FADEC

FULL AUTHORITY
DIGITAL ENGINE
CONTROL
Introduction
Of FADEC

2
 Introduction

▰ The FADEC (Full Authority Digital Engine Control)

is a total system for the control of an engine. It
controls all aspects of aircraft engine
performance. In simpler words, FADEC is a
computer that controls the engine of the
aircraft.
▰ FADEC’s main purpose is to provide optimum
engine efficiency for a given flight condition.
FADEC controls the aircraft’s engine and
propeller in order to perform at a maximum
efficiency.

3
 Introduction
fuel injection
timing and fuel/air
▰ The system controls the ignition ratio mixture
timing, fuel injection timing and
fuel/air ratio mixture thus, an Engine + Sensor
engine with FADEC doesn't need set
magnetos and no requirement Data
manual air/fuel mixture control. from
▰ FADEC works by receiving inputs sensor
during flight conditions such as set
density of air, throttle position,
engine temperature and pressure
and other parameters. These data
from sensor will go to ECU for ignition timing
processing and analysis.
4
 Introduction

▻ Ignition system: Magneto Ignition system replaced with Electronic

Ignition system.
▻ Fuel Injection system: Carburetor replaced with Electronic Fuel Injection
system.

5
Conceptual Diagram

Fuel injectors

6
 Introduction

▰ FADEC that reduces pilot workload in the cockpit down to

selecting a desired power setting using a single control
lever(throttle).
▰ The system automatically manages fuel to either “Best Power”
or “Best Economy”

7
Overview

8
 Function Of FADEC

▰ Controls the ignition spark.

▰ Controls the air-fuel mixture of the engine.
▰ Acceleration and deceleration limiting.
▰ Selection of alternative power modes.
▰ Monitors cylinder head, manifold and exhaust gas
temperatures and pressures.

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1
Components
And Their function

10
 Basic Components of FADEC

▰ Two Electronic Control Units (ECUs)

▰ Health Status Annunciator (HSA)
▰ Power Supplies
▰ Low voltage harness
▰ FADEC Sensor set

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 Basic Components of FADEC

▰ FADEC Sensor set

(1)Speed Sensor Assembly (SSA)
(4) Cylinder Head Temperature (CHT)
(4) Exhaust Gas Temperature (EGT)
(2) Manifold Air Pressure (MAP)
(2) Manifold Air Temperature (MAT)
(2) Fuel Pressure Sensors (FPS)
(1) Throttle Position Sensor (TPS)

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 Overview EGT Sensor

19 Pin Bulkheads CHT Sensor

Connector
Fuel injector
HSA Control Solenoid

SSA 25 Pin Fuel Pressure

Connector Sensor

MAT Sensor ECU 50 Pin

Connector
SSA
ECU

MAP Sensor ECU Circuit board

ECU Ground Strap 13

 Basic Components of FADEC

▰ Two Electronic Control Units (ECUs)

▰ Health Status Annunciator (HSA)
▰ Power Supplies
▰ Low voltage harness
▰ FADEC Sensor set

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 Basic Components of FADEC

▰ FADEC Sensor set

(1)Speed Sensor Assembly (SSA)
(4) Cylinder Head Temperature (CHT)
(4) Exhaust Gas Temperature (EGT)
(2) Manifold Air Pressure (MAP)
(2) Manifold Air Temperature (MAT)
(2) Fuel Pressure Sensors (FPS)
(1) Throttle Position Sensor (TPS)

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 Two Engine Control Units (ECUs)

Always referred as brain of the Engine Control System.

▰ ECU divided into an upper and lower portion
▻ Lower portion contains the Electronic Circuit Board that processes
all data
▻ Upper portion contains the ignition coils for the spark plugs (each
ECU has four coils).
▰ The electronic circuit board (lower portion) of each ECU contains two
independent microprocessor controllers which serve as control
channels.

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 Two Engine Control Units (ECUs)

ECU divided into an upper and lower portion .

Upper portion contains

The ignition coils for the spark plugs
(each ECU has (4) coils).

