positive fuel cut off • Overspeed Solenoid • Hot Start Solenoid Valve • Energized Closed to introduce fuel • De-energized open to cut fuel @ hot start • Windmill Bypass Valve • Provides mechanical fuel cutoff at PLA <5 August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication • Energized closed by ECU when N2 Overspeed trip is activated Rolls-Royce M250-C47 HMU Familiarization FADEC HMU Manual Mode A simple Hydro-mechanical back-up system allows for manual fuel scheduling should an electronic system malfunction occur. The manual mode control schedules fuel flow in direct relation to power lever angle through engagement of hydraulic control pistons Automatic Mode Shown Pistons are “Parked” August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 HMU Familiarization FADEC HMU Manual Mode When Manual Mode is selected, the auto/manual solenoid de-energizes open. This ports fuel pressure into the manual mode pistons which come together to take control of the metering valve. Positioning of the controlling piston is accomplished by regulating a variable orifice via a segment gear on the power lever shaft. Piston engagement speed is regulated by orifices to allow the follower piston to engage before the loading piston. Manual Mode Shown Pistons are “Engaged” August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 HMU Familiarization FADEC Reversion to Manual Mode The FADEC has two means of reverting to manual mode Pilot selects Manual Mode Direct reversion to Manual Mode The Bell 407 incorporates Direct Reversion to Manual Mode (DRTM) such that should a “FADEC Fail” be experienced, the system will automatically revert to manual mode. With the throttle in the “Fly” position, the NP will not overspeed. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 HMU Familiarization FADEC Power Lever Angle (PLA) Rigging The C47B with DRTM has an additional rig point to accommodate the “Fly” position at 70 PLA C47B critical rig points: Idle = 35 ± 5 Fly = >62 Cutoff = <5 Full Throttle = >92 NOTE: Use PLA rig pin @ HMU and set Twist Grip at Idle detent when connecting linkage August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Fault Detection The FADEC offers fault detection and fault isolation features. Fault information is stored in the Electronically Erasable Programmable Read Only Memory (EEPROM). This provides a history of any fault occurrence for troubleshooting or maintenance purposes. The ECU classifies faults into the following categories: Soft Fault;- No imminent operational effect, record in memory for maintenance action. Enunciated only after engine shut-down. Degraded Fault;- Has non-critical operational effect, degrades FADEC performance in Auto Mode. Enunciated to pilot in-flight as “FADEC Degraded” Hard Fault;- Critical affect on system operation and will revert system to Manual Mode. Enunciated to pilot in-flight as “FADEC Fail” August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Fault Status Indications The ECU will provide the Pilot with FADEC system status via following messages or lights: • “FADEC Fail” warning on when a Hard Fault is detected, manual mode operation is needed. • “Engine Ovspd” warning on when Power Turbine speed limit has been exceeded. • “FADEC Degraded” caution on when non-critical system fault is detected, ECU performance is degraded. • “FADEC Manual” caution on when FADEC is in manual mode, pilot must manually control rotor speed. • “FADEC Fault” caution on when minor-effect system fault is detected, ECU performance may be limited. • “Restart Fault” advisory on when engine start is likely to be inhibited in AUTO mode if shut down. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Power-up Mode During power-up, the ECU initializes all electronic components and executes selftests to establish system health. If faults are detected, one or more FADEC status messages will be “on”, prompting maintenance action. • A message ON with PLA @ cut-off indicates a currently existing fault or a fault from the previous engine run has been detected. • A message ON with PLA @ Idle position indicates a currently existing fault is detected. If the message turns white with PLA @ Idle, then the detected fault was last engine run but is not currently detected. NOTE: This could also be an exceedance from the previous flight. If the engine is operated, the exceedance warning light will be extinguished. • The “Last Run Fault” is removed once the engine is started with no fault present. It will stay in the “Accumulated Fault” memory until erased using the MT35 Maintenance Terminal. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Fault Identification Locate fault on ENG/ECU Faults page. The “Fault Isolation Manual” Section 73-2504 will then provide the troubleshooting task to follow. