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CFM56-7B EEC

Martin Koenemann

CFM56 Symposium
June 2017 – Milan
CFM56-7B
FADEC2 EEC

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7B FADEC2 EEC MTBUR
FADEC2 CFM56-7B MTBUR
30,000

25,000

20,000
MTBUR

15,000
12 Month Rolling MTBUR
10,000

5,000

MTBUR stabilizing at around 22K hours


Confirmation rate steady @ 53%
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7B FADEC2 EEC Exploded View

Electrical Chassis Assembly (ECA)


Input/Output Module (IOM)

Power Supply Unit (PSU)

Pressure Sub-System (PSS)


Digital Processing Module (DPM)

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7B FADEC2 EEC Removals
Service Bulletin 73-0143
Replaces pre- CPXD4s
Pressure Transducer
Top 20 Removal Causes - Last 12 Months
26
24
22 Service Bulletin 73-0173
20 Root Cause Determined
Addresses VSV TM Faults Containment Action Taken
18
16 Monitor
14 Investigating
12 Service Bulletin 73-0216 EEC Corrective Action In Place
10 Overhaul Focuses on these (*)
8
6
4
* *
2
0
* *

April 2016 to April 2017

Pre-CPXD4 & DPM solder joints addressed by Service Bulletins

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7B FADEC2 EEC Overhaul
FADEC2 EEC in service since 1997. Controls have 48,000+ flight hours
CFM56-7B FADEC2 EEC reliability (MTBUR) declining with EEC age
FADEC2 Overhaul package designed to extend reliable EEC operating life
• Details in CFM56-7B S/B 73-0216 (Replaces FADEC International SL-FI-0018)
• Recommended soft time interval of 30,000 hours or 26,100 cycles
• Provides three year extended warranty
Base Overhaul

• Incorporates lessons learned from investigations and repair history


• Expanded test coverage (subassembly test), complete teardown & detailed inspections
• Key Reliability Service Bulletins Included in Base Overhaul Offering
–Buck PSU 115V Disconnect Protection (CFM56-7B SB 73-0102)
–Removal of Chassis mounting feet gussets (CFM56-7B SB 73-0098)
–Digital Processing Module circuit card inspection for specific serial numbers (CFM56-7B 73-0059)
–Add lockwire screw to PSS for securing the PS3 line coupling nut (CFM56-7B SB 73-0062)
–Incorporates latest software version
Options

• Highly Recommended Service Bulletins – Not included in base overhaul offering


– Replacement of earlier PSS Transducers with CPXD4s (CFM56-7B SB 73-0143)
– PSS Robustness Modification (CFM56-7B 73-0065 (Non-PMUX) or 73-0106 (PMUX))

Improves High Time FADEC2 EEC Reliability


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7B FADEC2 EEC Overhauls Processed
Overhauls processed
60

50

40

30

20

10

0
4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q
2009 2010 2011 2012 2013 2014 2015 2016 2017
CFM56 7B 12 13 15 30 24 26 25 39 35 38 51 42 32 41 43 42 37 47 39 39 44 39 55 48 34 32 36 36 39 42

Over 1075 FADEC2 EEC Overhauls performed (S/B 73-0216)

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Interactive FADEC Overhaul Info
Learn more about Overhaul at http://www.baesystems-ps.com/cas/fadec-interactive.jspx

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CFM56-7B
FADEC3 EEC

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7B FADEC3 EEC Exploded View

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7B FADEC3 EEC MTBUR
FADEC3 CFM56-7B MTBUR
40,000

35,000

30,000

25,000
12 Month Rolling MTBUR
MTBUR

20,000

15,000

10,000

5,000

MTBUR stabilizing above 33K hours


Confirmation rate steady @ 50%
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7B FADEC3 EEC Low Time Removals
8
High reliability replacement part introduced by S/B 73-0223
7

6
OEM Production using new vendor part
# of Removals

Monitor
Investigating
Containment Action Taken
Root Cause Determined
Corrective Action in Place

Confirmed Removals (<3000 hours/404 days from OEM ship date) April 2016 to April 2017