Lower portion contains

the Electronic Circuit Board that
processes all data.
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Two Engine Control Units (ECUs)

Lower portion contains two

independent
microprocessor controllers which
serve
as control channels.

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Two Engine Control Units (ECUs)

Purpose of ECUs

▰ Receive the sensor inputs and monitor any changes.

▰ Precisely trim the fuel/air ratio.
▰ Control fuel injection and ignition timing.

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 Power Supplies

▰ To provide system redundancy, the FADEC has 2 power sources.

▰ The Primary Power Source (PPS) is aircraft’s main power distribution bus,
which powered by the alternator and/or primary battery.
▰ The Secondary Power Source (SPS) is powered by a separate battery
called Dedicated battery.

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 Power Supplies Prima
ry
Switc FADEC
Aircraft h Primary
alternator Power Bus
Aircr

Connectors
Wall Connectors
aft SSA
Start
Powe
ing
r Bus
Batte
ry
ECU
1

Fire Wall
ECU 2

Fire
Chargi Health
ng Status
Diode Annuncia
tor
FADEC
Secondary
FADEC
FADEC Second
Dedica
Dedica ary Power Bus 21
ted Switch
Battery
Battery
 Power Supplies

▰ Primary Power Source (PPS)

• 14v 60amp alternator and 12v 25Ah Lead
Acid type battery
• (located aft baggage compartment)
▰ • Secondary Power Source (SPS)
• 12v 7Ah Lead Acid type battery
• PPS and SPS have separate set of breakers
and the power supply circuits are separated
• Battery condition monitor will illuminate HSA
with PPWR FAIL or EBAT FAIL to alert pilot of
possible power supply loss
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 Power Supplies

▰ FADEC operates off of primary power source with alternator

indefinitely
• Alternator fails- FADEC will use primary battery until 12V then will
cycle between using PPS and SPS every volt (FADEC always looking
for best power source) until batteries are drained
▰ FADEC can operate on SPS (aka backup or emergency battery) for at
least 1 hour
• SPS is only to supply power to FADEC.

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 Health Status Annunciator (HSA)
▰ HSA provides information regarding the status of the
FADEC system
▰ Consists of (5) lights on panel and WOT
▰ RED LIGHTs indicate warning
▰ YELLOW LIGHTs indicate caution

Used to test HSA lights

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 Health Status Annunciator (HSA)

HSA lights
▰ FADEC CAUTION: Illumination of the FADEC CAUTION light
indicates
▻ Pressure or temperature sensor failures.
▻ Abnormal pressure.
▻ Temperature above limits.
▻ Misfire/cylinder not firing.

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 Health Status Annunciator (HSA)

HSA lights
▰ FADEC WARN:
▻  Illumination of the FADEC WARN light
indicates that more than one cylinder is
faulted.
▻ The FADEC WARN light is always preceded
and/or accompanied by illumination of the
FADEC CAUTION light.
▻ Land ASAP.
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 Health Status Annunciator (HSA)

HSA lights

▰ EBAT FAIL:
▻ The EBAT FAIL light
Indicating:
illuminates when there is
a fault condition with the ▻ the backup battery is not
backup (secondary) power being charged
supply.

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 Health Status Annunciator (HSA)

HSA lights

▰ PPWR FAIL: Illumination of the PPWR FAIL light

indicates that the FADEC system is drawing
power from the backup power supply because
the primary power source is off or has failed.

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 Health Status Annunciator (HSA)

HSA lights

▰ After loss or shutdown of alternator, EBAT FL and

PPWR FL annunciators illuminate. Engine may
continue to operate normally from the
emergency battery for up to 60 minutes if the
battery is properly maintained and fully charged.
▰ Plan to land well within 60 minutes.

