FADEC system-Autostart version PRELIMINARY
Contents
1. The user must provide an emergency shut off i e a servo operated cut off valve for increased security Please read and follow the GTBA code of practice http www gtba cnuce cnr it CODE HTM 9 Specifications Measures Temperature sensor K type thermocouple Temperature range 0 999 C Temperature resolution 2 C Temperature accuracy 2 R P M range 0 250 000 R P M R P M resolution 100 R P M R P M accuracy 0 05 Pump Battery measure voltage range 0 10 V Voltage measurement resolution 0 1 V Voltage measurements accuracy 2 Supply Receiver battery voltage 4to 10V Receiver battery supply current 30 mA Pump battery voltage 1 2to15V Pump current 6 A Max Continuous 50A peak Remote measures and configuration Asynchronous serial digital link Mechanical measures Plastic Box of 78 x 40 x 22 mm Weight 60 g Autostart amp advanced setup Apart from the operators parameters that are usually set by the users exist another parameters reserved to manufacturers and advanced users These parameters are Temperature calibration Timers reset Absolute maximum RPM Limit the maximum RPM that can be programmed by the operator Started reduced power in the ignition phase Starter RPM window min and max rpm in the gas ignition phase Starter switch off RPM Speed of the rotor were the starter will be switched off Starter switch on RPM Speed of the rotor were the starter will be recc2. Data Up Just as in the previous adjustments the button Menu up will cause the change of screen without varying the last recorded adjustment Once finished the programming of the transmitter this can be verified by means of the second screen of the HDT To the right of the value of the received pulse of the transmitter appears a value from the O to 100 This value must correspond to the relative position of the throttle stick corresponding 0 to stick and the trim to the minimum and 100 to stick and trim to the maximum If it were not arrived at these values or the limits of the 0 or 100 were reached before arriving stick in the end the calibration process is due to repeat When the superior and inferior limits are verified the adjustment of the trim can be verified This it is made through the green LED that incorporates the FADEC With the FADEC in start mode that is to say just started locating the trim and the stick at lower side the LED must be off When raising the trim slowly the LED must lit approximately to half of the throw of the trim From this point the FADEC considers that the motor must be running and below this stopped 5 2 Timers The last screen of the HDT shows the 3 timers included in the FADEC The first is the total engine time in minutes the second the last run time in seconds and the third is the start stop cycles counter These timers can be only cleared by a special PC software 5 5 User s manual
3. Screen 1 always appears first when starting switched on off the HDT and shows the main primary parameters of operation of the engine The representation of the screen is as follows S t a t u s T y R p m w w w w w w P w z Zz Zz The values displayed are Status A eight character word indicating the state of the FADEC Ready Fuel Ramp Temperature of exhaust in C lwwwwww Speed R p m SS Power of the pump This reading allows to know the applied voltage the pump and therefore its relative power Screen 2 Screen 2 shows the secondary parameters of operation they are the information received from the radio transmitter and the voltage of the battery u l s e X x x x H S y y Z V V e r Ww e W lt U o II N N Duration of the pulse of control received from the receiver This it is a absolute value read from the radio transmitter The usual values are between minimum 800 1000uS and 2000 2200 uS maximum Calculated value relative to the position of the throttle control The FADEC uses the programmed values of maximum and minimum along with the real reading to calculate the relative power setting for the control of the fuel pump Voltage of the battery supplying fuel pump Following screens The following screens have all the same structure except they are used of the programming of the FADEC control parameters and allow you to change the operating parameters even with the engine running As an e
4. software updates and user s support For the users with access to Internet there is a page with the versions of the user s manual and the PC software in different languages The URL is http www espiell com users1 htm and the e mail for FADEC related questions is gaspar espiell com 6 Starting the engine and tuning the system 6 2 Adjustment of the point of starting of the pump Pump start point Each pump has a minimum voltage of operation below that the motor of this doesn t turn The FADEC needs to know this point since below him the pump is stopped and it does not provide any fuel and it is the same as stop This point depends on the pump and of the elements of the battery Therefore if we change the pump or the number of cells of the battery we will have to adjust this parameter Adjust Install the complete system with pump thermocouple and fuel but with the exit of the pump towards the fuel tank so that this can work without filling of fuel the engine Set the parameter Pump start point to a value of 10 and the one of Start ramp to 0 Set the trim of the radio up The LED of the FADEC must ignite indicating the Ready to start phase Warm up the thermocouple with a lighter or set the Start Min temperature parameter below to the present temperature When the read temperature is higher than the programmed Start Min temperature the LED will begin to blink indicating the state of Fuel Ramp In this point t