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PSM CR1 and CR14 Rectifiers

• Constant failure rate present for Unscreened and Screened Rectifier

• New high reliability CR1/CR14 part validation completed


− Extensive performance and life testing performed
− Same internal base construction as FADEC2 PSU part

• Service Bulletin 73-0223 issued for fielded EEC introduction


− Current S/B 73-0167 will be superseded by new S/B

• New Sensitron rectifier P/N 364A3172P1 or


P/N 262732456

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Transzorb Function, Failures & Resolution

• Transient-voltage-suppression (TVS) diode (i.e transzorb) is


electronic component used to protect sensitive electronics
from voltage spikes
– Connected to J3/J4 input signals such as Engine Position, Airplane Model,
Alternate mode, Engine Start, Auto Start, Master Lever
– When transzorb fails, becomes resistive therefore indicating that discrete
detected closed switch position
– Failed parts indicating electrical overstress located at mechanical chip-out
‘weak-spots’
– Low-time (infant mortality) failure
• New transzorb supplier (MCC) on board
– Mechanical construction exhibits reduced number of chip-out areas
– New OEM FADECs being built with MCC parts – 2nd Quarter 2016
– Field repairs being performed with new supplier parts

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7B FADEC 3 EEC - Confirmed Removals
Population to be addressed by Overhaul Service Bulletin

50
Addressed
45
on LTR chart S/B 73-0140: Replaces K1 & K2 relays (FPA)
40
# of Removals

35 S/B 73-0196: Replaces MN82 (MCB)


30
25 S/B 73-0184: Replaces T2&T4 transforms (PSM)
20
15 S/B 73-0182: Replaces MN76 (MCB)
10
5
0

Monitor
Investigating
Containment Action Taken
Root Cause Determined
Corrective Action in Place

Confirmation Rate @ 67%


April 2016 to April 2017
Further details of top pareto items on following slides
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S/B 73-0196 MCB MN82 Rework

• Aircraft Level Symptoms:


– Internal EEC Fault messages (Various)

• Failure Mode:
– Mechanical failure of solder joints on MN82 leads
• No IFSD or operational events associated

• Configurations Affected:
– AW7 MCB FADEC Level P/N: 2042M67P04 and P/N 2044M16P04
– Contains AW7 MCB P/N: 392-251-101-0

• Field Action:
– Perform Service Bulletin 73-0196 to replace MN82
with new part secured with Eccobonding on corners

Avoid unscheduled removal by scheduling S/B


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S/B 73-0184 PSM T2/T4 Transformer
Category 5: Do as soon as EEC removed from engine
Condition: Solder cracks on pins of T2 and T4 transformers on power supply units led to functional
failures. Intermittent distortion and speed test failures experienced when running ATP tests.
CAUSE: Scotchweld 2216 epoxy used to bond T2 and T4 transformer identified as root cause of solder
cracks on leads. Average time to failure is 15-20K hours.
IMPROVEMENT: PSU T2 and T4 transformers along with Scotchweld 2216 epoxy removed. New T2 and
T4 transformers installed with no Scotchweld 2216 applied around perimeter.

T2 T4 T2 T4
→ Red arrow points out
solder crack
→ Yellow arrow points out
solder separation from Before – with Scotchweld After – without Scotchweld
solder pad

Cycle driven failures – Get S/B scheduled before failure


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S/B 73-0182 ASELEC MCB MN76
Category 2: Do as soon as possible without effect on revenue service:
MN76 • Within 12 months for EECs listed in SB TABLE 1 (25 EECs)
• Within 36 months for EECs listed in SB TABLE 2 (309 EECs)
• S/B issued September 2011 – Field compliance at 65%
CAUSE: Champagne voids in Bridge BGA solder balls on MCB degrade integrity of solder
connections
IMPROVEMENT: Bridge BGA (MN76) on MCB removed along with solder and replaced with new
solder and new BGA

BAD GOOD

(Bottom Side)