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 Health Status Annunciator (HSA)

HSA lights
▰ FUEL PUMP : It will illuminate when booster
pump is in on and off position.(switch out
of auto position ) or that the fuel pressure
is out of the 20-40 psi range.
-On ground (Engine start) illuminate when
booster pump is in on position until it’s in auto
position and booster pump not running so the
light go out.
-In flight if it illuminate with booster pump is
in auto position, it may indicate engine driven
fuel pump failure. 30
 Health Status Annunciator (HSA)

HSA lights
▰ WOT(Wide Open Throttle):
▻ It is situated below HSA panel. Illuminates
when Throttle Position Switch (TPS) is
contacted (full throttle),
▻ signal sent to ECU that max power is required
which causes FADEC to set fuel to air ratio for
Best Power.

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 Low Voltage Harness

▰ Connects all essential components of FADEC

▰ Fuel Injector Coils and all sensors are hardwired to the low voltage
harness (except SSA, Fuel Pressure, Manifold Pressure)
▰ All information from sensors will flow to the Electronic Control Units
for data processing and analysis

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 Low Voltage Harness

▰ This harness transmits sensor input to the

ECUs via a 50-pin connector.
▰ Cannon Connector connects to the engine
mounted Fuel pressure sensors and MAP
sensors.
▰ The 25-pin connectors connect the harness
to the Speed Sensor Assembly

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 Low Voltage Harness
▰ Primary/Secondary power is supplied by the Cabin Harness through
the Bulkhead Connectors.
▰ Information from the ECUs is conveyed to the HSA and the cockpit-
mounted data port through the same Cabin Harness/Bulkhead
Connector Assembly.
Bulkhead Connectors

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FADEC SENSOR SET

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 Basic Components of FADEC

▰ FADEC Sensor set

(1)Speed Sensor Assembly (SSA)
(4) Cylinder Head Temperature (CHT)
(4) Exhaust Gas Temperature (EGT)
(2) Manifold Air Pressure (MAP)
(2) Manifold Air Temperature (MAT)
(2) Fuel Pressure Sensors (FPS)
(1) Throttle Position Sensor (TPS)

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 Speed sensor assembly (SSA)

▰ Purpose
Monitor engine speed and crank position
▰ Principle
Hall effect
▰ Location
Camshaft gear
▰ Quantity
Equal the number of ECU

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 Speed sensor assembly (SSA)

▰ Low-Voltage Harness.
▰ The SSA isn’t hardwired to the low voltage harness.
▰ SSA connect to the Low Voltage Harness via two 25 pin connectors
which sends data to the FADEC computer indicating crankshaft speed
and crankshaft position for ignition timing and fuel injection.

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 Speed sensor assembly (SSA)

▰ The SSA consists of two separate parts: a signal conditioner (Figure 10-
9) and a (Hall effect) speed sensor array
▰ Looking from the rear of the engine, the signal conditioner is mounted
on the right-hand side magneto drive pad.

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 Speed sensor assembly (SSA)
▰ The speed sensor detects the camshaft position. The speed sensor array
consists of sensors that detect the speed and position of the camshaft gear.
▰ The sensors are working in pair, each having a speed target sensor (for reading
the outer track of 12 drilled holes on the camshaft gear) and a cam target sensor
(for reading the inner track of the camshaft gear).
▰ The number of sensor pair is equal to the number of ECU, which depends on the
number of cylinder.
SSA Pair SSA Pair
No.1 No.2

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 Speed sensor
assembly (SSA)

▰ The SSA sensor pairs detect the outer track of targets in the camshaft
gear as it rotates past the sensor array generating a signal pulse train
that is proportional to engine speed.

▰ The sensor sets also detect the top-dead-center target on the inner track
of the camshaft gear generating the cam pulse. This pulse is timed with
the piston in Cylinder 1 reaching top dead center (TDC) on the
compression stroke.

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 Speed sensor
assembly (SSA)

▰ When the SSA detects an “open” hole on the outer track of drilled holes,
the SSA creates and sends a corresponding electrical pulse to the
Electronic Control Units (ECUs) to determine engine speed and crank/cam
position.

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 Hall Effect Sensor

▰ Hall effect sensor consists of conductor(metal sheet in this diagram) with

current flowing through. In the normal condition, current will flow in
straight line from point 1 to point 2.