5. aircraft is much more difficult to fly A too short time implies that the FADEC tries to accelerate the engine fastest than it can Because the FADEC controls the exhaust temperature there is no trouble for the engine but when having the thermocouple a thermal inertia it can be a momentary overheat that causes that the acceleration is not continuous when being reached the maximum temperature at some moment The tuning is made by fast accelerating the engine from idle to maximum power and regulating this value until the motor accelerates fast and continuously Time of deceleration Deceleration delay For the calculation of the speed of deceleration the FADEC considers the same parameters as in the acceleration unless the fixed value is this other parameter In principle there is no mechanical limitation or of temperature referring to the speed of slope but it has been found that some engines tend to flameout when the fuel flow is reduced suddenly The habitual value is 20 but the user can increase this parameter to extend the time in case that the engine is extinguished The test is made in sense in opposition to the previous one with the engine in full power lower the stick suddenly to idle The motor must decelerate quickly without extinguishing itself Stability delay Once the engine has reached approximately the power corresponding to the value of the throttle setting the FADEC adjusts the fuel flow with the purpose of match the exact value
6. autostart cycle jCaution The current software is a Beta version and extra care should be applied There aren t activated the time outs This is useful wen testing the starter or other parts because it isn t necessary to Reset the unit continuously to repeat a test But this mean that the FADEC can have a problem in a phase like a empty gas can or fuel tank or battery weak and try to start it forever At present time the recommended starter motors are the Speed 300 6V and the Speed 400 RACE 4 8V Although the unit can work with lower voltages the recommended battery voltage should be of at least 6V to allow the solenoid valves to operate reliably Programming the manufacturer parameters 2 2 2 2 2 First adjust the operator parameters specially the radio throws Set the trim and stick to low Trim low readout should appear Switch off and on again the FADEC Wen the initial screen appear Fadec autostart press the data down button located in the right hand low side and then the menu down located in the left hand low side This should be done quickly and before that the normal screen appear It will appear a screen with a number of parameter and the data To change the parameter number use the left hand button and to change the data use the right hand buttons Raise the stick or reset the FADEC to return to the normal screens Caution The parameters are stored
7. case the motor will be giving all its power but the indication of pump power will be lower than 50 The LED red will be blinking indicating the full power speed but with a pump relative power lower than 75 In this case open bypass until the led led lit continuously If at the end of this adjustment the valve is more than half open it is recommendable to reduce the battery voltage if possible 3 The red LED lit continuously Nothing to do When starting for the first time after fitting the valve of bypass or change the battery voltage it is possible to value the starting slope start ramp and already change the values to obtain a more or less fast fuel ramp This value usually has a value of between 2 and 10 depending on the starter and the turbine After the adjustment of bypass or any other modification that can influence in the relation of power of the pump fuel flow it is necessary to go from idle to full power slowly in order that the FADEC can acquire new data of the behavior of the engine and store it In this first start the data stored in the FADEC is not correct and some delays in the acceleration or slow variations of the power without moving the stick can be done This is done because the FADEC is making the fine adjustment of the curve of power of the engine It is necessary to test the system in all of the range of power of the turbine in order that the FADEC have data of all the margin of operation The FADEC continuously corr
8. engine accelerates adjustment of bypass change of pump change of the number of adjustment of this lower the pov quickly until an intermediate point and later elements of the battery or change in the engine The internally it slowly until the maximum po the power raises slowly until arriving at the stored data do not agree with the real ones reason why the FADEC FADEC can find the data of all i maximum power must find the new values This case is habitual when the bypass like 10s minimum Once this is valve is opened engine responds immediately that the FADEC keeps the new 10 3 2 The value of acceleration delay is excessive Lower the delay The habitual Too slow acceleration engine The exhaust temperature is very high or the maximum programmed Verify the adjustment Maximum temperature is too low The FADEC modifies the time of acceleration on the basis of the margin of temperature between the maximum and the current one If this difference is small the acceleration will be slower since a greater risk exists of exceeding the maximum temperature 10 3 3 The value of acceleration delay is too low The FADEC tries to Increase the value of the acci Acceleration does not uniform When accelerate the engine more quickly than it allows causing that the without steps accelerating quickly the engine from idle to temperature raises excessively moment in which the FADEC Check that the thermocouple i the maximum thi
9. gas comi Glow plug brightness too low Check adjust glow turns pulled out an the correct brightens Gas tube incorrectly set inside the engine Ask the engine mani Wen the start gas is ignited the start bad message appear The starter failed to have the minimum RPM to continue the Check the RPMINII sequence Raise the starter pc The temperature read by the FADEC is lower to the Check the exhaust t Wen the start gas is ignited the FADEC does not begin to programmed start temperature due at that the start gas flow is Increase the gas fl pump fuel nor the LED blinks insufficient to reach start the temperature lower programmed lt Adjustment of the pump start point defective Repeat the adjustm Wen the start gas is ignited the LED of the the pump FADEC begins to blink but the pump does not work Excessive fuel flow at the beginning of the starting Start very Adjustment of the pump start point defective Repeat the adjustm hot the pump This must start smo Once the pump is started and the engine is running in fuel it The fuel Start Ramp value is too low Raise the start rar takes too much time in arriving to idle Once the pump is started an the engine is running in fuel the The fuel Start Ramp value is too high or weak starter motor Lower the start ran exhaust temperature is excessive Once the pump is started an the engine is running in fuel the Too low top RPM of the starter motor