329 pin Ball →Blue arrows point out macro-voids that are normal and acceptable
Grid Array
(BGA) → Red arrows point to champagne voids that are unacceptable and
cause joint to be weak and fracture resulting in an open
New 7BW software mitigates MN76 affects that led to significant events
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Questions

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CFM56-7B EEC
Logistics

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CFM56-7B EEC Reprogramming

EEC/PDL’s interface adapter cable


P/N 856A1616G02 or equivalent

PDL’s manufactured by Teledyne (ex Programming issues can be result of PDL


Demo Systems) recommended to mechanical failures (typically floppy disk
reprogram FADEC2 or FADEC3 EECs drive) or equipment setting problem such
• PDL-615/MSD as not applying power to EEC
• PMAT 2000
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Web Based Software Ordering
• Begin at www.baesystems-ps.com/customersupport/order_software.jsf
- Customers registration required prior to processing software orders – request account today
- Used for export screening and to determine entitlement

Account Problems
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Software Ordering Help

Step by step
instruction pdf

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FADEC OEM Repair Centers
• Two repair centers acting for FADEC International - Fort Wayne IN, USA
and Massy, France
FADEC International FADEC International
c/o BAE SYSTEMS c/o Safran Electronics & Defense
4250 Airport Expressway 11-13 rue Ampere
Fort Wayne, Indiana 46809 91334 Massy, France

Email: Email:
baefwaservctr@baesystems.com fadec.csc@sagem.com

• Product Support Program Managers


Martin Koenemann Stephane Laidet
Office phone: +1-260-434-5328 Office phone: +33-1-5811-9203
Cell phone: +1-260-341-7899 Cell phone: +33-6-0754-2433
marty.koenemann@baesystems.com stephane.laidet@safrangroup.com

AOG SUPPORT 24 Hours/day, 7 Days/Week


Phone +1-260-438-5600 Phone +33-1-6414-8331
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FADEC New and Used Spare Parts
• Two spare parts distribution centers acting for FADEC International - Fort
Wayne IN, USA and Massy, France
• Supplier Code 3E6E4
FADEC International FADEC International
Spare Parts Support Spare Parts Support
Jenny Collins Catherine Simonotti
Phone: +1-260-434-5664 Phone: +33-1-5811-2812
Fax: +1-260-434-5616 Fax: +33-1-5811-9318

Email: Email:
spares.enginecontrols@baesystems.com catherine.simonotti@sagem.com

ARINC/SPEC 2000: FWALMXD ARINC/SPEC 2000: PARHSCR

AOG SUPPORT 24 Hours/day, 7 Days/Week


Phone +1-260-438-5600 Phone +33-1-6414-8331

Products also available through ILSmart.com and Aeroxchange.com


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Reference Material

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7B FADEC2 EEC Service Bulletins

CFM56-7B Compliance Description


S/B# Category
73-0030 7 Introduction of New ECU/EECs with New DPM-3 and Conversion from DPM-2
73-0043 6 Pressure Subsystem Buffer Material Modification (Superseded by 73-0065)
73-0059 6 DPM Inspection looking for 11 specific PWB serial numbers. Expired in 2005.
73-0062 3 Lock Wire Modification on PS3 line and EEC Reidentification
73-0065 6 Pressure Subsystem Redesign introduction and modification for NON PMUX EECs
73-0070 7 Pressure Subsystem Conversion
73-0073 6 Resistor Modification for PSS Transducer Incompatibility (Old EECs with CPXD1 transducers)
73-0098 7 ECU Chassis Modification - removal of chassis flanges to prevent costly handling damage
73-0102 7 Buck Power Supply Robustness Modification for 115V 400Hz Disconnects - prevents damage
73-0106 6 Pressure Subsystem Redesign (6 thru 9 Transducer Configurations) for PMUX EECs
73-0143 6 CPXD4 pressure transducer incorporation - Reliability Improvement
73-0169 7 DPM R28 resistor solder joint inspection and relocation
73-0173 5 IOM R9/R32 solder joint inspection and bonding material removal - VSV TM signal affected
73-0178 7 Software version 7.B.V2 Introduction
73-0203 2 Software version 7.B.W Introduction for FADEC2 EEC DAC engines
73-0204 2 Software version 7.B.W Introduction for SAC engines and FADEC3 EEC DAC engines
73-0210 7 Software version 7.B.W1 Introduction for SAC engines and FADEC3 EEC DAC engines
73-0213 7 PSU CR519 diode replacement to help inprove reset designator ATP test yields
73-0216 7 FADEC2 First Overhaul Reliability Improvement Procedure (Replaces Service Letter SL-FI-0018)

