B737-800 NG Flight Mode Annunciator (FMA)

oem Flight Mode annunciator (737-800)

Automatic Flight System - Background

The Boeing 737-80 has a relatively sophisticated Automatic Flight System (AFS) consisting of the Autopilot Flight Director System (AFDS) and the Autothrottle (A/T).  



The Boeing 737-800 NG has a relatively sophisticated Automatic Flight System (AFS) consisting of the Autopilot Flight Director System (AFDS) and the Autothrottle (A/T).   The system is as follows:

  • The N1 target speeds and limits are defined by the Flight Management Computer (FMC) which commands airspeeds used by the A/T and AFDS;

  • The A/T and AFDS are operated from the AFDS Mode Control Panel (MCP), and the FMC from the Control Display Unit (CDU); 

  • The MCP provides coordinated control of the Autopilot (A/P), Flight Director (F/D), A/T and altitude alert functions; and,

  • The Flight Mode Annunciator (FMA), located on the Captain and First Officer side of the Primary Flight Display (PFD),  displays the mode status for the AFS.

If you read through the above slowly and carefully it actually does make sense; however, during in-flight operations it can be quite confusing to determine which system is engaged and controlling the aircraft at any particular time.

Reliance on MCP Annunciations

Without appropriate training, there can be a reliance on the various annunciations and lights displayed on the Mode Control Panel (MCP).  While some annunciations are straightforward and only illuminate when a function is on or off (such as the CMD button), others can be confusing, for example VNAV.

Do not reply on the MCP.  Always refer to the FMA to see what mode is controlling the aircraft.

Flight Mode Annunciator (FMA)

All Boeing aircraft are fitted with an FMA of some type and style.  The FMA on the Next Generation is located on the Captain and First Officer side Primary Flight Display, and is continuously displayed.  The FMA indicates what system is controlling the aircraft and what mode is operational.  All flight crews should observe the FMA to determine operational status of the aircraft and not rely on the annunciators on the MCP that may, or may not indicate a selected function.

The FMA is divided into three columns and two rows. The left column relates to the Autothrottle while the center and right hand column display roll and pitch modes respectively.  The two rows provide space for armed and selected annunciations to be displayed.  Selected modes that are operational are always coloured green while armed modes are coloured white. 

Below the two rows are the Autopilot Status alerts which are in larger green-coloured font, and the Control Wheel Steering (CWS) displays which are coloured yellow.  The Autopilot Status alerts are dependent upon whether a particular system has been installed into that aircraft.  For example, Integrated Approach Navigation (IAN), and various autoland capabilities.

When a change to a mode occurs (either by by a flight crew or by the Automatic Flight System), a mode change highlight symbol (green-coloured rectangle) is displayed around the changed mode annunciation.  The rectangle will be displayed for 10 seconds following the change in mode.

Unfortunately, not all avionics suites have the correct timing (10 seconds) and some displays the rectangle for only 2 seconds.  According to the Boeing manual the default time should be 10 seconds.

figure 1: common mode annunciations that the FMA can display.  FMA annunciations may differ between airframes depending upon the software installed to the aircraft (and avionics suite used in your simulation).  G, W and Y indicates the colour of the annunciation (green, white, or yellow). the pitch mode FOR column and CWS display are not populated. 

ERRATUM: ILS, SINGLE CH and IDLE HAVE NOT BEEN INCLUDED WHEN THEY SHOULD HAVE

Important Points:

  • An annunciation that is green-coloured indicates a selected mode.

  • An annunciation that is white-coloured indicates an armed mode.

  • If there is some confusion to what mode is currently flying the aircraft, the FMA should be what you look at - not the MCP.

Video

Boeing 737 ILS CAT IIIa Autoland PFD demonstrating FMA.

 
 

B737 Autothrottle (A/T) - Normal and Non-Normal Operations

Mode Control Panel (MCP) showing A/T on/off solenoid switch and speed window.  The MCP shown is the Pro model manufactured by CP Flight in Italy

The Autothrottle (A/T) is part of the Automatic Flight System (AFS) comprising the Autopilot Flight Director System (AFDS) and the autothrottle.  The A/T provides automatic thrust control through all phases of flight. 

The autothrottle functionality is designed to operate in unison with the Autopilot (A/P), Nevertheless, a flight crew will not always adhere to this use, some crews preferring to fly manually or partially select either the autopilot or autothrottle.

A search on aviation forums will uncover a plethora of comments concerning the use of the autothrottle which, combined with autopilot use and non-normal procedures, can be easily be misconstrued.  An interesting discussion can be read on PPRuNe.

This post will examine, in addition to normal A/T operation, some of the non-normal conditions, their advantages and possible drawbacks.  Single engine operation will not be addressed as this is a separate subject.

Additional Information:

Autothrottle (A/T) Use

The autothrottle is engaged whenever the A/T toggle is armed and the speed annunciator is illuminated on the Mode Control Panel (MCP).  Either of these two functions can be selected together or singularly. 

The autothrottle is usually engaged during the takeoff roll by pressing the TO/GA buttons located under the thrust lever handles.  This is done when %N1 stabilises for both engines at around 40%N1.  This will engage the autothrottle in the TO/GA command mode.  The reason the autothrottle is used during takeoff is to simplify thrust procedures during a busy segment of the flight.

FMA Captain-side PFD showing TO/GA annunciated during takeoff roll

Once engaged, the TO/GA command mode will control all thrust outputs to the engines until the mode is exited, either at the designated altitude set on the MCP, or by activating another automaton mode such as Level Change (LVL CHG).  When TO/GA is engaged, the Flight Mode Annunciator (FMA) will announce TO/GA providing a visual cue.

The use of the autothrottle is at the discretion of the pilot flying, however, airline company policy often dictates when the crew can engage and disengage the A/T. 

The Flight Crew Training Manual (FCTM) states:

‘A/T use is recommended during takeoff and climb in either automatic or manual flight, and during all other phases of flight’.

When to Engage / Disengage the Autothrottle

A question commonly asked is: ‘When is the autothrottle disengaged and in what circumstances’  Seemingly, like many aspects of flying the Boeing aircraft, there are several answers depending on who you speak to or what reference you read.

In the FCTM, Boeing recommends the autothrottle be used only when the autopilot is engaged (autopilot and autothrottle coupled).

In general, a flight crew should disengage the autothrottle system at the same time as the autopilot.  This enables complete manual input to the flight controls and follows the method recommended by Boeing.

My preference during an approach is to disconnect the autothottle and autopilot no later than 1500 feet AGL.  This corresponds to the altitude that the aircraft must be in landing configuration, gear down, flaps 30 and within vertical and lateral navigation constraints with landing checks completed.  Disconnecting the autothrottle and autopilot earlier in the approach provides additional time to transition from automated flight to manual flight, and establish a 'feel' for the aircraft before landing. 

It's not uncommon that  flight crew will manually fly the aircraft, especially 'old school' pilots who are very conversant with hand flying.   I know some crews that will fly from 10,000 feet to landing using the Flight Director (FD), ILS, VNAV and LNAV cues on the Primary Flight Display (PFD) for guidance and the information displayed on the Navigation Display (ND) for situational awareness.  Many pilots enjoy hand-flying the aircraft during the approach phase.

Important Point:

  • Whenever hand flying the aircraft with the autothottle not engaged, it's very important to monitor the airspeed.  This is especially so during the final approach, when thrust can easily decay to a speed very close to stall speed.

The Autothrottle is Designed to be used Coupled with the Autopilot

The autothrottle is a sophisticated automated system that will continually update thrust based on minor pitch and attitude changes, and operates exceptionally well when coupled with the autopilot.  But, when the autopilot is disengaged and the autothrottle retained, its reliability can be questionable.

Some crews believe that if a landing is carried out with the autopilot off and the autothrottle engaged, and a fall in airspeed occurs, such as during the flare, then the autothrottle will apply thrust causing the potential for a tail strike.  Likewise, if during the approach there are excessive wind gusts, pitch coupling (discussed below) may occur.

The advantages of using the autothrottle and autopilot together are:

(i)      Speed is stabilized;

(ii)     Speed floor protection is maintained;

(iii)    Task loading is reduced; and,

(iv)    Flight crews can concentrate on visual manoeuvring and not have to be overly concerned with wind additives

The disadvantages of using the autothrottlewithout the autopilot engaged are:

(i)     Additional crew workload and possible loss of situational awareness (due to workload);

(ii)    Potential excessive and unexpected throttle movement caused by pitch and attitude changes;

(iii)   Potential excessive airspeed when landing in windy conditions with gusts;

(iv)   The potential for pitch coupling to occur (discussed below); and,

(v)    A loss of thrust awareness (out of the loop).

Important Point:

  • The autopilot and autothrottle should not be used independent of one another.

737 Next Generation thrust levers

Boeing 737 Design

The design  of the 737 airframe is prone to pitch coupling because of its under wing mounted engines.  The engine position causes the thrust vector to pitch up with increasing thrust and pitch down with a reduction in thrust.

The autothrottle is designed to operate in conjunction with the autopilot, to produce a consistent aircraft pitch under normal flight conditions.  If the autopilot is disengaged but the autothrottle remains engaged, pitch coupling may develop.

Pitch Coupling

Pitch coupling is when the autothrottle system actively attempts to maintain thrust based on the pitch/attitude of the aircraft. It occurs when the autopilot is not engaged and manual inputs (pitch and roll) are used to control the aircraft. 

If the pitch inputs are excessive, the autothrottle will advance or retard thrust in an attempt to maintain the selected MCP speed.   This coupling of pitch to thrust can be potentially hazardous when manually flying an approach, and more so in windy conditions.

Scenario - pitch coupling

For example, imagine you are in level flight with autothrottle engaged and the autopilot not engaged, and a brief wind change causes a reduction in airspeed. The autothrottle will slightly advance the throttles to maintain commanded speed. This in turn will cause the aircraft to pitch slightly upwards, triggering the autothrottle to respond to the subsequent speed loss by increasing thrust, resulting in further upward pitch. The pilot will then correct this by pushing forward on the control column to decease pitch. As airspeed increases, the autothrottle will decrease thrust causing the aircraft to decrease more in pitch.