10. magnet has a metallic appearance but the mechanical properties aren t the same Think of it as a type of ceramic In particular it can be broken if force is applied Install it inside the nut or the compressor ensuring that there s enough room so as not to be crushed when tightening the nut Fit it with epoxy to avoid movement Never install it as a washer because it can break into pieces when tightening the nut and fly apart when the engine begins to run On engines with aluminium cover keep the thickness of it in the area between the magnet and the hall sensor under 1 5mm The aluminium attenuates the magnetic signal 6 times more at 120Krpm than at 10Krpm so a test on low speed doesn t guarantee full performance Try to align the magnet plane with the hall sensor plane as much as possible to have the maximum magnetic strength on it Omm Maximum between the center of the magnet the center of the hall sensor aximum signal strenght when aligned ZA 1 5 mm thicknes maximum j NZA FF 5 Programming of the FADEC The programming of the FADEC can be done using the HDT or the PC The programmable parameters are as follows FADEC user programable parameters Parameter Function y y y Re f fk Full speed RPM Sets the maximum rotor speed that will be reached by the engine with 0 250 000 RPM the throttle control at 100 Idle RPM Sets the rotor speed at idle 0 2
11. the PC Features RPM input Hall effect or Infrared Factory set RPM range up to 250 000 RPM Temperature range up to 1000 C using a K type thermocouple PWM control of 1024 levels for pump glow plug and starter motor Battery Voltage from 4 8 to 12V Adjustable power for the starter motor Build in electronic brake for the starter motor to help the clutch to disengage Blown glow plug detector Adjustable glow plug power Glow plug temperature independent of the battery voltage Adjustable gas off temperature Adjustable rpm starter switch on and off Engine running timers 2 status LEDs on the unit plus 2 more remote on option RS232 interface to interface to a PC Software upgradable trough the Data Terminal connection Black box function Record the engine measures each 0 5sec up to 12 minutes User programmable acceleration and deceleration ramps 8 points each curve in running mode and 3 point in start mode Adjusting the parameters On this software version there are 2 sets of parameters that can be changed The operator parameters are adjustable trough the Data Terminal using normal menus The manufacturer parameters are accessible by a special procedure and in some software versions are only accesible by the manufacturers The PC software can program all of the parameters if the user have the rights to do it The operator parameters are Radio throws adj
12. way between 30Krpm and 100Krpm This calculated equivalent speed is compared with the one read from the engine and the power to the pump is corrected adjusted until reaching the desired speed in this case 65Krpm The speed of the slope of spool up is a parameter programmed by the user To accelerate the engine the FADEC has to raise the power to the pump The system monitors the exhaust temperature reducing the rate acceleration if the temperature approaches to the maximum programmed temperature In case of arriving at this maximum temperature the system reduces the fuel flow until restoring the motor within its limits of operation being able to stop the pump if it can not lower the temperature With this system it is guaranteed that the engine accelerates in the minimum time possible without exceeding the max temperature or speed adapting itself to the variations of the engine room temperature pump fuel pressure etc With this system called closed loop the rotor RPM of the engine tracks linearly with the position of the throttle control independently of the type of pump batteries or engine This benefit is very useful in multiengine aircraft since the thrust of the engines is always in balance Aside from the safeguards of speed out of limits temperature or radio failure the system also incorporates two additional safeguards First is pump shutdown in case that the temperature of the exhaust is lower than the minimum protecting the engine
13. when operating it is highly recommended that the installation of all of the electrical equipment is done as far as possible from the R C receiver Keep the power cables at the minimum Fadec Autostart User s Manual V0 9 24 12 01 3 12 possible length and avoid installing the antenna near them Also anti spark capacitors must be installed on the pump motor 4 2 Selection of the Pump starter battery The FADEC needs for its operation two different power supplies The first is taken from the radio receiver through the throttle servo connection and the second is the battery that supplies the pump Reversing the polarity of the battery causes the destruction of the semiconductors of the FADEC The FADEC can work with pump battery voltages between 1 2v and 15v in manual start mode and from 4 8V to 15 in autostart mode The selection of the number of battery elements is due in consideration of the real needs of the ancillary equipment like starter motor solenoid valves and pump motor As a rule the voltage requirements of all the accessories should be as matched as possible Usually the minimum usable voltage is 4 8V limited only by the available solenoid valve voltages A common error is to use a high voltage of 6 8 4V to have good starter power and a low voltage pump that is very difficult to control in low regime due at the big voltage difference This battery does not need an on off switch in the airframe since the FADEC has an internal electronic s