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Isolation Task # Note: use the proper software version tables August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Fault Identification Faults can also be identified by use of EMC-35 Maintenance Terminal • The EMC-35 provides visibility of all recorded faults, either current, last run, accumulated or time stamped. • Provides greater detail of faults such as: Range: parameter out of allowable range Rate: rate of change out of allowable limits Difference: excessive difference between redundant parameters Voltage/Current: voltage or current out of allowable limits etc. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC EMC-35 Maintenance Terminal The maintenance terminal software version 2.00/2.01runs on a standard PC or lap top having Windows 95 or higher operating system. (Ref. CSL 5076/6076) Software version 2.3/2.3.1 runs on Windows 7 or higher OS. This software consists of the EMC-35 Maintenance Terminal program and a Model Specific Data Disc. This software allows the user to do the following: view real time analog and discrete data view real time faults and fault history clear stored faults view exceedances and stored history data clear exceedances and stored history data transfer ECU data to disc and back to ECU print ECU history data trend real time parameters for troubleshooting August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Incident Recording The FADEC has the capability of monitoring multiple parameters during operation that will be recorded in the ECU should an abnormal occurrence be experienced. When the ECU senses an out of range operation, it starts recording 60 seconds of data, 12 sec. prior to the event and 48 sec. after. This is intended as a tool for incident investigation. The data is overwritten if the engine is operated after a recorded event. Stepper Motor Hard Fault 140 800 MGT 120 700 600 100 Ng% 80 Q% 60 500 Nr% Np% PLA 400 300 Wf pph 40 200 Cp 20 100 0 0 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 NG NR August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication NP Q CP PLA WF MGT Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ ECU Reversionary Governor: • Provides Np governing in Reversionary mode in the event of a “Hard Fault” in the primary ECU. Seamless transfer from Primary to Reversionary mode. Reversionary Mode is not pilot selectable. • Pilot indication when operating in Reversionary Mode: FADEC Fault, FADEC Degraded & AUTO RELIGHT messages will all illuminate when in Reversionary Mode • DRTM mode automatic reversion to Manual Mode if both primary and reversionary ECU channels are “Hard Faulted” August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ ECU Reversionary Governor: • Reversionary is a Degraded Operation Mode Pilot should avoid aggressive maneuvers. Provides Np Governing based on minimum sensor set. Bell “Quite Mode” is disabled. No “Auto-relight” capability; use Manual Mode if operating in flameout prone environment. Manual Mode has continuous ignition. Other non-essential parameters are also disabled. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ ECU Reversionary Governor: • Engine Starting. Reversionary Channel does not have normal start protection. Starts should be made in Manual Mode if required (closely monitor MGT). • Aircraft May be dispatched with inoperable Reversionary channel. FAA will allow up to 150 hrs operation with in-op Reversionary channel. Inoperable Reversionary channel will show a Fadec Degraded message (check Engine/ECU faults page). • EMC35R+ Reversionary Governor engine shutdown. When operating in Reversionary channel, NR will stay @ 100% when the throttle is rolled to Ground Idle. It is OK to shut the engine down from 100% (fly position) Overspeed Test will not function but Overspeed protection still exists. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ Reversionary ECU: Software Enhancements • Start Fuel Flow Introduction T1 Threshold has changed: Fuel introduced @ 12% Ng when T1 is >= 28C Fuel introduced @ 10% Ng when T1 is < 28C • Hot Start Abort Activation Temp: Hot Start Abort lower limit is 885C. Upper limit stays 913C. • PLA Reference Voltage Fault Detection. Allows ECU to run PLA reference voltage and PLA 1&2 difference fault detection tasks separately and select the higher input. This maintains automatic governing mode and changes PLA Faults from Hard Fault to Degrade. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ Reversionary ECU: Software Enhancements • NG Difference Fault Accommodation. Allows ECU to conduct a continuous rate check on both NG 1 & 2 signals and select “Healthy” NG input. This maintains automatic governing mode and changes NG Difference Faults from Hard Fault to Degrade. • NP 1&2 Fault Accommodation. If both NP 1&2 fail, system will substitute NR. Changes from Hard Fault to Degrade. • Stepper Motor Fault Accommodation. SM faults accommodated in Reversionary Governor by monitoring NDOT (speed derivative). This maintains Automatic N2 Governing in Reversionary mode. • T1 Fault Accommodation. Reclassifies T1 faults from Hard Fault to Degrade. Allows use of synthesized T1 values. • Adds protection against inadvertent throttle roll-up after shutdown. Requires starter switch activation before fuel introduction. Aircraft must comply with BELL TB 407-00-24 (adds start relay pull-up resister). August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ Reversionary ECU: Np Exceedance Recording • Np Exceedances are recorded separately from Q in Engine History • Exceeding the Run Limit for over 15 sec. will record the following: NpRLmPk = Peak value of NP over 102.1 >15 seconds NpRLmTm = Time in seconds that Np was over 102.1 (will never be less than 15 seconds). • Exceeding the Mid limit of 107.3 immediately records the following: NpLmPk = Peak value of NP over 107.3 NpLmTm = Time in seconds that Np was over 107.3 5 events allowed between 107.3 & 113.3, on 6th event PT wheels must be replaced. Operator must record the peak value in engine logbook then clear the fault history and clear NpLMPk and NpLmTm from engine history each time an exceedance between 107.3 & 113.3% occurs. Do not clear exceedance above 113.3%. • NpRLmTout is recorded in Fault History. this drives the FADEC degrade on shutdown. If one of the above limits is exceeded, the overspeed lamp will light during the event. On Engine Shutdown, the Engine Ovsp and FADEC Degraded messages will display. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization N2 operating speed avoidance ranges: Max Overspeed Transient LOG ONE EVENT, RECORD MAX N2, REMOVE AND REPLACE POWER TURBINE WHEELS UPON 6 EVENTS Event Threshold Remove and replace Power Turbine Wheels if continuous operation > 15 sec. TRANSIENT OPERATION ONLY PERMITTED IN THIS RANGE SEE WARNING August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization N2 operating speed avoidance ranges: Transient Operation Only Range WARNING IN ALL OPERATING REGIMES, EXCEPT AUTOROTATION WITH NP SPLIT: TO PREVENT POSSIBLE POWER TURBINE FAILURE, TRANSIENT OPERATION ONLY IS PERMITTED BETWEEN 68.4% & 87.1% N2. ANY OTHER OPERATION IN THIS RANGE IS PROHIBITED. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ Reversionary ECU: Np Exceedance Recording • Additional variables monitored: NpLmEvts = NP Limit Exceedance Events (Number) Number of events over 107.3% NP NpRLmEvts = NP Run Limit Exceedance Events (Number) Number of events over 102.1% NP for more than 15 seconds NpMLmEvts = Np Max Limit Exceedance Counter (Number) Number of events over 113.3% NP NpExcInd = NP Exceedance Indication for Engine Maintenance (True or False) When this is TRUE, the FADEC Fault caution will come on during flight indicating a maintenance action is required The Engine Ovspd warning will also display upon engine shutdown • These counter variables track the number of OS events: These counter variables help to dictate required engine maintenance actions They must be cleared once a turbine or the PT rotor is replaced August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ Reversionary ECU: Np Exceedance Recording Engine History Data for EMC35R+ ECU Engine History Data (5.358/later) Name Value -------EngRnTm 0.00 NpRLmPk 0.00 NpRLmTm 0.00 NumStrt 1 OSCyc A SgCtr 0 EngRunCtr 410.42 NpLmPk 0.00 NpLmTm 0.00 OSCtr 0 NpLmEvts 0 NpRLmEvt 0 NpMLmEvts 0 NpExcInd FALSE Units Description --------------Hours Engine Operating (Running) Time(counter) %Np Np Run Limit Exceedance Peak Value Seconds Np Run Limit Exceedance Time Starts Number of Engine Starts Boolean Overspeed Cycle Surges Number of Surge Occurrences Counter Seconds Engine Run Time Interval Counter %Np Np Limit Exceedance Peak Value Seconds Np Limit Exceedance Time Events Engine Overspeed Counter Counts Np Limit Exceedance Events Counts Np Run Limit Exceedance Events Counts Np Max Limit Exceedance Counter Boolean Np Exceedance Indication for Engine Maintenance August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization EMC35R+ Reversionary ECU: Q Exceedance Recording • Q Exceedances are recorded in Engine History, not Fault History This is a hidden record as the A/C gage is primary source Must be requested via user define page logs using Maintenance Terminal • Exceeding Q Run Limit over 10 sec. will record the following: QRLmPk = Peak value of Q over 100% >10 seconds QRLmTm = Time in seconds that Q was over 100% (will never be