The outcome is that a coupling between pitch and thrust will occur causing a roll-a-coaster type ride as the aircraft increases and then decreases pitch, based on pilot input and autothrottle thrust control.

A/T ARM solenoid, N1 and speed button.  The N1 and speed button illuminate when either is in active mode.  In the image, the A/T is armed; however, the speed option is not selected (the annunciator is extinguished).  This enables thrust to be controlled manually

Autothrottle Non-Normal Operations (Arm Mode)

The primary function that the A/T ARM mode is to provide minimum speed protection.  A crew can ARM the throttle but not have it linked to a speed.  To configure the autothrottle in ARM mode, the  A/T toggle solenoid on the MCP is set to ARM, but the SPEED button is not selected (the annunciator is not illuminated).

Scenario - speed button not selected during approach

Some flight crews prefer during an approach, to arm the autothrottle, but not have the speed option engaged (speed annunciator extinguished). 

By doing this during a non-precision approach, it enables a Go-Around to be executed more expediently and with less workload  (the pilot flying only has to push the TO/GA buttons on the thrust lever and the autothrottle will engage).

If the approach proceeds smoothly and a Go-Around is not required, the crew will prior to landing, disengage the A/T solenoid switch on the MCP by either manually 'throwing' the toggle or pressing the A/T buttons located on the thrust levers.  Although favoured by some flight crews, this practice is not authorized by all airlines, with some company policies expressly forbidding the ARM A/T technique.

The recommendation by Boeing in the B737 Flight Crew Training Manual (FCTM) states:

‘The A/T ARM mode is not normally recommended because its function can be confusing. The primary feature the A/T ARM mode provides is minimum speed protection in the event the airplane slows to minimum maneuvering speed. Other features normally associated with the A/T, such as gust protection, are not provided’.  (When the A/T is armed and the speed button option not selected).

Autothrottle Speed Protection and Vref in Windy, Gusty and Turbulent Conditions

To provide sufficient wind and gust protection, when using the autothrottle during an approach in windy conditions, the command speed should set to the correct wind additive based on wind speed, direction and gusts (between Vref+5 and Vref +20).  

The use of an additive creates a safety envelope that takes into account potential changes in wind speed and minimises the chance of the autothrottle commanding a speed that falls below Vref.  Remember, that as wind speed varies the autothrottle will command a thrust based on the speed.

During turbulence, the autothrottle will maintain a thrust that is higher than necessary (an average) to maintain command speed (Vref).

Important Points:

  • When the autothrottle is not engaged, or the speed option on the MCP deselected, minimum speed protection is lost.

  • Always add a wind additive to Vref based on wind strength and gusts.  Doing so provides speed protection when the autothrottle is engaged.

Refer to Crosswind Landings Part 2 for additional information on Vref.

A/T disengage button on throttle thrust lever.  This is an OEM throttle from a B737-300 series.  The button is identical to that used in the NG with the exception that the handles are usually white and not grey in colour.  Depressing this button will disengage the autothrottle and disconnect the A/T solenoid switch on the MCP

Manual Override - Engaging the Clutch Assembly

Occasionally, for any number of reasons, the flight crew may need to override the autothrottle. 

The Boeing autothrottle system is fitted with a clutch assembly that enables the flight crew to either advance or retard the thrust levers whilst the autothrottle is engaged.  By moving the thrust levers, the clutch assembly is engaged and the autothrottle goes offline whilst the levers are moved.

The clutch is there to enable the autothrottle to be manually overridden, such as in an emergency or for immediate thrust control.

ProSim737 does not (as at 2018) support manual autothrottle override.

Simulation Nuances

The above information primarily discusses the systems that operate in the real aircraft.  Whether these systems are functional in a simulation, depends on the avionics suite used (Sim Avionics, Project Magenta, etc).

For example, the autothrottle may not maintain the speed selected in the MCP during particular circumstances (for example, turns in high winds). If this occurred in the real world, a crew would manually override the autothrottle.  However, if the avionics suite does not have this functionality, then the next best option is to either:

(i)      Disengage the autothrottle and manually alter thrust; or,

(ii)     Deselect the speed annunciator on the MCP.

Deselecting the speed annunciator will cause the throttle automation to be disengaged; however, the autothrottle will remain in the armed mode.  The second option is a good way to overcome this shortfall of not having manual override.  By deselecting the speed option, the thrust levers can be jiggled forward or aft to adjust the airspeed.  When the speed has been rectified by manual input, the autothrottle can be engaged again by depressing the speed  button.

It's important if the autothrottle is not engaged, or is in the ARM mode, that the crew maintains vigilance on the airspeed of the aircraft.  There have been several incidents in the real world whereby crews have failed to observe airspeed changes.

Manual Flying (no automation engaged)

The benefit of flying with the autothrottle and autopilot not engaged is the ease that the aircraft can be maneuvered.  The crew sets the appropriate %N1 that produces the correct amount of thrust to maintain whatever airspeed is desired; gone are the thrust surges as the autothrottle attempts to maintain airspeed.

Granted, it does take considerable time and patience to become competent at flying manually in a variety of conditions, but the overall enjoyment increases three-fold.

Company Policies

Airline policies often dictate how a flight crew will fly an aircraft, and while some policies are expedient, more often than not they are based on economics (cost savings) for the company in question.

Policies vary concerning autothrottle use.  For example, Ryanair has a policy to disconnect the autothrottle and autopilot simultaneously, as does Kenya Airways.  Air New Zealand and QANTAS have a similar policy, however, define an altitude that disconnection must occur at or before.   If an airline doesn't have a policy, then it's at the discretion of the flight crew who should follow Boeing's recommendation in the FCTM.

Confusion and Second Guessing - Vref with A/T Engaged or Disengaged

There is considerable confusion and second guessing when it comes to determining the Vref to select dependent on whether the autothrottle is engaged or disconnected at landing.  To simplify,

  • If the autothrottle is going to be disconnected before reaching the threshold, the command speed should be adjusted to take into account winds and gusts (as discussed above and refer to Crosswind Landings Part 2).  It's vital to monitor airspeed when the autothrottle is not engaged as during the approach the speed can decay close to stall speed.

  • If the autothrottle is to remain engaged during the landing (as in an autoland precision approach), the command speed should be set to Vref +5.  This provides speed protection by keeping the engine thrust at a level that is commensurate with the Vref command speed.  If wind and gust indicate a higher additive speed, then this should be added to Vref.

Refer to Wind Correction Function (WIND CORR) for information on how to use the Wind Correction function in the CDU.

Final Call

There is little argument that the use of the autothrottle is a major benefit to reduce task loading; however, as with other automated systems, the benefit can come at a cost, which has lead several airlines to introduce company policies prohibiting the use of autothrottle without the use of the autopilot; pitch coupling, excessive vertical speed, and incorrect thrust can lead to hard landings and possible nose wheel collapse, unwanted ground effect, or a crash into terrain.

Ultimately, the decision to use or not use the autothrottle and autopilot as a coupled system is at the discretion of the pilot in command, and depends upon the experience of the crew flying the aircraft, the environmental conditions, and airline company policy.  However,  the recommendation made by Boeing preclude autothrottle use without the autopilot being engaged.

Disclaimer

The content in this post has been proof read for accuracy; however, explaining procedures that are convoluted and often subjective, can be challenging.  Occasionally errors occur. If you observe an error, please contact me so it can be rectified.

Acronyms and Glossary

  • A/P – Autopilot (CMD A CMD B).

  • A/T – Autothrottle.

  • AFDS – Autopilot Flight Director System
.

  • Command Speed - In relation to the Autothrottle, Command Speed is Vref +5 knots.

  • FCTM – Flight Crew Training Manual (Boeing Corporation).

  • FMA – Flight Mode Annunciator.

  • Manual Flight – Full manual flying. A/T and A/P not engaged.

  • MCP – Mode Control Panel.

  • Minimal Speed Protection – Function of the A/T when engaged.  The A/T has a reversion mode which will activate according to the condition causing the reversion (placard limit). (For example, flaps, gear, etc).

  • Pitch Coupling – The coupling of A/T thrust to the pitch of the aircraft.  A/T thrust increases/decreases as aircraft pitch and attitude changes.  Pitch coupling occurs when the A/P is not engaged, but the A/T is enabled.

  • Selected/Designated Speed – The speed that is set in the speed window of the MCP.

  • Take Off/Go Around (TO/GA) – Takeoff Go-around command mode.  This mode is engaged during takeoff roll by depressing one of two buttons beneath the throttle levers.

  • Vref – Landing reference speed.

Updated and Amended 04 July 2019

Primary Flight Display (PFD) - Differences Between Sim Avionics and ProSim737 Avionics Suites

As I work on a slightly more technical article, I thought I would post some images of the Primary Flight Display (PFD) belonging to two of the most popular avionics suites - ProSim737 and Sim Avionics. For reference, I also have also included PFDs used by Aerosoft Australia, Project Magenta and Sismo Soluciones. What is readily apparent is not all suites are identical. Clearly, some developers are using artistic license or do not process the information to be able to replicate the OEM counterpart. Bear in mind when you look at the images, that Sim Avionics and ProSim737 are regularly updated and updates may alter how the PFD is displayed. ProSim737 currently has three releases - Version 1, 2 and 3.

So which PDF accurately reflects the OEM counterpart. It’s a difficult question to answer as the Next Generation encompasses four aircraft types (600, 700, 800 & 900) with each aircraft type using different software and software versions, and this is not discussing company options. Put simply there is subtle variance in how the PFD is displayed.

One aspect that should not be used when comparing suites is the colour; the colour of the PDF can easily be altered by changing the hue in the computer’s display settings.