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 Hall Effect Sensor

• When the metal sheet is placed in magnetic field, EMF is developed in

perpendicular to the current line.
• The magnitude of this developed EMF is depending upon the density of the flux
• This property of this current carrying conductor is called hall effect.

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 Hall Effect Sensor

• When current is applied to terminal 1 and 2 then output can also be

measured at point 3 and 4.

2 3

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 Hall Effect Sensor
• According to that metal has a lot lower reluctance than air, when metal
pass near the magnet, it allows magnetic flux to pass through the
conductor in hall effect sensor.
• So, the strongest magnetic flux will pass through the hall effect sensor at
the moment that metal is closest to the sensor and conductor in hall
effect sensor will produce more EMF.

46
 Exhaust Gas Temperature Sensor
(EGT)

▰ Purpose
 measurement of the temperature of the exhaust
gases
▰ Principle
 Thermocouples
▰ Location
 Exhaust pipe
▰ Quantity
 Equal the cylinder

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 Exhaust Gas Temperature Sensor
(EGT)

▰ ▪ Type K thermocouple
A thermocouple is an electrical device consisting of two dissimilar electrical
conductors forming electrical junctions at differing temperatures. A thermocouple
produces a temperature-dependent voltage as a result of the thermoelectric effect, and
this voltage can be interpreted to measure temperature

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 Exhaust Gas Temperature Sensor
(EGT)
Thermocouple

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 Exhaust Gas Temperature Sensor
(EGT)
▰ ▪ Thermoelectric effect
is the direct conversion of temperature differences to electric voltage and vice
versa via a thermocouple. A thermoelectric device creates voltage when there is a
different temperature on each side. Conversely, when a voltage is applied to it, heat is
transferred from one side to the other, creating a temperature difference At the atomic
scale, an applied temperature gradient causes charge carriers in the material to diffuse
from the hot side to the cold side.

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 Manifold Absolute Pressure Sensor
(MAP)
▰ Purpose
 MAP sensors measure the air pressure in your
intake manifold which helps to determine air / fuel
ratios.
▰ Principle
 MAP sensor uses Piezoresistive effect to measure.
▰ Location
 In intake manifold.
▰ Quantity
 2

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 Manifold Absolute Pressure Sensor
(MAP)

Piezoresistive Effect
▰ Piezoresistive materials are materials that
change resistance to the flow of current when
they are compressed or strained.
▰ Most pressure sensors use the semiconductor
silicon. When force is put on the silicon, the
resistance decreases.

High MAP -> Low Resistance -> Voltage

Signal

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 Manifold Absolute Pressure Sensor
(MAP)

Piezoresistive Effect
▰ A Piezoresistive Pressure Sensor contains
several thin wafers of silicon embedded
between protective surfaces. The surface is
usually connected to a Wheatstone bridge
▰ The Wheatstone bridge runs a small amount of
current through the sensor. When the
resistance changes, current passes through
the pressure sensor changes too.
▰ The Wheatstone bridge detects this change
and reports a change in pressure.
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 Fuel Pressure Sensor

▰ Purpose
 To check the fuel pressure and to control the injection of F/A correctly.
▰ Principle
 A FPS uses Piezoresistive effect
▰ Location
 Injection manifold, fuel distributor manifold
▰ Quantity
 2

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 Manifold Air Temperature Sensor
(MAT)
▰ Purpose
 MAT monitors the temperature of the air entering the engine.
▰ Principle
 MAT is a thermistor, which means its electrical resistance
changes in response to changes in
temperature.
▰ Location
 MAT sensor is installed into the intake manifold .
▰ Quantity
 2

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 Manifold Air Temperature Sensor
(MAT)

Thermistor
▰ A thermistor is a type of resistor whose
resistance is dependent on temperature,
more so than in standard resistors. The
word is a portmanteau of thermal and
resistor

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Manifold Air Temperature Sensor
(MAT)

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 Cylinder head temperature sensor
(CHT)

▰ Purpose
• to measure the cylinder head temperature
▰ Principle
• A thermistor
▰ Location
• Cylinder head near spark plug
▰ Quantity
• Equal the cylinder