14. 50 000 RPM Stop RPM Sets the minimum rotor speed which the engine can run If the speed is 0 250 000 RPM lower the FADEC will shut down the engine Start Minimum Minimum temperature at which the engine can work In the start phase 0 999 C Temperature the FADEC will begin to provide power to the fuel pump In the running operating phase it will stop the engine if the temperature is less this setting Max Temperature Maximum Temperature of operation of the engine The FADEC will try 0 999 C to maintain the EGT temperature below this value finally stopping the motor in case it can t be obtained Acceleration delay This parameter allows the adjustment of the time of acceleration ramp 0 255 delay of the engine The higher the value the more slowly the engine will respond The total time of acceleration is not fixed since it depends on other parameters as they depend on the present temperature and speed Deceleration delay Just as the acceleration delay this parameter defines the time required 0 255 for deceleration This parameter must be increased if the motor tends to flame out when going abruptly from maximum power to the idle Stability delay This parameter allows stabilising the power once the system has arrived 1 255 at the value set by the throttle control The value must be increased if the power setting is not stable Pump start point This parameter sets the minimum pump voltage where the pump just 0 255 begin
15. FADEC system Autostart version PRELI MI NARY Users guide Contents Description of the FADEC Description of the Hand Data Terminal HDT Interface RS232 Installation instructions FADEC Pump Battery Radio Receiver Thermocouple Fuel pump Fuel system Infrared R P M sensor Programming the FADEC Programming using the Hand Data Terminal HDT Programming using the personal computer PC Accessing the Software Version User s manual and software updates Starting the turbine engine and tuning the system Bypass valve installation Adjustment of the fuel pump start point Adjustment of the fuel Bypass valve Engine start up procedure Setup and adjustment of the values for Acceleration speed ramp up delay Deceleration spool down delay Stabilisation Stability delay Standard values of the parameters in known engines Warranty Specifications Troubleshooting Starting Running Acceleration Deceleration Autostart parameters and setup Copyright Gaspar Espiell All rights reserved No part of this document may be reproduced or transmitted in any form without prior written consent of Gaspar Espiell Gaspar Espiell shall not be liable for technical or editorial errors or omission contained herein nor for incidental or consequential damages howsoever resulting from the use of this material Fadec Autostart User s Manual V0 9 24 12 01 1 12 Description of the FADEC The FADEC Full Authority Digital Engine Co
16. and it cannot push the Change starter ch exhaust temperature is excessive and the engine doesn t engine to self above to self sustain battery arrive at idle Wen the engine arrives at idle the system changes to The fuel Start Ramp value is too high Lower the start rar automatic mode extinguishing the LED but the speed is higher than the programmed lowering slowly until arriving at idle Fadec Autostart User s Manual V0 9 24 12 01 11 12 10 2 Running Solution Verify the Maximum speed and The engine does not reach the maximum Too open Bypass battery of the pump empty or with too low cells Verify the indicator of power of tl defective or insufficient pump defective plumbing including the fuel bypass valve until it indicates 80 injectors inside the turbine obstructed arrive at full power check the pt 10 2 2 Too much closed Bypass The FADEC has little margin of Open the bypass valve until th Instability of the power at medium and regulation maximum power of the turbine ir and low power Pump too much powerful Change the pump or install a by Stability delay too low Increase the Stability delay problems Solution 10 3 1 An external change to the FADEC in the circuit of fuel supply has Wait until the engine accelerate When changing quickly the throttle from taken place from the last normal start stop cycle as it can be the of the power of the pump in idle to full power the
17. djustment procedure and to consider that any external variation of the operation of the system as it is the adjustment of the by pass valve change of pump battery voltage etc implies that the memorized values will be no longer valid and the FADEC needs some time to adapt Adjustment Set all of the system ready to start and set the bypass valve half open Set the parameter Acceleration delay to 120 Deceleration delay to 30 and Stability delay to 4 6 4 Engine startup Start the engine Once in idle slowly raise the control of the gas until arriving to the maximum power When arriving at full throttle three situations can occur Fadec Autostart User s Manual V0 9 24 12 01 7 12 1 The valve of bypass is too open the voltage of the battery is too low or the pump is too small and the engine does not give all of its power The red LED will be off In this case the indicator of power of pump of screen 1 will indicate 100 Close the bypass valve slowly until the engine arrives at its maximum power programmed moment at which the red LED will lit and the indication of pump power will begin to lower when regulating the FADEC the power Fit the valve until at the maximum power of the turbine the indication of pump power is of 80 95 In this point the red LED will lit continuously wen the engine is at full power 2 The bypass valve is too much closed the pump battery voltage is too high or the pump is too much powerful In this
18. ects the values of operation adapting to the possible changes of voltage of battery level of the tank etc Once the bypass and the battery voltage is adjusted and the engine run OK set the parameter Acceleration delay to 60 Deceleration delay to 30 and Stability delay to 10 6 5 Adjustment of the values of speed of acceleration Acceleration delay deceleration Deceleration delay and stabilization Stability delay Habitually these values do not need adjustment and the recommended values are useful to most of the engines but with the purpose of being able to use the FADEC with any type of turbine they are included in the parameters adjustable by the user Time of acceleration Acceleration delay The FADEC calculates the speed of acceleration depending of the exhaust temperature the current rotor speed and this parameter Acceleration Delay and therefore it is possible to modify the global time of acceleration modifying it With values of 20 an acceleration of 3s is obtained in a standard KJ 66 from 7N to 75 N lowering to 2s of 17N to 75N This times are temperature dependants and is assumed a EGT of 550 C of the engine and 800 C programmed maximum If the engine is running hotter or the programmed max temperature is lower the time will be much longer Increasing the value of this parameter the time of acceleration is longer and diminishing it lower A too long time does not have any repercussion for the engine but the