  • Sim Avionics is owned by Flight Deck Solutions (FDS) in Canada and simulates both the 737 Next Generation and the B777. 

  • ProSim737, developed in the Netherlands, is dedicated solely to the 737 Next Generation.

  • Aerosoft Australia is developed in Australia.

In the interests of disclosure, I own Sim Avionics and ProSim737, but use ProSim737 Version 3.

Important Point:

  • Bear in mind the date of this article (2014). I have no doubt that the display from all avionics suites will change and improve with time becoming closer to the OEM.

A post located on the ProSim737 forum discusses the various PFD differences.  The post can be read here: Comparing the ProSim PFD (thanks Jacob for sending this to me).

BELOW:  Gallery of Primary Flight Displays.

Boeing 737-800 Takeoff Procedure (simplified)

One aspect novice virtual pilots find difficult to grasp is the correct method of flying the aircraft, especially the takeoff, climb and transition to cruise.

The sheer volume of information available on the Internet often results in information overload and it’s understandable that many become bewildered as the boundaries between fact and fiction blur.  Add to this that many articles on the Internet have not been peer reviewed, and you have a recipe set for disaster!

In this article,  I will instruct on the basic procedures used to takeoff, climb, and transition to cruise.  I’ll also provide some insight into how flight crews fly the aircraft, and discuss some of the more important concepts that should be known.

I will not discuss before and after takeoff checklists, the overhead, how to determine aircraft weights, or how to use of the Control Display Unit (CDU).   I will assume all essential elements of pre-flight have been completed.  Also, the following procedures assume both engines are operational.  I will not be addressing engine-out procedures or discussing derates in detail.

Please take note that some procedures are dependent upon what software is used in the Flight Management System (1). Furthermore, the display of specific items, such as the speed reference indicators on the Primary Flight Display (PFD), will only be displayed if the CDU is correctly set-up prior to takeoff.

I have attempted to try and simplify the procedure as much as possible.   However, the automated systems that can be used on the Boeing aircraft are complicated, can be used fully or in part, and can easily generate confusion. Add to this that some procedures are different between an automated and manual takeoff, and some procedures are dictated by airline policy. 

It is a challenge to simplify what in the first place is convoluted and technical.

I have set out the content in three parts:

  • Section One refers to a simplified generic procedure for takeoff (numerical sequence 1–20).  Below each numerical number are important points (summarized as dot points).  Although this section primarily refers to hand flying the aircraft, some automation concepts are discussed.

  • Section Two discusses takeoff procedures using automation.

  • Section Three provides additional information concerning important points mentioned in Section One and Two.

To minimise wordiness in this article, I have for the most part, used acronyms and footnotes.  Refer to the end of the article for a list of acronyms and their meaning.

Peer Review

The information in this article has been peer reviewed by 737 Captain and First Officer.

Automation and Variability

The Boeing 737-800 can be flown with, without, or partly with automation.  The combinations that can be used, how they work, and more importantly when to use them, can fill a book.  Indeed, there is a book (two books) – they’re called the Flight Crew Operations Manual and the Flight Crew Training Manual.

The first point to take on board is that there is no absolute correct method for takeoff and climb.  Certainly, there are specific tasks that need to be completed, however, there is an envelope of variability allowed.  This variability may relate to how a particular flight crew flies the aircraft, environmental considerations (ice, rain, wind, noise abatement, obstacles, etc.), flight training, or a specific airline policy.

Whenever variability is injected into a subject, individuals who think in absolutes - black and white - will have difficulty.  If you are the kind of person who likes to know exactly what to do at a particular time, then I suggest you find a technique that fits with your liking and personality.

SECTION ONE:  Takeoff Guideline (1-20)

The following procedures assume essential elements of pre-flight have been completed (for example, correct set-up of CDU).

1.  Using the Mode Control Panel (MCP), dial into the altitude window an appropriate target altitude, for example 13,000 feet.

2. Command speed is set in the MCP speed window.  The speed is set to V2.  V2 is determined by calculations made by the Flight Management Computer (FMC) based on aircraft weight, environmental conditions and several other parameters.

Important Points:

  • V2 is the minimum takeoff safety speed and provides at least 30° bank capability with takeoff flaps set.  This speed provides a safe envelope to fly with one engine (if an engine failure occurs).

  • You can fly either +15 or +20 knots (maximum +25 knots) above the V2 command speed.  This is done for a number of reasons:  to lower or increase pitch due to the aircraft's weight, or to take into account other environmental variables (this assumes both engines operational), or it is dictated by airline policy.

  • A white-coloured airspeed bug is displayed at V2 +15/20 on the speed tape (part of the PFD). V2+15 knots provides 40° bank capability with takeoff flaps set.   The bug is a visual aid to indicate the correct climb-out speed (bug is discussed later on).  

  • Although not required, it is a good idea is to set the minimums selector to the Acceleration Height as indicated in the CDU.  This will place a green line on the altitude tape of the PFD at the height at which the aircraft’s nose is to be lowered and flap retraction to begin.  This is a visual aid.

3.    Toggle both Flight Director (FD) switches to the O’ position (pilot flying side first).

4.    Set flaps 5 and using the electric trim switch on the yoke, trim the aircraft to the correct trim figure for takeoff. The trim figure is shown on the CDU (for example, 5.5 degrees) and is calculated dependent upon aircraft weight with passengers and fuel.  Normally the trim figure will place the trim tabs somewhere within the green band on the throttle quadrant. Takeoff should not occur if the trim tabs are outside of the green band.

5.    Arm the autothrottle (A/T) by moving the toggle on the MCP to ARM.  This may differ between airlines (when to arm the A/T) Consult the FCOM & FCTM.

6.    Release the parking brake and manually advance the thrust levers to around 40%N1.  %N1 can be airline specific with some airlines recommending 60%N1.  Consult the FCOM & FCTM.

7.    Monitor the EGT on the EICAS and when there is a decrease in EGT and the throttles are stabilised, either:

  • Advance the thrust levers to takeoff thrust (if hand flying); or,

  • Press one or both TOGA buttons if wishing the autothrottle system to be selected.  If the autothrottle system has been selected for takeoff, both thrust levers will automatically begin to advance to the correct %N1 output calculated by the Flight Management System.

Interesting Point:

  • After takeoff configuration is complete, and with the parking brake in the OFF position, some flight crews quickly advance and retard the thrust levers.  The purpose being to check for errors in the takeoff configuration.  An error will trigger the audible configuration horn when the thrust levers are advanced.

  • Become conversant with derates. Using a particular derate is normal practice, but in particular will help control over-pitching and high vertical speeds, which are a common occurrence when the aircraft is light (minimal fuel load, passengers and/or cargo).

Important Points:

  • You do not have to stop the aircraft on the runway prior to initiating 40%N1.  A rolling takeoff procedure is often recommended, as this expedites the takeoff (uses less runway length) and reduces the risk of engine damage from a foreign object being ingested into the engine (engine surge/stall due to a tailwind or crosswind).

  • When the thrust has reached 40%N1, wait for it to stabilise (roughly 2-3 seconds).  Look at the N1 thrust arcs and the EGT gauge (on the EICAS display).  Both N1 arcs must be stable and the EGT values decreasing slightly.  In the real aircraft, the EGT should reduce between 10C-20C after N1 has stabilised at 40%.  If the engines are NOT allowed to stabilise, prior to advancing the thrust levers, the takeoff distance can be adversely affected.

  • There is considerable confusion around when to actually press the TOGA buttons.  As stated, %40N1 is common, but some airline procedures indicate 60%N1, while others recommend a staged approach – meaning, initially advance the thrust levers to 40%N1, allow the thrust to stabilise, and then advance the thrust levers to 70-80%N1 and press TOGA.

  • Do not push the thrust levers forward of the target %N1 - let the autothrottle do its job (otherwise you will not know if the autothrottle system has failed).  See Point 10 concerning hand placement.

  • Ensure the autothrottle has reached the target %N1 by 60 knots ground speed.  If not, execute a Rejected Takeoff (RTO).

  • Unless you select a different mode, the TOGA command mode that was engaged at takeoff (assuming you used the autothrottle system), will remain engaged until you reach the assigned altitude indicated on the MCP.

  • Selecting N1 on the MCP does not disengage TOGA mode.  If you want to disengage TOGA mode, the Flight Director switches must be toggled to the OFF position, or another vertical mode selected.

  • In some simulators that use ProSim737 software (Version 2 & 3), you will notice that when throttle arm is displayed on the PFD, the throttle will retard slightly (%N1).  This is NOT normal and is a ProSim737 software glitch.  The issue is easily resolved by moving the thrust levers forward slightly.  This glitch does not appear to cause other problems.

8.    Maintain slight forward pressure on the control column to aid in tyre adhesion to the runway. Focus on the runway approximately three-quarters in front of the aircraft.  This will assist you to maintain visual awareness and to keep the aircraft on the centreline.  Use rudder and aileron input to control any crosswind.

9.    During the initial takeoff roll, the pilot flying should place their hand on the throttle levers in readiness for a rejected takeoff (RTO).  The pilot not flying should place his hand behind the throttle levers.  Hand placement facilitates the least physical movement should an RTO be required.

10.    The pilot not flying will call out 80 Knots  Pilot flying should slowly release the pressure on the control column so that it is in the neutral position.  Soon after the aircraft will pass through the V1 speed (this speed is displayed on the speed tape).  Takeoff is mandatory at V1, and Rejected Takeoff (RTO) is now not possible.  The pilot flying, to reaffirm this decision, should remove his or her hands from the throttles; thereby, reinforcing the must fly rule.  (see important points below).

11.    At Vr (rotation), pilot not flying calls Rotate.  Pilot flying slowly and purposely initiates a smooth continuous rotation at a rate of no more than 2 to 3 degrees per second to an initial target pitch attitude of 8-10 degrees (15 degrees maximum).

