Universal Fault Interrupter (UFI)

Application: Center Tank Override

Pump Auto Shutoff with Ground &
Arc Fault Protection

Presented by:
Gerald Bench – President, CEO
Andrew Wagner – Mgr, Business
Development
 UFI Technology
Fuel System Protection
•Relay sized, microprocessor based
monitoring device adaptable to control center
tank override pumps on B737, B757, B767, &
B747
•Provides pump dry-run protection within
FAA specified 15 second window
•Comprehensive electrical fault protection
• Line-to-Line
• Line-to-Ground
• Intermittent opens (wires, connectors)
• Phase imbalance
•Other out-of-range conditions such as locked
rotor, & bearing wear
•Downloadable history database
•No scheduled maintenance
2
 UFI Technology
System Features

• Fully certified to meet Amendment 25-

102 without exceptions
– UFI Hardware DO-254, Software DO-
178B, Both to assurance level B
• Satisfies two of three SFAR 88 regulatory
requirements
• Passive monitoring – can not introduce
electrical signals into fuel tank wiring
– Actively controls fuel pump relay
• Reliability greater than existing system
components, MTBF >100K hours (calc)
• Non-intrusive installation, piggy-back or
close proximity to existing pump relay
• Transparent operation, crew reset-able
• Technology adaptable to any 3-phase
synchronous pump motor

3
 UFI Technology
Development Status

• FAA Certified December 2005 to Amendment

25- 102, latest fuel tank safety requirements,
granted STC # ST01844LA (Boeing 737-300)
• Installation development and certification for
B757, B737NG, & B767 in work.
– Remote mounting and universal voltage adapter
(RAM) added to accommodate any relay or
panel space configuration
• Expansion capability:
– Adaptable to meet future regulatory
requirements resulting from SFAR 88

4
 UFI Technology
‘How Stuff Works’

• The UFI is a micro computer device which monitors the

three phase wiring to the center tank pumps.
• The UFI is an in-the-loop device between the cockpit
switch and the pump control relay.
• Each time the pump switch is energized the UFI checks
for pump and wiring fault conditions.
• Any time the UFI detects a fault condition it will remove
power to the pump relay.
• The cockpit crew will be alerted to the fault by a ‘pump
pressure low’ indication.
• Two UFI’s are required for complete center tank
protection.
– One for each pump relay.

5
 UFI Technology - Block Segmentation
CONTROL
RELAY

Current Sensor A

Full-Wave
Rectifier

GAIN

GS Current Sensor B MS

Full-Wave
Rectifier

GAIN

Current Sensor C
FAULT
SUM COMPARATOR
Full-Wave
Rectifier
DAC_OUT FAULT_DET
GAIN
DAC

V IN A
V IN B
I2C
V IN C I IN A
I IN B
I IN C

V IN A PROCESSOR CPLD

V IN B INT_0

V IN C INT_1

GAIN RELAY_CONTR

UFI POWER
SUPPLY

+28 VDC
FUEL
BOOST
Unique to “microcontroller” detection path PUMP
SWITCH

Unique to “hardware” detection path

Common to both detection paths
Common circuits and Relay Control (FET)

6
 UFI Technology
Example of Run-Dry Electrical Signature

Current Trace of Fuel Pump Dry-Run Condition

7
 UFI Technology
Example of Run-Dry Electrical Signature, (event continued)

Last current surge above Dry-Run Delay Power Removal

predetermined threshold.

Current Trace of Fuel Pump Dry-Run Condition

8
 UFI Technology
Examples of System
Level Testing

Pump Startup Current

APU Load Transient

GPU – APU Switchover

9
 UFI Technology
Repetitive Auto Shutoff Testing

Auto Shutoff @ Inlet Uncovered

Note: Independent detection. Shutoff sequence not tied to fuel pump
pressure determination or other less-reliable aircraft systems.
10
 UFI Technology
Ground Fault Protection Demonstrated

Line to Ground Fault Detected

Note: Power removed at control relay. Electrical surge
not continued upstream to circuit breaker.
11
 UFI Technology
Arc Fault Protection Demonstrated

Line to Line Fault Detected

Fault mitigated locally regardless of whether origination
occurred upstream or downstream of control relay.
12
 FAA Comments Regarding Project No. ST10777LA-T

“Based on the review of the UFI 3000 design and system safety assessment the FAA
credits the following attributes to the UFI 3000 functionality, effecting the airplane electrical
fuel pump system:
A) Transient Fault Detection
1) Line-to-ground current (parallel fault)
2) Line-to-line current (parallel fault)
3) Opened phase (series fault)

B) Steady-State Fault Detection

1) Unbalanced phase currents
2) Out-of-range phase currents

C) In response to any of the above electrical faults the UFI 3000 will de-energize the
airplane electromechanical relay to shutoff the fuel pump.

D) Fuel Pump Auto-Shutoff. The UFI 3000 will de-energize the airplane
electromechanical relay to shutoff the pump in response to pump inlet being
uncovered, uninterrupted for fifteen (15) seconds”.

“Upon review of the applicants position and supporting documentation, the FAA finds that
the applicant meets all the applicable requirements including compliance with 14 CFR
25.981 amendment 25-102, for the installation of UFI 3000 in Boeing 737-300 airplanes
center wing tank pumps.” (Issue Paper)

13
 SFAR88 & 14 CFR Part 25 §25.981
Amendment 25-102
• What is SFAR88?
– It is a recently adopted Rule that requires design approval holders of
certain turbine-powered transport category airplanes, and of
any subsequent modifications to these airplanes, to
substantiate that the design of the fuel tank system precludes
the existence of ignition sources within the airplane fuel tanks

– It also requires developing and implementing maintenance and

inspection instructions to assure the safety of the fuel tank
system

– For new type designs it requires compliance to 14 CFR Part 25

§ 25.981 Amendment 102
The FAA has indicated that terminating actions will be mandated to existing AD’s.

Georgios Roussos, FAA Aerospace Engineer, ANM-130S

Presentation: 2003 Seattle ACO DER Seminar
November 4, 2003
14