19. ent it to generate interference to the radio receiver The minimum recommended filter must be made with 3 ceramic capacitors of 10KpF one between the terminals of the pump and the other two between each terminal and the housing of the motor It is necessary to watch that the pump does not have too much friction and the starting is smooth 4 6 Fuel system If the fuel pump used too much powerful for the real engine needs it is recommendable to install the fuel system with a bypass This consists of a T fitting installed on the fuel line between the pump and the turbine that allows it to return fuel back to the fuel tank regulating the volume of this through an adjustable valve This adjustment function is to limit the maximum fuel volume sent to the motor Also it has additional safeguard function in case of failure of the FADEC the engine never receive more fuel than the maximum possible allowable flow volume 4 7 R P M sensor installation Place the magnet inside the compressor nut The nut or the compressor should be machined to have room inside for the magnet Do not install it like a washer Fix the hall sensor over the front cover using spacers See the drawing below for the correct alignment Fadec Autostart User s Manual V0 9 24 12 01 4 12 Important notes The magnet is custom made from Neodymium Although it is from a temperature tolerant variety it can loose its magnetic properties if heated beyond 150 C The
20. ess by lowering the trim or commanding other power different to idle A pump prime system is added Wen in the start phase the user raise the throttle stick up to 100 during 5 sec the pump is switched on at 25 of power for 1 second maximum This allows to prime the pump and the fuel tubes before the start 4 Installation of the FADEC Connections Throttle input JR type servo cable Other types on demand Propane butane valve JR type connector receptacle Fuel valve JR type connector receptacle The central cable is negative and the two of the sides positive RPM sensor JR type connector receptacle Thermocouple JR type connector receptacle Battery input Red black cable Fuel pump Red Green cable Glow plug Red Yellow cable Starter Red Blue cable Note In all power cables the red is the common and positive This means that all the red cables are connected internally together and to the positive of the pump starter battery Connect all of the cables in his places Note that some of the JR type connectors used can be connected in wrong place or inverted Use the coloured labels on the FADEC body to connect all the connectors in his place The configurations of the pins have done in the way that no damage can be produced to the electronics in the case of a bad connection Please note that The solenoid valves connectors have the central pin red negative and the external pins brown and orange
21. from flooding itself of non burned fuel in case of flameout The second is fuel pump shutdown due to a too low rotor speed The system stops the fuel pump in case that the rotor speed is less than the programmed stop pressure This safeguards the engine from continued running in case that rotor speed is less than that required to self sustain the engine or in a rom sensor failure The engine can be started manually semiautomatic or full autostart system In order to start the engine in manual mode the user must first raise the transmitter throttle trim and leave the throttle stick in idle minimum position The green Light Emitting Diode LED on the FADEC illuminates indicating the system is ready for start Once in this position the operator must 1 turn spin up the engine with the starter motor blower etc 2 open the butane propane gas and ignite it When the FADEC registers an exhaust temperature higher than the programmed start minimum temperature and the rotor turning the LED begins to blink and 3 the system begins to pump fuel to the motor raising the fuel pump power slowly until the idle speed is reached This final condition is signalled by the system extinguishing the LED To start the engine automatically the user should cycle the throttle from idle to full power and back to idle again In this moment the start procedure is triggered and the autostart sequence progress until the engine is at idle The user can abort the start proc
22. he pump will begin to receive voltage which will be confirmed by a sound like a buzzer in it Raise the value of Pump start point until the motor of the pump begins to turn Once found this point verify it raising and lowering the trim the pump starts at the minimum possible speed lowering or raising it a little to be sure that the pump starts each time and at minimum possible speed The normal values of this point usually are between 10 and 30 Higher values than 35 indicate that the pump is hard and it has some problem of friction or inadequate motor It is advised to repair or to replace a pump in this state since surely it will cause excessive power consumption and a great difficulty of regulation along with an abrupt starting When this point is fit set the value of Start ramp to 4 This test is only possible wen the HDT shows the pump start point screen In all other screens the pump doesn t start if the rpm rotor is zero to prevent to flood the engine 6 3 Adjustment of the valve Bypass if installed To control the engine in an efficient way and to obtain to a stable operation along with minimum times of acceleration lt 3s for a JG100 the FADEC uses a system of fuzzy logic combined with an intelligent system that learns the engine variable parameters when it is in operation These parameters are stored in the non volatile memory to use them in the future Therefore it is important to follow the order of the indicated a