Important Points:

  • Normal takeoff attitude for the 737-800 is between 8 and 10 degrees.  This provides 20 inches of tail clearance at flaps 1 and 5.  Tail contact will occur at 11 degrees of pitch (if the aircraft is still on or close to the ground).

  • Takeoff at a low thrust setting (low excess energy, low weight, etc) will result in a lower initial pitch attitude target to achieve the desired climb speed.

  • The correct takeoff attitude is achieved in approximately 3 to 4 seconds after rotation (depending on airplane weight and thrust setting).

  • Point 10 (above) discusses hand placement during the takeoff roll.  Another method used differentiates responsibility between the Captain and First Officer.  The Captain as Pilot in Command (PIC) will always have control of the thrust levers, while the pilot flying (First Officer) will concentrate solely on the takeoff with both hands on the control column.  Removal of the hand after V1 is a standard operational procedure (SOP).  This assumes that the First Officer will be pilot flying.

12.    Following takeoff, continue to raise the aircraft’s nose smoothly at a rate of no more than 2 to 3 degrees per second toward 15 degrees pitch attitude.  The Flight Director (FD) cues (pitch command bars) will probably indicate approximately 15 degrees.

Be aware that the cues provided by the Flight Director may on occasion be spurious; therefore, learn to see through the cues to the actual aircraft horizon line.

  • The Flight Director pitch command is NOT used during rotation.

13.    At this stage, you most likely will need to trim the aircraft to maintain minimum back pressure (neutral stick) on the control column.  The 737 aircraft is usually trimmed to enable flight with no pressure on the control column.  It is quite normal, following rotation, to trim down a tad to achieve neutral loading on the control column.  Do not trim during the actual rotation of the aircraft.

14.    When positive rate has been achieved, and double checked against both the actual speed the aircraft is flying at (see speed tape on PFD), and the vertical speed indicator, the pilot flying will call Gear Up and the pilot not flying will raise the gear to minimize drag and allow air speed to increase.  The pilot not flying will also announce Gear Is Up when the gear has been retracted successfully (green lights on the MIP have extinguished).

15.    The Flight Director will command a pitch to maintain an airspeed of V2 +15/20.  Follow the Flight Director cues (pitch command bar), or target a specific vertical speed.  The vertical speed will differ widely when following the FD cues as it depends on weight, fuel, derates, etc. If not using the FD, try to maintain a target vertical speed (V/S) of ~2500 feet per minute.

Important Points:

  • V2 +15/20 is the optimum climb speed with takeoff flaps (flaps 5).  It results in maximum altitude gain in the shortest distance from when the aircraft left the runway.

  • If following rotation the FD cues appear to be incorrect, or the pitch appears to be too great, ignore the FD and follow vertical speed guidance.

  • Bear in mind that vertical speed has a direct relationship to aircraft weight - if aircraft weight is low to moderate, use reduced takeoff thrust (derates) or Assumed Temperature Method to achieve a recommended vertical speed.

  • If LNAV and VNAV were selected on the MCP prior to takeoff, LNAV will provide FD inputs at 50 feet and VNAV will engage at 400 feet.

  • When VNAV is engaged, the speed of the aircraft will be automatically updated on the speed tape and the speed window on the MCP will become blank. 

  • If LNAV and VNAV have not been selected prior to takeoff, it is common practice to manually select a roll mode (LNAV) at 400 feet.  VNAV is usually selected after flaps UP.

  • If LNAV and VNAV has been selected prior to takeoff. LNAV is advisory. VNAV will automatically update the autothrottle system. The aircraft will not fly the LNAV course or the VNAV vertical profile until the autopilot is selected (CMD) on the MCP.

16.    Follow and fly the cues indicated by the FD (automation), or maintain a command speed at V2 +15/20 (hand flying) until you reach Acceleration Height (AH).  AH is often stipulated by company policy and is usually between 1000-1500 feet ASL. AH can be changed in the CDU.

17.    At or when passing through Acceleration Height (~1500 Feet RA), a number of tasks may need to be completed. These tasks will cause the PFD display to change.

  • The nose of the aircraft is to be lowered (pitch decreased).  This will increase airspeed and lower vertical speed.  A rough estimate to target is half the vertical speed used at takeoff. 

  • The flaps should be retracted as per the Flaps Retraction Schedule.  If noise abatement is necessary, flaps retraction may occur at the Thrust Reduction Height. 

  • Retract flaps as per the Flaps Retraction Schedule. Retract each degree of flaps as the aircraft's speed passes through the next flap increment détente.  The flaps increment détente is displayed in green on the PFD speed tape.  For example, as the aircraft passes through the flaps 1 designation you would select flaps 5 to flaps 1.  Then, when the airspeed passes through the flaps UP position you would select flaps 1 to flaps UP.  You do not want to exceed the flaps limit speed.  (See Interesting Points (second dot point) regarding the Speed Trend Vector).

  • Do not retract flaps unless the aircraft is accelerating, and the airspeed is at, or greater than V2 +15/20 - this ensures the speed is within the manoeuvre margin allowing for over-bank protection.  Do not retract flaps below 1000 feet RA.

  • When flaps retraction commences, the airspeed bug will disappear from the speed tape on the PFD.

  • If hand flying (VNAV not selected), at Acceleration Height set the speed in the speed window of the MCP to a speed that corresponds to the flaps UP speed.  The flaps UP speed can be found displayed on the speed tape on the PFD.  This is often referred to as Bugging Up.

  • Some flight crews when reaching Acceleration Height call Level Change, Set Top Bug.  This ensures that TOGA speed is disengaged (by selecting another mode).

  • If VNAV has been selected prior takeoff, the flaps UP speed will be automatically populated and displayed on the speed tape on the PFD.  However, the speed will not be displayed in the MCP speed window (the window will be blank).

18.    When the aircraft flies through the flaps UP speed, and after the flaps have been fully retracted, the desired climb speed is dialed into the speed window of the MCP (If VNAV is not selected).  If VNAV has been selected, the climb speed will be automatically populated and displayed on the PFD (as will the cruise speed when the aircraft reaches cruise altitude).

Important Points:

  • If VNAV is selected, the speed window in the MCP is blank.  However, if VNAV is not selected the speed window is open.

  • If automation and the autothrottle system (TOGA) is not being used, and you are hand flying the aircraft, Press N1 on the MCP (if desired) at Acceleration Height and follow FD cues to flaps UP speed. 

  • When N1 is selected, the autothrottle will control the speed of the aircraft to the N1 limit set by the FMS.  Selecting N1 ensures the aircraft has maximum power (climb thrust) in case of a single engine failure.

  • If the autothrottle system (TOGA) has been used during takeoff, N1 is automatically selected (by the FMS) at Thrust Reduction Altitude (usually ~1500 feet RA).  There is no need to press the N1 button on the MCP.

  • N1 mode doesn’t control the aircraft’s speed - it controls thrust. The autothrottle will set the maximum N1 thrust (power).  The aircraft’s speed is controlled by the pitch attitude.

  • Selecting N1 on the MCP does not provide any form of speed protection.

  • Acceleration Height can be changed in the CDU.

  • The auotpilot should NOT be engaged prior to flaps UP. This is often stipulated by airline policy,

19.    The aircraft is usually flown at a speed no faster than 250 KIAS to 10,000 feet.  At 10,000 feet, speed is usually increased to 270 KIAS. Environmental factors and/or ATC may result in differing speeds being set.

At this stage, the aircraft can be hand flown with or without VNAV and/or the autothrottle. You can either:

  • Continue to hand fly the aircraft to altitude. Appropriate climb and cruise speeds will need to be dialed into the MCP; or,

  • Select a suitable pitch and roll mode (LVL CHG, V/S, LNAV & VNAV) and engage the autopilot or select CWS. If a pitch and roll mode is selected and the autopilot not selected, the FD will provide visual cues.

20.    At 10,000 feet, dial 270 KIAS into the MCP speed window and then at 12,000 feet dial in 290 KIAS.  Follow the Flight Director cues, or if the FD is not being used, maintain roughly 2000-2500 fpm vertical speed.  At cruise altitude, transition to level flight and select on the MCP speed window 290-310 KIAS or whatever the optimum speed is (see CDU).

Interesting Points:

  • Many pilots had fly the aircraft to 10,000 feet before engaging the autopilot.  To enhance situational awareness, it is common practice, if hand flying, to have LNAV and VNAV selected. This enables the pilot to follow the navigation cues displayed on the PFD.

  • Located on the speed tape on the PFD, is a green coloured line called a Speed Trend Vector (STV).  The Speed Trend Vector will display an upwards, neutral or downwards facing arrow.  During climb-out, the Speed Trend Vector arrow can be used to determine how long it will take for the aircraft, at the current thrust setting, to reach the speed that the arrow is pointing at (usually around 10 seconds).  Therefore, when the upward arrow reaches the flaps indicator, the aircraft will pass through this flaps détente in approximately 10 seconds. The Speed Trend Vector can be used to help know when to initiate retraction of the flaps.

Summary

The above procedures are general.  Specific airline policy for a particular airline may indicate otherwise.  Likewise, there is considerable latitude to how the aircraft is flown, whether it be without automation selected, or with part or full automation selected.

It is very easy to become confused during the takeoff phase - especially in relation to automation, V speeds, acceleration heights, and how and when to change from hand flying to automation  The takeoff phase occurs quickly, there is a lot to do, and quite a bit to remember - there is little time to consult a manual or cheat sheet.

SECTION TWO:  Takeoff Guideline (LNAV, VNAV & autopilot selected prior to takeoff)

Although I have mentioned some of the VNAV procedures in the above discussion, I though it pertinent to include this section which will address a takeoff with LNAV and VNAV selected (points 1-10 below).  This information relates to FMS software U10.8A. 

Important Point:

  • The aircraft requires information from the FMS when automation (LNAV & VNAV) is used.  For the takeoff to be successful, the PERF INIT and navigation data must be inputted into the CDU.