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7B FADEC3 EEC Service Bulletins
CFM56-7B Compliance Description
S/B# Category
73-0121 6 Front Panel Assembly Alignment Pin Height Correction
73-0122 6 SIA Side Transient Protection Board (STPB) P1 Connector Mounting Hardware Inspection
and Correction
73-0126 6 Addition of Side Transient Protection Board (STPB) Protection Circuits for ARINC
Transmitter 3 (TX3)
73-0127 6 Replacement of Zener Diodes and Tantalum Capacitors on Power Supply with Screened
Parts to Improve Reliability
73-0140 6 Replacement of Front Panel K1 and K2 Ignition Relays with Higher Reliability Relays
73-0141 2 Front Transient Protection Board Fuse Inspection and Rework (1 amp fuse versus 5 amp)
73-0149 6 Removable Chassis Wall Inspection and Replacement (Mounting Holes not Drilled Deep
Enough to Allow Proper Screw Seating)
73-0154 7 EEC Conversion from 2042M67P02 to P04 by Installing Two Artwork 7 Main Channel
Boards if Replacement Artwork 4 Main Channel Board is not Available to Repair EEC
73-0157 2 Software version 7.B.U1 Introduction
73-0167 7 Replacement of CR1 and CR14 rectifiers on the Power Supply Module with Screened
73-0178 7 Parts
Software version 7.B.V2 Introduction
73-0182 2 MCB Replacement/Rework of MN76 on Specific Lots of ASELEC Manufactured MCB
73-0184 5 PSM T2 and T4 Transformer Replacement with Unbonded Version Parts
73-0196 6 Replacement of MN82 ARINC/CCDL/IMSB Controller on Tronico Manufactured MCB
73-0204 2 Software version 7.B.W Introduction for SAC engines and FADEC3 EEC DAC engines
73-0210 7 Software version 7.B.W1 Introduction for SAC engines and FADEC3 EEC DAC engines
73-0222 7 MCB ADC components replacement/relocation to allow the product improvement
introduction that addresses related field failures and ATP test failures
73-0223 7 Replacement of CR1 and CR14 rectifiers on the Power Supply Module with High Reliability
Sensitron Parts
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Fault Messages Related to PSM CR1/CR14 Rectifiers

Fault Code
73–x135n THE APL VOLTAGE INPUT TO THE EEC IS OUT OF RANGE
73–x127n THE ALTERNATOR VOLTAGE INPUT TO THE EEC IS OUT OF RANGE
73-x128n EEC CHANNEL IS NOT ENERGIZED WITH THE ALTERNATOR VOLTAGE
73–x164n THE ADIRU1 AND ADIRU2 TOTAL PRESSURE DATA DISAGREE
73–x168n ADIRU PS DATA AND THE ENG P0 SIGNAL DISAGREE
73–x171n ADIRU1 TAT DATA AND ADIRU2 TAT DATA DISAGREE

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Fault Messages Related to Transzorb Failures

These faults may be displayed if transzorb fails on aircraft discrete:


• 73-028 – The Alternate Mode Signals Disagree.
• 73-031 – Engine Start Switch Signals Disagree.
• 73-131 – Start Switch Signal and ARINC Bus Data Disagree.
• 76-136 – Start Lever Reset Signal Disagree Fault.
• 73-138 – Engine Position Signal is Out of Range.
• 73-139 – Airplane Model Signal is Out of Range.
• 73-146 – TLA Position Signals Disagree.
• 73-158 – The Alternate Mode Signal and DEU1 data disagree.
• 73-159 – The Alternate Mode Signal and DEU2 data disagree.