23. in the same time that are modified so be careful before to modify any parameter The meaning of each parameter is These recommended values are for a KJ66 engine eS 3 TEZES Units Mnemonic _ Description 1 C 2 OFFSTEMP Temperature sensor offset calibration This value is subtracted from the one read on the fadec Changes only are read after reset Factory set do not change 2to 15 Not Used 16 2 Rpm 1000 RPMINICI Minimum safe rpm in the fuel ramp phase Lower RPM than this value than this will abort the sequence i 153 Oto255 POWERSTA Starter power in the ignition phase Real power is full power this value 255 18 3 Rpm 1000 RPMIGN Rpm where the starter is switched off in the ignition phase 19 1 Rpm 1000 RPMSTOGA Rpm where the starter is reconnected in the ignition phase 20 0 Cycles NUMINTEN Maximum ignition cycles not operative in the current release 2l 0 Sec TEMSTAR Start sequence maximum time not operative in the current release 22 100 C 4 T_STOP_G Propane switch off temperature Real temperature is this value multiplied by 4 23 20 Rpm 1000 R_STOP_S Starter switch off RPM a 153 0 to 255 POWSTIR Starter power at the beginning of the fuel ramp Real power is full power this value 255 25 16 Rpm 1000 RPMERAM rpi where the starter power arrive at 100 26 uv Rpm 1000 RPMITRA erst Rpm point in the fuel ramp From 0 to this value the RAMP1 value will be a
24. ntrol is a total system for the control of a model gas turbine engine Its main function is to control and regulate the fuel pump providing to the turbine engine the necessary amount of fuel for safe and controlled operation The FADEC measures the exhaust gas temperature the relative position of the throttle stick and the rotor speed It monitors all of the controls necessary to guarantee that the engine stays between the user defined parameters of operation also providing failsafe shutdown of the engine when it has detected any important anomaly In order to make this assessment the FADEC has a rpm sensor a thermocouple input a throttle servo input power connections for the fuel pump starter glow plug fuel and gas valves and the battery and a digital RS232 serial port to program and read the data in real time to a PC The measurements made by the FADEC are Temperature of the exhaust gas Pump battery voltage Width of the throttle pulses from the radio transmitter Engine rotor RPM Engine run time External analog signal All of these FADEC measurements can be read into and displayed on the Handheld Data terminal HDT that is connected to the FADEC by a RJ 45 connector or into a personal computer trough a RS232 adapter The FADEC is totally programmable by the user to adapt the margins of operation of each individual turbine engine The configuration setup parameters are stored in the FADEC by the terminal of hand or
25. of thrust The speed what the FADEC make this adjustment can be programmed with this parameter The habitual values vary between 4 and 20 depending on the time of programmed acceleration deceleration the temperature and the inertia of the whole system including pump engine tubes etc If a too low time is programmed the engine will not become stabilized and will be raising and lowering to the power when correcting the FADEC more quickly than the response time of the turbine If the time is very long the FADEC will take more time to adapt itself to the engine in case of change in the bypass valve batteries pump etc 7 Recommended values of the parameters on known engines in Autostart Mode Engine _ K6_ GOO Mg Maximum speed 120 000 Rpm 126 000 RPM_ 160 000 J y O Idespeed 37 000Rpm 32 000Rpm_ 45 000 o Stopspeed 25 000Rpm 20 000Rpm_ 830 000 S o a ay temperature 4 8V Speed400 4 8VR SE ae StartRamp 6 _ 6 Fadec Autostart User s Manual V0 9 24 12 01 8 12 Aplication First Start Test bench Normal fly Sport fly Acceleration delay 120 6 OT Deceleration delay Stability dela 8 Warranty The FADEC unit has one year warranty This includes only the repair replacement of the main unit and the HDT Improper use like polarity reversal short circuit or crash damage are not included This warranty does not include any damage to the engines airframes people or anything else
26. onected if the fuel ramp phase if the RPM s decay below this point Gas Switch off temperature Minimum RPM to start Minimum rpm that the rotor should have after 1 5s of starter switch on If the rom are below this limit a bad start label will appear and the start process aborted Useful to detect starter clutch failure Starter power at the beginning of the fuel ramp Rpm were the starter power is at 100 Wen the system detects the ignition had occurred it starts the starter motor at reduced power and this power is increased during the fuel ramp until arrive at the value of this parameter that is set at 100 This feature allows to use small low voltage rated starter motors without the risk of burning them due at too much power in the low speed phase Starter ramps The rpm range from 0 to idle are divided in 3 sectors by 2 rpm points In each sector a defined fuel time slope is applied So the real fuel increase in each rpm range depends on the current rpm the slope value for this rpm range and the pump start ramp parameter that is added to the ramp value for each rpm sector For example if the rom points are set to 16 000 and 30 000 RPM the rampi at 3 ramp2 at 1 ramp3 at 4 and the pump start ramp at 2 then the real fuel ramp applied from 0 to 16 000 will be ramp1 pump start ramp 3 2 5 From 16 000 to 30 000 will be ramp2 pump start ramp 1 2 3 and from 30 000 to idle ramp3 pump sta
27. opened and the glow plug powered Wen the RPM are lower than the ignition min Rom parameter default 1000 the starter is switched on again to raise the rotor speed to the ignition max rpm and the cycle is repeated Wen the thermocouple register a increase of 50 C in temperature or it is higher than the start minimum temperature that mean that the ignition have occurred the starter is switched on immediately at reduced power increasing his power accordingly to the real rotor rom At the same time the pump is switched on and the fuel valve is opened The engine begin to accelerate at the fuel ramp values depending on the real RPM Once the exhaust temperature EGT arrives at a predefined value usually 400 C the gas valve is closed and wen the RPM arrive at the predefined starter off value the starter is switched off and the brake applied to it The engine continues accelerating alone until the idle RPM are reached The user can finish the sequence in any moment simply setting the trim to off position If the engine was on running a cooling sequence will be triggered cycling the starter motor until the EGT is below the minimum programmed temperature If the engine is hot EGT higher than the minimum temperature at the moment that the user triggers the autostart cycle then the FADEC will begin a cooling cycle until the temperature is below the minimum programmed temperature At this moment it will continue with the normal