The following 10 points outline a VNAV selected takeoff:

  1. Select from the CDU a Standard Instrument Departure (SID) and press the illuminated annunciator (EXEC) on the CDU. 

  2. Verify the Flight Director switches are selected to the ON.

  3. ARM LNAV and VNAV on the MCP (press the LNAV & VNAV buttons on the MCP).

  4. ARM the Autopilot (press CMD A/B) and set the Command Speed in the speed window of the MCP to V2 (The V2 speed can be found in the takeoff page of the CDU).

  5. Takeoff (as discussed earlier).

  6. VNAV will engage at 400 feet and the Flight Director will command V2 +15/20.  The appropriate bugs on the PFD speed tape will be populated automatically.  The speed should always be crosschecked against the actual speed that the aircraft is flying and the white bug on the speed tape.

  7. At Acceleration Height (between ~1000-1500 feet RA or as indicated in the CDU) the Flight Director will command a speed 10 knots above the FLAPS UP speed.

  8. Lower the aircraft’s nose and follow the FD cues (command pitch bars).

  9. Commence FLAPS retraction and follow the Flaps Retraction Schedule (Point 18 above).

  10. As the FLAPS retract into the UP position the Flight Director will command 250 knots.

  11. Select CMD A/B (autopilot) or fly to 10,000 feet or cruise altitude and select autopilot.

SECTION THREE:  Additional Information - Summarised Important Points

Understanding %N1

To understand the various levels of automation it is important to have a relative understanding of %N1.

N1 is a measurement in percent (%) of the maximum RPM of an engine, where maximum RPM is certified at the rated power output for the engine (most simple explanation).  Therefore, 100%N1 is maximum thrust, while 0%N1 is no thrust.  (%)N1 will be at a percentage commensurate with the settings that have been inputted to the CDU (aircraft weight, fuel, derates, etc).

Important Points:

  • The autothrottle logic when TOGA selected controls the aircraft’s thrust (%N1).  The aircraft’s speed is controlled by pitch (attitude).  

  • To clarify what automated system is controlling the aircraft, always refer to the Flight Mode Annunciations (FMA) in the PFD (Refer to Table 1 for a quick overview of annunciations displayed during the takeoff).

Common Practice - What to Select For Takeoff

It is not the purpose of this article to rewrite the FCOM or FCTM.   Needless to say, there are several combinations, that can be selected at varying stages of flight.  All are at the discretion of the pilot flying, or are stipulated as part of airline policy.

After Acceleration Height has been reached, the aircraft’s nose lowered to increase speed, and the flaps retracted, it is common practice to use LVL CHG, V/S, or LNAV and VNAV, and either hand fly the aircraft, select CWS, or select the autopilot (usually at or above 3000 feet, but certainly after flaps UP) and fly to cruise altitude.

If the takeoff does not use LNAV and VNAV (not selected on the MCP) LNAV can be selected at, or after 50 feet RA and VNAV can be selected at, or after 400 feet RA.  After either of these two modes have been selected, the Flight Director cues will automatically update to reflect the data that has been inputted into the CDU.

Theoretically, a crew can hand fly the aircraft following the FD cues at V2 +15/20 to the altitude set in the MCP.  However, there will be no speed protection, and if the pitch cues recommended by the FD are not followed, then the airspeed may be either below or above the optimal setting or safety envelope.  Selecting an automation mode (not V/S) is what engages the speed protection (speed protection will be discussed shortly).

In the above scenario (assuming the aircraft is being hand flown), unless another vertical mode is selected, the aircraft will remain in TOGA command mode (thrust controlled by N1) until the altitude set in the MCP is reached.  To deselect (cancel) TOGA as the command mode, another mode such as LVL CHG, VNAV or V/S will need to be selected.  Altitude Hold (ALT HOLD) also deselects TOGA as does engaging the autopilot. 

Flight crews typically hand fly the aircraft until the flaps are retracted (flaps UP) and the aircraft is in clean configuration.  A command mode is then selected to continue the climb to cruise altitude. CWS or the autopilot may or may not be engaged.

Important Point:

  • It is important to understand what controls the various command modes.  For example, LVL CHG is controlled by N1 and pitch.  In this mode, the autothrottle will use full thrust, and the speed will be controlled by pitch.  

 

TABLE 1:   N1 MCP annunciation and FMA displays for common time events during takeoff and climb

 
 

TABLE 2:  Throttle command modes for common time events during takeoff and climb.  The flight crew can manually override the autothrottle logic by advancing or retarding the thrust levers by hand.  This can only be done at certain phases of flight.  Throttle online means that the crew can override the autothrottle logic, while Throttle offline means that the logic cannot be overridden

 

Speed Protection

One of the advantages when using the automated systems is the level of speed protection that some of the systems provide.  Speed protection means that the autothrottle logic will not allow the aircraft’s speed to be degraded to a value, by which the aircraft can stall or be below maneuvering speed.

Speed protection is not active with every automated system.  Whether speed protection is active depends upon the U version of the FMS software in use, the automation mode selected, and whether the flaps are extended or fully retracted.

  • The following examples indicate whether speed protection is available;

Level Change (LVL CHG): When you select LVL CHG, the speed window will open allowing you enter a desired speed.  LVL CHG is speed protected, meaning that the aircraft's speed will not increase beyond the speed inputted into the MCP.  This is because LVL CHG is controlled by N1 (thrust) while the aircraft’s speed is controlled by pitch.

VNAV: VNAV has active speed protection for the leading edge devices (U10.8A and above) .  This is why VNAV can be selected on the ground.

Vertical Speed (V/S): V/S provides no speed protection.  This is because V/S holds a set vertical speed.  In V/S, if you are not vigilant, you can easily encounter an overspeed or under speed situation.

N1: Selecting N1 by pressing the N1 button on the MCP (without any other mode selected) does not provide speed protection.  Using the N1 mode, only ensures maximum thrust is generated.

Important Points:

  • Speed protection is armed only for some levels of automation.

  • It is imperative that you observe the Flight Mode Annunciator (FMA) to check that the aircraft is flying the mode intended.    

ryanair taking off from bristol airport england (Adrian Pingstone)., Ryanair Boeing 737-800 (EI-DWO) takes off from Bristol Airport, England, 23Aug2014 arp, marked as public domain, more details on Wikimedia Commons)

Always Think Ahead

As stated, the takeoff phase happens quickly, especially if the aircraft’s weight is light (cargo, passengers and fuel).

Soon after rotation (Vr), the aircraft will be at Acceleration Height and beyond…  It’s important to remain vigilant and know what’s happening, and to think one step ahead of the automated system that is controlling the aircraft.  You do not want the automation to get ahead of you and hear yourself thinking what’s it doing now.

Aircraft Weight

Although briefly discussed earlier,  I would like to enlarge upon how the weight of the aircraft can have an affect on takeoff and climb.  An aircraft’s weight is altered by the volume of fuel on board, the number of passengers, and the amount of cargo carried in the holds.

In some respects, a heavily laden aircraft, although requiring higher thrust settings and longer runway length, will be more stable than the same aircraft at a lighter weight.  A lightly laden aircraft will use less runway and, unless thrust settings are managed accordingly, will be prone to an excessive rate of climb (high vertical speed and high pitch angle).  This can lead to tail strike and uncomfortably high rates of ascent.

To manage this, flight crews often limit the takeoff thrust by using one of several means.  Typically, a thrust derate is used with either CLB 1 or CLB 2 set in the CDU, or an assumed temperature thrust reduction is used.   Selecting either option will cause a longer takeoff roll (less thrust) and delay the rotation point (Vr), however, the climb-out will be less aggressive and more manageable.

Final Call

Reiterating, the above guidelines are generalist only.  Flight crews use varying methods to fly the aircraft, and often the method used will be chosen based on company policy, crew experience, aircraft weight, and other environmental factors, such as runway length, weather and winds.

Additional Information:  

Future Articles

Time permitting, other articles will be published dealing with: descent, initial approach, and landing (ILS, VNAV, Circle to Land and RNAV).

Disclaimer

The content in this post has been proof read for accuracy, however, explaining procedures that are convoluted, technical, and somewhat subjective can be challenging.  Errors on occasion present themselves.  If you observe an error (not a particular airline policy), please contact me so it can rectified.

Footnotes

(1): For example, there are different protocols between FMC U10.6 and FMC U10.8 (especially when engaging VNAV and LNAV prior to takeoff).  I have purposely not addressed these differences because they can become very confusing (another article will do this).  As at writing (2020), ProSim737 uses U10.8A.

Acronyms and Glossary

  • AFDS – Autopilot Flight Director System

  • AH - Acceleration Height.  The altitude above sea level that aircraft’s nose is lowered to gain speed for flap retraction.  AH is usually 1000 or 1500 feet and is defined by company policy.  In the US acceleration height is usually 800 feet RA

  • CDU, FMC & FMS – Control Display Unit / Flight Management Computer (term often used interchangeably).  The visual part of the Flight Management System (FMS) that enables input of variables. FMS is the system and software (U10.8A). FMC is the actual computer, and the CDU is the hardware.

  • CLB 1/2 – Climb power

  • Command Mode – The mode of automation that controls thrust

  • EICAS – Engine Indicating and Crew  Alerting System

  • F/D – Flight Director (Flight Director cues/crosshairs)

  • FMA – Flight Mode Annunciation located upper portion of Primary Flight Display (PFD)

  • KIAS – Knots Indicated Air Speed

  • LNAV – Lateral Navigation

  • LVL CHG – Level Change Command Mode

  • MCP – Mode Control Panel

  • N1 & N2 – N1 and N2 are the rotation speeds of the engine sections expressed as a percentage of a nominal value. ... The first spool is the low pressure compressor (LP), that is N1 and the second spool is the high pressure compressor (HP), that is N2. The shafts of the engine are not connected and they operate separately. Often written N1 or %N1.