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Fault Messages Related to MCB MN82 Solder Issue

Fault Code
73–x010n INTERNAL EEC FAULT
73–x015n EEC OUTPUT BUS
73-x128n EEC OUTPUT BUS IS NOT AVAILABLE
73–x144n DEU2 DATA IS MISSING
73–x143n DEU1 DATA IS MISSING
73–x009n INTERNAL EEC FAULT
73–x032n THE HMU FMV CONTROL CURRENT IS OUT OF RANGE
75–x052n THE HMU LPTACC CONTROL CURRENT IS OUT OF RANGE
73-x004n INTERNAL EEC FAULT
73–x161n ADIRU2 DATA FROM DEU2 IS MISSING
73–x168n ADIRU PS DATA AND THE ENG P0 SIGNAL DISAGREE
73–x001n INTERNAL EEC FAULT
73–x013n INTERNAL EEC FAULT
75–x029n THE HMU HPTACC CONTROL CURRENT IS OUT OF RANGE
75–x037n THE HMU VSV CONTROL CURRENT IS OUT OF RANGE
75–x042n THE HMU VBV CONTROL CURRENT IS OUT OF RANGE
75–x057n THE HMU TBV CONTROL CURRENT IS OUT OF RANGE
73–x160n ADIRU1 DATA FROM DEU1 IS MISSING
73–x169n ADIRU1 AND ADIRU2 TAT DATA FROM DEU1 AND DEU2 IS MISSING
73–x031n THE START SWITCH SIGNAL AND ARINC BUS DATA DISAGREE
73–x129n DEU1 BLEED DATA AND DEU2 BLEED DATA DISAGREE

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Fault Messages Related to PSM T4 Transformer Solder

Fault Code
73-x128n EEC OUTPUT BUS IS NOT AVAILABLE
73–x013n INTERNAL EEC FAULT
73–x127n THE ALTERNATOR VOLTAGE INPUT TO THE EEC IS OUT OF RANGE
73–x001n INTERNAL EEC FAULT
73–x135n THE APL VOLTAGE INPUT TO THE EEC IS OUT OF RANGE
75–x029n THE HMU HPTACC CONTROL CURRENT IS OUT OF RANGE
73–x032n THE HMU FMV CONTROL CURRENT IS OUT OF RANGE
75–x037n THE HMU VSV CONTROL CURRENT IS OUT OF RANGE
75–x042n THE HMU VBV CONTROL CURRENT IS OUT OF RANGE
75–x052n THE HMU LPTACC CONTROL CURRENT IS OUT OF RANGE
75–x057n THE HMU TBV CONTROL CURRENT IS OUT OF RANGE

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Fault Messages Related to MCB MN76 Solder Issue

Fault Code
73-x128n EEC CHANNEL IS NOT ENERGIZED WITH THE ALTERNATOR VOLTAGE
73-x004n INTERNAL EEC FAULT
73–x010n INTERNAL EEC FAULT
73–x032n THE HMU FMV CONTROL CURRENT IS OUT OF RANGE
75–x052n THE HMU LPTACC CONTROL CURRENT IS OUT OF RANGE
73–x001n INTERNAL EEC FAULT
73–x011n INTERNAL EEC FAULT
73–x013n INTERNAL EEC FAULT
75–x057n THE HMU TBV CONTROL CURRENT IS OUT OF RANGE
73–x062n THE HMU BSV CONTROL CURRENT IS OUT OF RANGE
75–x037n THE HMU VSV CONTROL CURRENT IS OUT OF RANGE
75–x042n THE HMU VBV CONTROL CURRENT IS OUT OF RANGE
75–x029n THE HMU HPTACC CONTROL CURRENT IS OUT OF RANGE
75–x040n THE VSV POSITION SIGNALS DISAGREE
75–x060n THE TBV POSITION SIGNALS DISAGREE
77–x084n THE TOP RIGHT EGT SIGNAL (T495S1) IS OUT OF RANGE

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Thank You – Grazie

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