less than 10 seconds) • Exceeding Q Transient Limit over 2 sec. will record the following: QLmPk = Peak Value of Q over 108% QLmTm = Time in seconds that Q was over 108% • Exceeding Q Max limit immediately records the following: QLmPk = Peak value of Q over 116.3% QLmTm = time in seconds that Q was over 116.3 August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Maintenance Terminal Hidden Memory Interrogation • The FADEC ECU records exceedances that are hidden and must be requested in order to view. MGT, NG & Q Exceedances are not displayed on engine history page. This is because these parameters are displayed on the A/C gages. These exceedances will display on the “Exceedances and Chip History” page of the B407GX. • These ECU records can be used to confirm suspected faulty A/C gage exceedance recordings BUT they can be misleading. Exceedance recording in the ECU will display the maximum peak and total accumulated time of all exceedances for that parameter. Example: – Q exceedance 1 = 118% for 5 sec, maint. is performed but not cleared – Q exceedance 2 = 108% for 1.5 sec, in limit so no maint. required – If checked, the ECU record will show 118% for 7 sec, (Maint. Required?) Therefore, the data in this page MUST be viewed and cleared on a regular scheduled basis in order to maintain accuracy. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Maintenance Terminal Hidden Memory Interrogation • The engine OMM states that the A/C gage exceedance recording is to be used • for determining maintenance actions. The ECU exceedance record can be used to confirm suspected faulty A/C gage exceedance recording. If hidden memory exceedance records are maintained accurate, they can be a useful tool & filed in engine maintenance history records. • To view the hidden parameter memory, proceed as follows: From EMC-35 task bar, select “Real Time” then “User Define”. Save a Blank Screen then re-open that saved “Blank Screen” by clicking “File” > “Open” > “Real Time Screen” then select “Blank Screen”. Enter desired parameters by clicking “Edit” > “Add” then type a parameter ident in the drop down box & click OK. Repeat for each desired parameter. Save exceedance page…”File” > “Save Real Time Screen”, name it & OK. See next page for parameter idents. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Maintenance Terminal Hidden Memory Interrogation MGTLmPK MGTLmTm MGTRLmPK MGTRLmTm MGTSLmPK MGTSLmTm QLmPK QLmTm QRLmPK QRLmTm NgLmPk NgLmTm NgRLmPk NgRLmTm MGT Max Temp over 905C (engine running) MGT Total Time over 905C (engine running) MGT Max Temp over 779C (engine running) MGT Total Time over 779C (engine running) MGT Start Temp Peak over 926C (during engine start) MGT Total Time over 926C (during engine start) Torque Max Peak over 108% Torque Total Time over 108% Torque Run Peak over 100% Torque Run Peak Time over 100% Ng Max Peak over 106% Ng Total Time over 106% Ng Max Run Peak over 105% after 15 seconds Ng Total Run Time over 105% after 15 seconds NOTE: Torque % recorded in the ECU does not directly correspond to torque % as recorded by the B407 gages. To calculate ECU Pk torque to airframe gage torque for determination of maintenance requirements, multiply ECU torque by 1.0535 to get torque as recorded by the airframe sensors. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization C47 Reversionary ECU: Potential issue • Momentary N2 overspeed events above 107% Multiple momentary NP overspeeds above 107% have been recorded on the EMC35R+. The NP overspeeds typically occurred during flat pitch descents or autorotation practice. With the collective down during decent, the FADEC tries to hold the Np @ 100% but if decent speed is too fast the NR decouples the NP. When the pilot realizes the NR is too high, (usually by the NR OS light) the pilot pulls in collective to increase blade pitch and arrest the NR overspeed. By pulling collective, the CP potentiometer tells the FADEC to anticipate a power demand and thus it commands a fuel increase. With no load due to being decoupled from the rotor, the NP rapidly accelerates into the restricted range. This is typically between 107.5 & 109% for about 1 second or less before re-coupling with the NR and then decelerating back to 100%. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Maintenance & Troubleshooting Tips August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Common FADEC Issues Moisture in the Electrical Connectors Cause of multiple and often unrelated FADEC Faults. Dry out connectors if engine or transmission deck areas have been washed. Damaged Harness or Connectors Bent Pins from miss-handling. Harness breakdown from solvents or chafing. Degrade & Restart Faults when A/C is powered-up Battery power shut off before engine N1 has completely stopped. Manual Mode pistons not parked, perform piston parking procedure. Ignition Circuit Bit Faults Aircraft Starter Relay (1K1 on B407), check contacts, replace relay (New ECUSoftware will reduce occurrence). PLA or MV POT Faults Range Faults either from faulty Harness or Potentiometer. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC Harness Contact Enhancer CSL 6116; releases Stabilant 22 contact enhancer for use on FADEC harness connector pins. Refer to CSL for proper application. When installing connectors, always ensure they are clean and properly tightened. Always cover/protect connectors when not connected. Just two clicks loose can allow moisture to leak into connector or cause faulty signal Refer to CSL 6069 for maintenance guidance on FADEC system components. Connector not tight If red line is exposed Insure Clamp does not cover vent hole on TQ transducer August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC PMA Leaks Repeated PMA lip seal leaks can actually be coming from the un-used tach drive seal on the front of the gearbox. Unused Tachometer Pad PMA Driveshaft Oil Leak Path August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Bell 407 Ignition Circuit Troubleshooting • A possible issue during start is registering an IgnIFlt. • The fault is usually a result of the 1K1 start relay slow to actuate or on very • rare occasions, the 2K4 ignition relay. Following a start attempt, an Igniter V-bit Fault will be recorded. “FADEC Degraded” message will display with throttle in cut-off and power on. If the lamp goes out when throttle is rolled to GI, then the fault is “Last Run” If the “FADEC Degraded” message does not turn white @ GI position, a “Current fault” is detected and a start is not recommended. • If the fault is not current, a successful engine start can be made and the • problem may be investigated later. Troubleshooting:- Refer to Bell 407 Maintenance Manual Usually replacing the 1K1 Start Relay with a unit having the “T” or later stamped at the end of the 4 digit manufacture date resolves this. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Starting Difficulties Probable causes: Weak Battery (Late Light-off, Aborted or Hot Starts) Can cause slow acceleration and possible hot start abort. Severe case, ECU can drop off line during the start if voltage drops below 11vdc which shifts HMU into manual mode… Hot Start! High Residual MGT prior to start attempt (above 150 C) High Ambient Temperature @ High Altitude Refer to Alternate Start Procedure Improper Fuel Nozzle Shimming Poor Fuel Nozzle Condition Combustion Liner Fuel Nozzle Ferrule wear August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Starting Difficulties Delayed Light-off or No Light-off • Incorrect Fuel Nozzle Shimming; Check nozzle shimming per OMM instructions. • Typical shim stack • It is preferred to have the nozzle shimmed to the aft position (high end of limit). This provides for better spray cone relationship to igniter. 5½ shims August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Starting Difficulties Delayed Light-off or No Light-off Worn Fuel Nozzle Ferrule Ridges Inspect for heavy wear by feeling with finger for flat area in ridges through Fuel Nozzle mounting hole. Ware area will be at the 11 to 1 o’clock position. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Low Smoke Combustion Liner Characteristics to remember about Low Smoke Liners: • Soft carbon accumulation on fuel nozzle tip and inside liner dome is common. • Often, a low rumble sound is noticed during engine start (combustion rumble). This • usually dissipates after about 35-40% NG. During extreme cold temperatures (-15C and below), light white smoking may occur from exhaust at ground idle but will go away when throttle is rolled up. This is also possible at ground idle during the 2 minute cool down and is considered a normal condition, (ref CSL 6085). August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Low Smoke Combustion Liner; Soft Carbon on Fuel Nozzle Face Per the OMM: Clean tip by soaking in solvent Separate and clean air shroud and filter regularly. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Starting Difficulties Delayed Light-off or No Light-off Dirty Fuel Nozzle Tip or Faulty Fuel Nozzle Spray Pattern • Hard carbon build-up on nozzle spray tip can distort spray pattern. • Soft carbon build-up on shroud may block air holes. • Clean the tip by soaking in solvent and observe spray pattern by motoring engine with nozzle spraying into glass container. NOTE: only acceptable for start flow pattern check, this will not show faulty secondary flow pattern. A proper flow check should be performed at regular intervals. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Starting Difficulties Delayed Light-off or No Light-off Often associated with the first start of the day, it can also be experienced randomly throughout the operational day. Contributing factors to look at are: • Leaking Boost Pump Check Valve; Usually associated with delayed light-off on first start of the day. Check by closing fuel Shutoff Valve after shutdown at end of day or by checking for fuel drain back. Attach clear tube to airframe fuel filter inlet line, fill with fuel, mark the level and let sit overnight. If drain back is observed, troubleshoot boost pump check valves. • Poor Igniter or exciter performance; Hang igniter out of combustion case and monitor spark quality and rate. Should be bright blue and consistent spark, a weak spark is insufficient. Troubleshoot Ignition system components if spark quality is poor. This should include harness connectors & A/C relays. To check spark on B407GX engines, pull GIA 1 SYS circuit breaker and switch to Manual Mode. Igniters should spark continuously. Try moving the igniter to opposite side of OCC. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Starting Difficulties Rapid severe MGT rise at Initial Light-off • Excessive Fuel introduction due to faulty Wfmv signal: Connect Maintenance Terminal, open “Real Time > Sensor 2” page and observe Wfmv raw position with engine shut down. Correct Wfmv position should be -10pph ± with engine shut down. If Wfmv is excessively higher negative number, this is a faulty signal. On start, the ECU will correct by moving the metering valve to -10pph but because this is a faulty signal, it is actually opening the metering valve too much thus allowing excessive initial fuel introduction. Typically the start will abort automatically or by the pilot. There will not be a fault registered. If this is encountered, conduct FIM task 73-25-04-105 for WfmvFlt. Experience has shown that if this is intermittent or if the HMU pot resistance reads correctly, the harness is usually the problem. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Misc. Troubleshooting tips • Faulty Sensor Raw Open Circuit Default Signals: Q raw: >200% = open circuit CP raw: <-20% = open circuit PLA raw PLA1 (or 2) Raw >120 = open circuit Wfmv Raw: < -10 PPH = open circuit MGT raw: >1315C = open circuit Ng raw Ng1 (or 2) CyBit = open circuit Nr raw NrCyBit = open circuit T1 raw T1A (or B) Raw < -68C = open circuit August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Misc. Troubleshooting tips • NR goes up then drops and stabilizes @ 100% with collective increase from the full down position: Not a FADEC problem Adjust Pitch Change Links for Auto Rotation RPM • PLA Faults on newly overhauled HMU’s: PLADFlt PLA12Flt PLAHdFlt HardFlt RGRejFltRG This combination of fault codes indicated a faulty PLA pot and usually is associated with the unit heating up; checks good when @ room temp. August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Misc. Troubleshooting tips Faulty PLA Potentiometer Signals: Always run a PLA screening with the Maintenance Terminal when troubleshooting PLA faults. This helps to identify potentiometer discrepancies. These screenings should be supplied to the HMU overhaul facility when an HMU is sent for repair or overhaul. Be sure to run both PLA1 & PLA 2 on the same strip chart for overlay comparison. PLA 1 PLA 2 Noise on PLA 2 Typically found around the 70 PLA position on Bell 407 HMU’s August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Excessive difference between PLA 1 & 2 Rolls-Royce M250-C47 FADEC Familiarization Misc. Troubleshooting tips Faulty PLA Potentiometer Signals:- Noise on PLA 1 Located at lower end of PLA August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization Authorized HMU Service Centers Triumph Engine Control Systems; West Hartford, CT, USA +1-860-523-2236 Linda McKnight H&S Aviation; Portsmouth, UK +44-(0)-2392-304250 Standard Aero Limited; Winnipeg, MB, Canada +1-204-277-5445 Vector Aerospace; Vancouver, BC, Canada +1-604-276-7600 August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization FADEC system Troubleshooting & AOG Support 24 Hour Triumph AOG Hot Line +1-877-232-6264 FADEC Troubleshooting Support Brian Beal O - +1-860-231-2760 C - +1-860-794-9833 F - +1-860-236-1873 E - bcbeal@triumphgroup.com August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication Rolls-Royce M250-C47 FADEC Familiarization QUESTIONS? August 2015 The information in this document is the property of Rolls-Royce Plc & may not be copied or used for any purpose other than for which it is supplied without express written consent of Rolls-Royce Plc. This information is considered current at time of publication