  • RTO – Rejected Take Off

  • T/O Power – Takeoff power

  • Throttle On & Offline – Indicates whether the throttle is being controlled by the A/T system

  • TOGA – To Go Around Command Mode

  • TRA - Thrust Reduction Altitude.  The altitude that the engines reduce in power to increase engine longevity.  The height is usually 1500 feet; however, the altitude can be altered in CDU

  • V/S – Vertical Speed Command Mode

  • V1 – is the Go/No go speed.  You must fly after reaching V1 as a rejected take off (RTO) will not stop the aircraft before the runway ends

  • V2 – Takeoff safety speed.  The speed at which the aircraft can safely takeoff with one engine inoperative (Engine Out safe climb speed)

  • VNAV – Vertical Navigation

  • Vr – Rotation Speed.  This is the speed at which the pilot should begin pulling back on the control column to achieve a nose up pitch rate

  • Vr +15/20 – Rotation speed plus additional knots (defined by company policy)

  • Updated April 2021.

  • Updated March 2024.

  • Updated February 2025.

OEM 737-800 Lights Test Toggle Switch - Wired and Installed to MIP

OEM Lights Test Switch (before cleaning...) One toggle switch that comprises several switches

The lights test is an often misunderstood but simple procedure.  The light test is carried out by the crew before each flight to determine if all the annunciators are operating correctly (illuminating).  The crew will toggle the switch upward to lights test followed by a routine scan of each annunciator on the overhead, center pedestal and instrument panel.  An inoperative light may preclude take off.

The lights test switch is a three-way switch which can be placed (and locked) in one of three positions; it is not a momentary switch.  Toggling the switch upwards (lights test) illuminates all annunciators located in the MIP, forward and aft overhead and fire suppression panel (wheel well annunciator may not illuminate), while the central position (BRT) provides the brightest illumination for the annunciators (normal operation).  Toggling the switch downwards activates the DIM function dimming the brightness by roughly half that observed when the toggle is in BRT mode (28 volts to 16.7 volts).

Depending upon which manufacturer’s Main Instrument Panel (MIP) you are using, the toggle switch may not function this way.  For example, Flight Deck Solutions (FDS) provide a three-way momentary toggle which is not the correct style of switch.  You should not have to hold the toggle to light test as you make your pre-flight scan.  The real toggle switch in the Boeing 737 aircraft is not a momentary switch.

Anatomy of the Toggle Switch

The OEM Light Test switch may appear to be a ‘glorified’ toggle switch with an aviation-sized price tag; however, there is a difference and a reason for this high price tag.  

The switch although relatively simple in output, encompasses 18 (6+6+6) high amperage individual switches assigned to three terminals located on the rear of the switch.  Each terminal can be used to connect to a particular aircraft system, and then to each other.  This allows the toggle switch to turn on or off multiple aircraft systems during the light test. 

The purpose of these multi-terminals is to allow the toggle switch to cater towards the high amperage flow of several dozen annunciators being turned on at any one time during the lights test, in addition to generators and other aircraft systems that are not simulated in Flight Simulator.  In this way, the switch can share the amperage load that the annunciators draw when activated during the light test.

The switch can control the annunciators (korrys) for the MIP, forward overhead, aft overhead, fire suppression panel and any number of modules located in the center pedestal which use 28 volt korrys.  

OEM Lights Test switch.  The appearance of the OEM switch is not dissimilar to a normal toggle switch; however, the functionality is different in that there are a number of terminals on the rear of the switch to allow multi-system connection

Terminals, Interfacing and Connection

To determine the correct terminals to be used for the light test is no different to a normal toggle-style switch. 

First, ascertain which of the six terminals correlate to the switch movement (toggle up, center and down).  The three unused terminals are used to connect with other systems in the real aircraft (not used in Flight Simulator).

To determine the correct terminals for wiring, a multimeter is set to conductivity (beep) mode.  Place one of the two multimeter prongs on a terminal and then place the other prong on the earth (common) terminal.  Gently move the toggle.   If you have the correct terminal for the position of the toggle, the multimeter will beep indicating an open circuit. The toggle switch does not require a power source, but power is required to illuminate the annunciators during the lights test.  

For an overview of how to use a multimeter see this post - Flight Deck Builders Toolbox - Multimeter.

Daisy Chaining and Systems

Any annunciator can be connected to the light test function, and considering the number of annunciators that the light test function interrogates, it is apparent that you will soon have several dozen wires that need to be accommodated. 

Rather than think of individual annunciators, it is easier to relate a group of like-minded components as a system.  As such, depending upon your simulator set-up, you may have the MIP annunciators as one system, the overhead annunciators as another and the fire suppression panel and modules mounted in the center pedestal as yet another.  If these components are daisy chained together (1+1+1+1+1=connection), only one power wire will be required to be connected at the end of the array.  This minimises the amount of wire required and makes connection easier with the toggle switch.

Two Methods to Connect to the Switch

There are two ways to wire the switch; either through the flight avionics software (software-based solution), or as a stand-alone mechanical system.  There is no particular benefit to either system.  The software solution triggers the lights test by opening the circuit on the I/O cards that are attached to the computer, while, the mechanical system replicates how it is done in the real aircraft.

Switch in-line (software connection using ProSim737)

The on/off terminal of the toggle switch is connected to a Leo Bodnar card or other suitable card (I use a Flight Deck Solutions System card), and the card’s USB cable connected to the main computer.  Once the card is connected, the avionics suite software (ProSim737) will automatically register the card with to allow configuration.  Depending upon the type of card used, registration of the inputs and outputs for the card may first need to be registered in Windows (if using Windows 7/10, type into the search bar joystick and then select calibration).

To configure the toggle switch in ProSim737, open the configuration/switches tab and scroll downward until you find the lights test function.  Open the tab beside the name; select the appropriate interface card (Leo Bodnar card) from the drop down menu and save the configuration.  

ProSim737 will automatically scan the interface cards that are installed, and if there is a card that has a power requirement, such as a Phidget 0/16/16 card (used to convert OEM annunciators, modules and panels), the software will make a connection enabling the lights test to function.

Considering the connection is accomplished within the ProSim737 software, it stands to reason the lights test will only operate when ProSim737 is open.

To illuminate the annunciators when the switch is thrown, a 28 volt power supply will need to be connected to the annunciators either separately or in a daisy chain array.

OEM aviation relay mounted in center pedestal

Stand-alone (mechanical connection)

The second method, which is the way it is done in the real aircraft, is to use an OEM 50 amp 6 pull/6 throw relay. 

Depending upon the type of relay device used (there are several types), it may be possible to connect up to three systems to the one relay.

Lights Test Busbar

Although the lights test toggle switch has the capacity to connect several systems to the actual switch, it would be unmanageable to attempt to connect each panel to the lights test switch.

To solve this issue a centrally-placed aviation-grade relay has been used in association with a busbar.

The benefit of using an OEM relay and busbar is that the relay acts as a central point for all wires to attach.  The wires from the various systems (panels, korrys, etc) attach to the busbar which in turn connects to the various posts on the relay.

When the lights test toggle is positioned to lights test, the relay will open or close enabling power to reach the annunciators (via the busbar).

The stand-alone system will enable the lights test to be carried out without ProSim737 or flight simulator being open.

The OEM relay is not large - the size of a small entree plate, however, it can be problematic finding a suitable area in which to mount the relay where it is out of the way.  A good location is to mount the relay inside the pedestal bay. In my case, the relay is attached to a flat wooden board which is secured to the lower section of the center pedestal.

Using the DIM Functionality (toggle thrown downwards)

This article has only discussed the lights test function of the toggle switch. The DIM function is used to dim the OEM annunciators (korrys) for night work. 

 

Diagram 1: basic overview to how the oem lights test toggle is connected

 
 

diagram 2: flow schematic between oem light test toggle and annunciators

 

Crosswind Landing Techniques Part Two - Calculations

crosswind landing with right main gear touching first (Jeroen Stroes Aviation Photography from Netherlands, EI-FIZ (27608888537), CC BY 2.0

Determining Correct Landing Speed (Vref)

Vref is defined as landing speed or the threshold crossing speed, while Vapp is defined as the approach speed with wind/gust additives.

When landing with a headwind, crosswind, or tailwind the Vref and Vapp must be adjusted accordingly to obtain the optimal speed at the time of touchdown.  Failure to do this may result in the aircraft landing at an non-optimal speed causing runway overshoot, stall, or floating (ground affect).

Mathematical calculations can be used to determine Vref and Vapp based on wind speed, direction, and gusts.

This is the second segment of a two-segment post.  The first segment dealt with methods used to land in cross wind conditions  - Crosswind Landing Techniques Part One Crab and Sideslip.

Normal Conditions

When using the autothrottle, position command speed to Vref+5 knots.

If the autothrottle is disengaged or is planned to be disengaged prior to landing, the recommended method of approach speed correction to obtain Vapp (approach speed), is to add one half of the reported steady headwind component plus the full gust increment above the steady wind to the reference speed.

One half of the reported steady headwind component can be estimated by using 50% for a direct headwind, 35% for a 45-degree crosswind, zero for a direct crosswind, or interpolation between.

When making adjustments for wind additives, the maximum command speed should not exceed Vref+20 knots or landing flap placard speed minus 5 knots, whichever is lower.

The minimum command speed setting with autothrottle disconnected is Vref+5 knots.  The gust correction should be maintained to touchdown while the steady headwind correction should be bled off as the airplane approaches touchdown. 

It is important to note that Vref+5 knots is the speed that is desired when crossing the threshold of the runway - it is NOT the approach speed.  The approach speed (Vapp) is determined by headwind with/without gusts.  If the wind is calm, Vref+5 knots will equal Vapp.

When landing in a tailwind, do not apply wind corrections. Set command speed at Vref+5 knots (autothrottle engaged or not engaged).

Non-Normal Conditions

When Vref has been adjusted by the non-normal procedure, the new Vref is called the adjusted Vref and is used for the landing.  To this speed is added the wind component (if necessary).