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 Throttle Position Sensor (TPS)

▰ Purpose
 Reports throttle position to ECUs.
▰ Principle
 Micro Switch or Proximity Sensor
▰ Location
 The butterfly spindle/shaft
▰ Quantity
 1

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 Throttle Position Sensor (TPS)

Proximity Sensor
▰ Proximity sensor is a sensor able to detect the
presence of nearby objects without any physical
contact.
▰ A proximity sensor often emits an electromagnetic
field or a beam of electromagnetic radiation , and
looks for changes in the field or return signal. The
object being sensed is often referred to as the
proximity sensor's target. Different proximity sensor
targets demand different sensors. For example, an
inductive proximity sensor always requires a metal
target.

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2
OPERATION

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 Operation
Ignition system
▰ The ignition system consists of the high-voltage coils atop the ECU, the
high-voltage harness and spark plugs. Since there are two spark plugs
per cylinder on all engines, a 4-cylinder engine has 8 leads and 8 spark
plugs.
▰ One end of each lead on the high-voltage harness attaches to a spark
plug, and the other end of the lead wire attaches to the spark plug
towers on each ECU.

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 Operation
▰ Since there are two spark plugs per cylinder on all engines, a four-cylinder
engine has eight leads and eight spark plugs. The spark tower pair is
connected to opposite ends of one of the ECU’s coil packs.
▰ Two coil packs are located in the upper portion of the ECU. The high
voltage harness carries energy from the ECU spark towers to the spark
plugs on the engine.
▰ Electronic Control Unit 1 fires the top and bottom spark plugs for Cylinders
1 & 2; ECU 2 fires the top & bottom spark plugs for Cylinders 3 & 4.

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Operation

64
 Operation
Sensor Set
▰ These diagrams show how redundancy of sensors are correspond to control
channels. (4-cylinder engine)

MAT No.1 MAT No.2

MAP No.1 MAP No.2

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ECU 1 ECU 2
Operation

FPS No.1 FPS No.2

66
ECU 1 ECU 2
Operation

SSA Pair SSA Pair

No.1 No.2

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ECU 1 ECU 2
Operation

MAP , MAT, MAP , MAT,

FPS FPS

3 4 5 6

ECU 1 ECU 2 ECU 3 68

Operation

SSA 1 SSA 2 SSA 3

3 4 5 6

ECU 1 ECU 2 ECU 3 69

 Operation

▰ Eg. If CHT sensor of cylinder 1 broken, ECU will use the data from
CHT sensor of cylinder2 for cylinder1. In worst case if CHT sensor
of cylinder1&2 broken, synthetic software default values will be
used.

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 Operation

Fuel injection system

▰ The Fuel Injection System is composed of:

▻ An engine-driven Fuel Pump
▻ Fuel Distribution Block and fuel lines
▻ Solenoid-controlled Fuel Injection Nozzles

(4 Cylinders 71
Engine)
 Operation

▰ Each computer channel in the ECU

obtains data from its own sensors
and computes the amount of fuel to
inject.
▰ The electronic fuel injector injects
fuel into the intake port upstream of
the intake valve.
▰ The flow is therefore intermittent,
and not a continuous flow.

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 Operation
▰ The control channel in the ECUs controls
fuel flow through the fuel injector by
switching electrical current ON and OFF
to the control coil of the fuel injector
assembly.
▰ In the ON state, the solenoid coil creates
an electromagnetic field that lifts the
pintle valve opening the path for fuel to
flow.
▰ The amount of time the injector is held in
the ON state determines how much fuel
is delivered to the cylinder.

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3
Advantage
and Disadvantage
74
Advantage & Disadvantage

Expensive

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 Engine Data Interface

Function : Used to Capture the engine

data from ECU such as
▰ Time and Date
▰ Event History
▰ Individual Cylinders
▰ Outside Air Pressure
▰ Fuel Flow
▰ Faults
The data is recorded on a compact flash memory
card which can be removed and downloaded to a
personal computer and evaluated using the
Powerlink Engine Diagnostic Software.
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