28. pplied 27 25 Rpm 1000 RPM2TRA Second Rpm point in the fuel ramp From the 1st RPM point to this value the RAMP2 value will be applied Above this value to idle RAMP3 will be used 28 0 RAMP1 ist Fuel ramp The real value used will be this value added to the Pump start ramp value 29 REN 2on Fuel ramp The real value used will be this value added to the Pump start ramp value p p p 30 RAMP3 3th Fuel ramp The real value used will be this value added to the Pump start ramp value 31 15 Rpm 1000 RPMONFU Rpm where the starter is reconnected in the fuel ramp phase if the rpm fall below this point Itis available a Excel spreadsheet to calculate and store all of the parameters Fadec Autostart User s Manual V0 9 24 12 01 10 12 10 Troubleshooting 10 1 Start Problem Solution Wen raising the trim of the radio the LED Switch off an then o is not illuminated Program the parame connections switch Pump battery disconnected After cycling the throttle nothing happens Starter motor bad disconnected Check starter and later the Start bad message appear Starter power too low Check starter power After cycling the throttle the rotor turns but later the Start RPM sensor failure Check RPM bad message appear Starter power too low or ignition roms set to low Check the autostart The RPM are cycling but the gas doesn t ignite Gas can empty or gas solenoid valve disconnected or blocked Check the
29. rt ramp 4 2 6 Adding the pump start ramp parameter to all values allow at the operator to modify the whole start time without modifying the manufacturer parameters Starting the engine The present version of Autostart uses only one channel to all of the engine functions To trigger the autostart cycle the process is as follows The user raises the trim Ready will appear on the HDT Hand data terminal screen wen the engine is supposedly to be to idle If the trim is on stop position Trim low will be read on the HDT If higher than idle StickLo will be read Wen Ready is displayed the user raise the stick to full power Once at full power if the stick is left in this position more than 5 seconds the pump prime function is triggered and the pump Fadec Autostart User s Manual V0 9 24 12 01 9 12 2 2 2 2 22 22 2 2 and fuel valve are energized at the 25 of his power for one second as much The user can switch off it before this time by lowering the stick Wen the stick is at idle again the start sequence begins The glow plug is checked and if OK the starter is engaged at reduced power soft start to test it If the glow test fail a Glow Bad message is displayed and the red led blinks Wen the rotor arrives at more than the ignition max rom programmed parameter default 4000 the starter is disconnected and the brake applied At the same time the gas valve is
30. s accelerates quickly to reduces the fuel flow to maintain the temperature controlled This installed in the hottest part of 1 an intermediate point in which it becomes effect is harnessed with the use of thermocouples with an excessive improve this problem since tt stabilized during a second raising to diameter that cause a considerable delay between the changes of temperature maximum power next temperature and the reading and correction of the fuel flow by the FADEC 10 3 Acceleration 10 4 Deceleration Solution 10 4 1 The value of the deceleration delay too low In some engines the Increase the value of the Dect Extinguished of the engine When lowering abrupt reduction of the fuel flow causes a flame out standard KJ 66 is between 20 ai quickly the throttle from maximum power to idle the engine is stopped Fadec Autostart User s Manual V0 9 24 12 01 12 12 Fadec Autostart User s Manual V0 9 24 12 01 13 12
31. s to turn This value is dependant on the voltage of the battery and the pump motor Start Ramp Sets the rate of increase of fuel flow during the start up phase The 0 255 higher the value more quickly the motor will accelerate up to idle High values along with a under powered starter can cause the engine to blow Fadec Autostart User s Manual V0 9 24 12 01 5 12 flames out the exhaust Wet Hot starts Low values imply a slow starting Stick travel This parameter sets up the throttle limits at the three key points Stop a adjusts Idle and maximum power Glow Plug power _ Sets the brightness of the glow plug Po 5 1 Programming the FADEC with the terminal of data HDT The HDT has aLCD with 16 characters x 2 rows and four buttons which allow you to move through the various menus and to change the data settings in each menu page The presentation of data has been organised in screens The first two displays the engine status readings in real time and the following screens allow you to modify the operating parameters as above table All of the parameters can be modified while the engine is running so it is easy to tune the engine without having to start it again to test the new settings Both left buttons allow you to move through the different screens in an ascending mode Menu Up or descending mode Menu Down Both right buttons allow you to change the data in increasing value Up Data or decreasing value Down Data Screen 1
32. to positive They can be connected in any position If you use a fuel or gas valve from other manufacturer remove the internal diode that these valves have or invert the polarity on the plug cables The negative usually brown cable of these valves should be connected to the central pin and the orange cable left disconnected Damage to the ECU can occur if left connected If the thermocouple connector is connected inverted the temperature will decrease wen heated and the FADEC will fail in to recognise the gas ignition 0 If the RPM sensor is connected inverted no RPM will be read Use a adequate starter motor and use a battery voltage adequate for this motor If bigger voltages are used then the high current from the motor can damage the ECU If after a start attempt you feel that the ECU becomes warm this is a sign that something is wrong The ECU should be cold all of the time The glow plug is connected to the engine body This means that the whole turbine is connected to the positive of the pump battery Take this on account if you plan to connect the negative in other place 4 1 FADEC main unit Because the FADEC is an electronic piece of equipment the installation in the model aircraft is similar to that of the radio receiver It has to be in an accessible location within the airframe with limited vibration and far from the heat of the engine Also because the pump motor uses DC power that can produce sparks in the collector