For example, if a non-normal checklist specifies 'Use flaps 15 and Vref 15+10 for landing', the flight crew would select flaps 15 and look up the Vref 15 speed (in FCTM or QRH) and add 10 knots to that speed.  The adjusted Vref does not include wind corrections and these will need to be added.

If the autothrottle is disengaged, or is planned to be disengaged prior to landing, appropriate wind corrections must be added to the adjusted Vref to arrive at command speed.  Command speed is the safest speed used to fly the approach (Vapp).  If the speed is above command speed then it will need to be bleed off prior to touchdown.

Autoland Limitations

If using autoland (CAT II & CAT IIIA) the autothrottle remains engaged and the command speed is set to Vref+5.

The following autoland limitations must be complied with:

  1. Glide slope angle tolerance - maximum 3.25 degrees / minimum 2.5 degrees;

  2. Engines 1/2 operational;

  3. Maximum​ tailwind - 15 kts​;

  4. Maximum headwind - 25 kts​;

  5. Maximum crosswind - 20​ kts ;

  6. Maximum tailwind at flaps 30 - 12 knots (winglets); and,

  7. Landing in gusty​ wind​ or windshear​ conditions is not approved during CAT II and CAT IIIA operations.

Guideline (an easy way to remember the above - cheat sheet)

This information assumes the autothrottle will be disengaged prior to landing.

  • Headwind less than 10 knots:  Vref+5

  • Headwind greater than 10 knots:  Vref +headwind / 2 (half your headwind) - This is your Vref

  • If Vref is > 20 knots, then:  Vref+20 (as per placard guide)

With Gusts

  • Formula (Wind < 10 knots):  Vref+5 + gust – headwind

  • Formula (Wind > 10 knots):  Vref + headwind/2 (half your headwind) + gust – headwind

Calculating Directional Wind

A wind component will not always be at 90 Degrees or straight on to your landing direction.  The following calculation is often used to determine the directional component.  One half of the reported steady headwind component can be estimated by using 50% for a direct headwind, 35% for 45 degree crosswind, zero for a direct crosswind and interpolation in between.

Tail Winds

Tail winds are very challenging for conducting a stabilized approach.  Because of the increased ground speed caused by a tail wind, Boeing does not publish Vref correction factors for tail winds. 

Typically, to maintain the proper approach speed and rate of descent while maintaining glide slope, thrust must be decreased which minimizes the available safety envelope should a go-around be required.  If a go-around is required, precious seconds might be lost as the engines accelerate; the aircraft would continue to descend and might touch down on the runway before the engines produce enough thrust to enable a climb.

The International Civil Aviation Organization (ICAO) recommends that the tail wind component must not exceed 5 knots plus gusts on a designated runway; however, adherence to this recommendation varies among members.  Several airlines have been certified for operation with a 15 knot tailwind. 

In the United States, Federal Aviation Administration (FAA) sets the tail wind component limit for runways that are clear and dry at 5 knots, and in some circumstances 7 knots, however FAA allows no tail wind component when runways are not clear and dry.  Note, that many manuals subscribe to the 10 knots no tailwind rule (see table below).

Crosswind components can be variable dependent upon flight crew discretion and airline policy; therefore, the above is to be used as a 'guide' only.

The below table (limitations) summarizes much of what has been written above.

 

table 1: wind limits for 737-800. the table provides a good summary of what has been written in the article

 

The CDU if configured correctly can provide information concerning wind components.  Press the key on the CDU named 'PROG' followed by 'PREV PAGE'.  This page provides an overview of the wind component including head, tail and crosswind.

Wind Correction Field (WIN CORR)

The approach page in the CDU has a field named WIN CORR (Wind Correction Field or WCF).  Using this field, a flight crew can alter the Vref+ speed (additive) that is used by the autothrottle.  The default reading is +5.   Any change will alter how the FMC calculates the command speed that the autothrottle uses; changes are reflected in the LEGS page.  It's important to update the WIND CORR field if VNAV is used for the approach, as VNAV uses data from the FMC to fly the approach.  If hand flying the aircraft, it's often easier to to add the Vref additive to the speed window in the MCP.

WIND CORR Explained

The WCF is a handy feature if a flight crew wishes to increase the safety margin the autothrottle algorithm operates.

Boeing when they designed the autothrottle algorithm programmed a speed additive that the A/T automatically adds to Vref when the A/T is engaged.  The reason for adding this speed is to provide a safety buffer to ensure that the A/T does not command a speed equal to or lower than Vref.   (recall that wind gusts can cause the autothrottle to spool up or down depending upon the gust strength).  

A Vref+ speed higher than +5 can be inputted when gusty or headwind conditions are above what are considered normal.  By increasing the +speed, the  speed commanded by the autothrottle will not degrade to a speed lower than that inputted.

Important Points:

  • During the approach, V speeds are important to maintain.  A commanded speed that is below optimal can be dangerous, especially if the crew needs to conduct a go-around, or if winds suddenly increase or decrease.  An increase or decrease in wind can cause pitch coupling.

  • If using VNAV, it's important to update the WIND CORR field to the correct headwind speed based on conditions.  This is because VNAV uses the data from the FMC.

If executing an autoland (rarely done in the B737), the WIND CORR field is left as +5 knots (default).  The autoland and autothrottle will command the correct approach and landing speed.

Crosswind Landing Techniques Part One - Crab and Sideslip

 
 

This video very clearly illustrates my point that landing in a strong crosswind can be a challenging and in some cases downright dangerous (Video © CargoSpotter (with thanks); courtesy U-Tube).

Generally, flight crews use one of two techniques or a combination thereof to approach and land in crosswind conditions.  If winds exceed aircraft tolerances, which in the 737-800 is 33 knots (winglets) and 36 knots (no winglets), the flight crew will divert to their alternate airport (Brady, Chris - The Boeing 737 technical Guide).

crab approach. Wind is right to left at 16 knots with aircraft crabbing into the wind to maintain centerline approach course.  Just before flare, left rudder will be applied to correct for drift to bring aircraft into line with centerline of runway.  This technique is called 'de-crabbing’. During such an approach, the right wing may also be lowered 'a tad' (cross-control) to ensure that the aircraft maintains the correct alignment and is not blown of course by a 'too-early de-crab'.  Right wing down also ensures the main gear adheres to the runway during the roll out

Maximum crosswind figures can differ between airlines and often it's left to the pilot's discretion and experience.  Below is an excerpt from the Landing Crosswind Guidelines from the Flight Crew Training Manual (FCTM).  Note that FCTMs can differ depending on date of publication.

There are several factors that require careful consideration before selecting an appropriate crosswind technique: the geometry of the aircraft (engine and wing-tip contact and tail-strike contact), the roll and yaw authority of the aircraft, and the magnitude of the crosswind component.  Consideration also needs to be made concerning the effect of the selected technique when the aircraft is flared to land.

Crosswind Approach and Landing Techniques

There are four techniques used during the approach and landing phase which center around the crab and sideslip approach.  The crab and sideslip are the primary methods and most commonly used while the de-crab and combination crab-sideslip are subsets that can be used when crosswinds are stronger than usual.

It must be remembered that whatever method is used it is at the discretion of the pilot in command.

  1. Crab (to touchdown).

  2. Sideslip (wing low).

  3. De-crab during flare.

  4. Combination crab and sideslip.

1:  Crab (to touchdown)

  • Airplane maintains a crab during the final approach phase.

  • Airplane touches down in crab.

  • Flight deck is over upwind side of runway (Main gear is on runway center).

  • Airplane will de-crab at touchdown.

  • Flight crew must maintain directional control during roll out with rudder and aileron.

With wings level, the crew will use drift correction to counter the effect of the crosswind during approach.  Drift correction will cause the aircraft to be pointing in a direction either left or right of the runway heading, however, the forward energy of the aircraft will be towards the centerline.  This is called the crab because the aircraft is crabbing at an angle left or right of the aircraft's primary heading.

Most jetliners have the ability to land in a crab, however, it must be remembered that landing in a crab places considerable stress on the main landing gear and tyre side-walls, which in turn can cause issues with tyre and wheel damage, not too mention directional control.

The later is caused by the tandem arrangement of the main landing gear that has a strong tendency to travel in the direction that the nose of the aircraft is pointing at the moment of touchdown.  This can result in the aircraft travelling toward the edge of the runway during the roll out.  To counter this, and align the nose of the aircraft with the centreline of the runway, the pilot flying must apply rudder input when lowering the nose wheel to the runway surface.

A reference to the maximum amount of crab that can be safely applied in the B737 was not found, other than maximum crosswind guidelines must not be exceeded.  The crab touchdown technique is the preferred choice if the runway is wet.

2:  Sideslip (wing low)

  • Upwind wing lowered into wind.

  • Opposite rudder (downwind direction) maintains runway alignment.

  • In a sideslip the aircraft will be directly aligned with the runway centerline using a combination of into-wind aileron and opposite rudder control (called cross-controls) to correct the crosswind drift.

The pilot flying establishes a steady sideslip (on final approach by applying downwind rudder to align the airplane with the runway centerline and upwind aileron to lower the wing into the wind to prevent drift.  The upwind wheels should touch down before the downwind wheels touch down.

The sideslip technique reduces the maximum crosswind capability based on a 2/3 ratio leaving the last third for gusts.  However, a possible problem associated with this approach technique is that gusty conditions during the final phase of the landing may preempt a nacelle or wing strike on the runway.

Therefore a sideslip landing is not recommended when the crosswind component is in excess of 17 knots at flaps 15, 20 and 30, or 23 knots at flaps 40.

The sideslip approach and landing can be challenging both mentally and physically on the pilot flying and it  is often difficult to maintain the cross control coordination through the final phase of the approach to touchdown.  If the flight crew elects to fly the sideslip to touchdown, it may also be necessary to add a crab during strong crosswinds.

3:  De-crab During Flare(with removal of crab during flare)

  • Maintain crab on the approach.