33. ust Maximum rpm Idle RPM Stop RPM Minimum temperature Maximum temperature Acceleration time Deceleration time Stability time Pump start point Pump start ramp Glow plug power From these parameters the readings of the engine and the position of the throttle control the FADEC adjusts the power to the fuel pump in the following way First the FADEC verifies that the control pulse of the transmitter is correct that is to say is between the limits set by the user If the pulse is not correct or the pulses are not received during 0 5 seconds the system assumes that there is a trouble with the radio link and shuts down the engine fail safe During this time of delay the system assumes that the throttle is at idle and decelerates the engine to this power Once verified that the pulse is correct the relative position of the throttle stick determined by the limits programmed by the user is calculated This calculation gives a value between 0 and 100 that can be read on the HDT or a PC This value is Fadec Autostart User s Manual V0 9 24 12 01 2 12 transformed into a value of equivalent rotor speed from the values of full power speed and idle speed programmed by the user For example if we programmed a idle speed of 30 000 rpm and a full power speed of 100 000 rpm this speed will be reached with the throttle control at 100 With the throttle stick at 50 the equivalent speed would be 65 000 rpm half
34. vement in the transmitter Servo reverse If the reading does not arrive at these values means that the transmitter has order to do it the HDT has 4 screens Move to the screen Transmitter programming This first menu is only informative and it warns us of the entrance in the screens of programming of the throttle control Press the button Data Up to enter in the programming menus Next it appears the screen of programming the full throttle position In order to program this parameter locate the trim and stick in the superior position Once located in this position push the button Data Up At this moment the FADEC will record the received order of the radio as the position of full power and in the HDT the following phase of adjustment is shown If it is not wanted to modify this adjustment is enough with pushing the key Menu up This also causes the change of screen but the throw is not programmed The following screen allows programming the lower limit Stop In order to do it is enough with locating the trim and stick to the minimum and push the button Data Up Also in this case pushing the button Menu up will cause the change of screen without varying the previous adjustment The last screen of adjustment of the transmitter is the position of the trim that will correspond to the idle of the engine In order to make this adjustment it is sufficient with locate the stick to the minimum and the trim to maximum and push the button
35. witch which disconnects it when the power to the receiver is switched off The NiMh batteries are not recommended due at his high internal resistance 4 3 Receiver of radio The FADEC is connected to the radio receiver like a standard throttle servo inserted in the channel for the throttle receiving the information of the throttle control pulses and the receiver battery supply 4 4 Thermocouple The FADEC use a thermocouple of type K apt until 1100 C The provided standard thermocouple consists of a wire of Inconel of 1 5mm of diameter finished in a connector who fits directly on the FADEC The recommended installation consists of practising a drill of 1 5 mm in the exhaust nozzle of the engine and inserting the end of the thermocouple so that it be 2mm within the flow of exhaust gases Because the sensible zone to the temperature is the end of the thermocouple in any case DO NOT CUT it since it will be destroyed Also do not bend it with pliers or other utensils that cause very acute angles of curvature The installation is due by hand and the curves must have the greater radius possible In principle any type of thermocouple k can be installed but it is necessary to consider the thermal inertia of it since the temperature of the engine can raise much quickly that the one of the thermocouple and cause not controlled situations of overheating 4 5 Fuel pump The fuel pump must have a Radio Frequency Filter installed in order to prev
36. xample the first next screen that appears is the maximum speed The expression x xx indicates the value stored in the FADEC In order to change it is necessary it to use the right buttons Data Up to increase the value and Data Down to decrease it The programming of all the data is made sequentially changing to the next screen using the button Menu Up The programming of the radio transmitter is a special case and needs a different procedure described next Programming of the radio transmitter setting with the HDT For the programming of the radio you need to have the FADEC and the HDT working with the radio receiver with its battery pack and the transmitter It is not necessary to install the thermocouple the pump or RPM sensor Preparation and verification of the transmitter The transmitter must not have programmed any reduction of throw trim slow movement the center value or the linearity modified In case of doubt it is recommended to connect a servo to verify that the movement is correct from end to end and fast Once the transmitter is OK connect the FADEC and by means of the key Menu Up change to screen 2 With the trim and stick of the transmitter raised Full power the reading of Pulse xxxx must be between 1900 2200 With stick and the trim lowered the reading must be between 800 and 1000 In case that the readings are inverted like in some Futaba transmitters it is necessary to change the sense of the mo
Download Pdf Manuals
Related Search