  • At ~100 foot AGL the flight crew will de-crab the aircraft; and,

  • During the flare, apply rudder to align airplane with runway centreline and, if required slight opposite aileron to keep the wings level and stop roll.

This technique is probably the most common technique used and is often referred to as the 'crab-de-crab'.

The crab technique involves establishing a wings level crab angle on final approach that is sufficient to track the extended runway centerline.  At approximately 100 foot AGL and during the flare the throttles are reduced to idle and downwind rudder is applied to align the aircraft with the centerline (de-crab). 

Depending upon the strength of the crosswind, the aircraft may yaw when the rudder is applied causing the aircraft to roll.  if this occurs, the upwind aileron must be placed into the wind and the touchdown maintained with crossed controls to maintain wings level (this then becomes a combination crab/sideslip - point 4).

Upwind aileron control is important, as a moderate crosswind may generate lift by targeting the underside of the wing. Upwind aileron control assists in ensuring positive adhesion of the landing gear to the runway on the upwind side of the aircraft as the wind causes the wing to be pushed downwards toward the ground.

Applied correctly, this technique results in the airplane touching down simultaneously on both main landing gear with the airplane aligned with the runway centerline.

4:  Combination Crab and Sideslip

  • De-crab using rudder to align aircraft with runway (same as point 3 de crab during flare).

  • Application of opposite aileron to keep the wings level and stop roll (sideslip). 

The technique is to maintain the approach in a crab, then during the final stages of the approach and flare increase the into-wind aileron and land on the upwind tyre with the upwind wing slightly low.  The combination of into-wind aileron and opposite rudder control means that the flight crew will be landing with cross-controls.

The combination of crab and sideslip is used to counter against the turbulence often associated with stronger than normal crosswinds.

As with the sideslip method, there is the possibility of a nacelle or wing strike should a strong gust occur during the final landing phase, especially with aircraft in which the engines are mounted beneath the wings.

FIGURE 1:  Diagram showing most commonly used approach techniques (copyright Boeing)

Operational Requirements and Handling Techniques

With a relatively light crosswind (15-20 knot crosswind component), a safe crosswind landing can be conducted with either; a steady sideslip (no crab) or a wings level, with no de-crab prior to touchdown.

With a strong crosswind (above a 15 to 20 knot crosswind component), a safe crosswind landing requires a crabbed approach and a partial de-crab prior to touchdown.

For most transport category aircraft, touching down with a five-degree crab angle with an associated five-degree wing bank angle is a typical technique in strong crosswinds.

The choice of handling technique is subjective and is based on the prevailing crosswind component and on factors such as; wind gusts, runway length and surface condition, aircraft type and weight, and crew experience.

Touchdown Recommendations

No matter which technique used for landing in a crosswind, after the main landing gear touches down and the wheels begin to rotate, the aircraft is influenced by the laws of ground dynamics.

Effect of Wind Striking the Fuselage, Use of Reverse Thrust and Effect of Braking

The side force created by a crosswind striking the fuselage and control surfaces tends to cause the aircraft to skid sideways off the centerline.  This can make directional control challenging.

Reverse Thrust

The effects of applying the reverse thrust, especially during a crab ‘only’ landing can cause additional direction forces.  Reverse thrust will apply a stopping force aligned with the aircraft’s direction of travel (the engines point in the same direction as the nose of the aircraft).  This force increases the aircraft’s tendency to skid sideways.

Effects of Braking

Autobrakes operate by the amount of direct pressure applied to the wheels.  In a strong crosswind landing, it is common practice to use a combination of crab and sideslip to land the aircraft on the centerline.  Sideslip and cross-control causes the upwind wing to be slightly down upon landing and this procedure is carried through the landing roll to control directional movement of the aircraft. 

The extra pressure applied to the ‘wing-down’ landing gear causes increased auto-braking force to be applied which creates the tendency of the aircraft to turn into the wind during the landing roll.  Therefore, a flight crew must be vigilant and be prepared to counter this unwanted directional force.

If the runway is contaminated and contamination is not evenly distributed, the anti-skid system may prematurely release the brakes on one side causing further directional movement.

FIGURE 2:  Diagram showing recovery of a skid caused by crosswind and reverse thrust side forces (source: Flight Safety Foundation ALAR Task Force)

Maintaining Control - braking and reverse thrust

If the aircraft tends to skew towards the side from higher than normal wheel-braking force, the flight crew should release the brakes (disengage autobrake) which will minimize directional movement.  

To counter against the directional movement caused by application of reverse thrust, a crew can select reverse idle thrust which effectively cancels the side-force component.  When the centerline has been recaptured, toe brakes can be applied and reverse thrust reactivated.

Runway Selection and Environmental Conditions

If the airport has more than one runway, the flight crew should land the airplane on the runway that has the most favourable wind conditions.  Nevertheless, factors such as airport maintenance or noise abatement procedures sometime preclude this.

I have not discussed environmental considerations which come into play if the runway is wet, slippery or covered in light snow (contaminated).  Contaminated conditions further reduce (usually by 5 knots) the crosswind component that an aircraft can land.

Determining Correct Landing Speed (Vref)

Vref is defined as landing speed or threshold crossing speed.

When landing with a headwind, crosswind, or tailwind the Vref must be adjusted accordingly to obtain the optimal speed at the time of touchdown.  Additionally the choice to use or not use autothrottle must be considered. Failure to do this may result in the aircraft landing at a non-optimal speed causing runway overshoot, stall, or floating (ground affect).

This article is part one of two posts.  The second post addresses the calculations required to safety land in crosswind conditions: Crosswind Landing Techniques Part Two Calculations.

OEM Brackets to Secure Gauges and Modules to Boeing 737 MIP

oem brackets. brackets for different sized modules and gauges.  The brackets when tightened provide a snug and secure fit for any OEM gauge or module

Original Equipment Manufacturer (OEM) parts usually attach to the infrastructure of the flight deck by the use of DZUS fasteners.  The easy to use fasteners allow quick and easy removal of panels and modules.  But what about the gauges that are used in the Main Instrument Panel (MIP); for example, the yaw dampener, brake pressure and AFDS module.

These items do not use DZUS fasteners for attachment to the MIP; rather they are inserted into the MIP from the front and secured from behind by a specially designed bracket.  The different sized brackets are made from lightweight aluminum and are designed to fit particular gauges and modules.   Each bracket incorporates, depending on the style, a number of screws.  These screws are used to loosen or tighten the bracket. 

The gauge is inserted into the MIP from the front.  The bracket is then placed over the gauge from behind the MIP and tightened by one or more of the resident screws.  The screws cause the bracket to clamp tightly to the shaft of the gauge and ‘sandwich’ the MIP between the flanges of the gauge and the edge of the bracket.  Once fitted, the Canon plug is then re-attached to the gauge.

selection of oem and reproduction gauges (flaps is reproduction)

Of interest is that some brackets have been designed to fit the differing thicknesses between MIPs.  By turning the bracket end on end the appropriate thickness of the MIP is selected.  

As mentioned above, the brackets are designed to fit specifically sized and shaped gauges and modules; therefore, it is important to purchase the bracket that fits the gauge you are using.  There are several different sized brackets on the market that are used in the Boeing 737 classics and NG airframes.  The 'NG' for the most part incorporates identically sized gauges as the classics, so a bracket is not necessarily NG specific.

One of the benefits in using the OEM brackets is that they are designed for the purpose, are very easy to install, and facilitate the quick removal of a gauge or module should it be necessary.

In the next post we look more at flight training and discuss crosswind landings.

Approach Tools: Vertical Bearing Indicator, Altitude Range Arc and Vertical Deviation Scale

On 12 February 2012, the flight crew of a Boeing 737 aircraft, registered VH-TJS and operated by Qantas Airways Limited, was conducting a scheduled passenger service from Sydney, New South Wales to Canberra, Australian Capital Territory. Due to scheduled maintenance the instrument landing system at Canberra was not available and the crew prepared for an alternate instrument approach that provided for lateral but not vertical flight path information. The flight was at night with rain showers and scattered cloud in the Canberra area.

Shortly after becoming established on the final approach course with the aircraft’s automatic flight system engaged, the flight crew descended below the minimum safe altitude for that stage of the approach. The crew identified the deviation and leveled the aircraft until the correct descent profile was intercepted, then continued the approach and landed. No enhanced ground proximity warning system alerts were generated, as the alerting thresholds were not exceeded.

During those phases of flight when terrain clearance is unavoidably reduced, such as during departure and approach, situation awareness is particularly crucial. Any loss of vertical situation awareness increases the risk of controlled flight into terrain. This occurrence highlights the importance of crews effectively monitoring their aircraft’s flight profile to ensure that descent is not continued through an intermediate step-down altitude when conducting a non-precision approach (Australian Transport safety Bureau, 2013).

Determining the correct rate of descent (RoD) or vertical speed (V/S) is a critical attribute if an aircraft is to arrive at the correct altitude and avoid excessive descent rates.  Control of the vertical path uses two different methods: the step-down method and the constant descent method.  Both methods assume that the aircraft is being flown in landing configuration at the final approach speed (VaPP) from the final approach fix (FAF) to the landing initiation of the missed approach.

Non Precision Approaches (NPA)

Historically non precision approaches reference ground navigation aids that exhibit a degree of inaccuracy, which is often enhanced by the poorly defined vertical path published on an approach chart; NPA charts typically provide only an assigned altitude at the FAF and the distance from the FAF to the MAP.  Thus, flight crew awareness of the aircraft’s vertical position versus the intended vertical path of the final approach can be quite low when executing traditional style step-down approaches.

To determine the best vertical speed to use during a non precision approach, flight crews use a number of 'back of the envelope' calculations.

Rate of Descent & Glideslope Calculations

There are several calculations that can be used determine rate of descent – some more accurate than others.  Search ‘determine descent rate’ in Google.  Some of the more commonly used rules of thumb are:

  • Divide your ground speed by 2, then add a zero (120 kias / 2 = 60, add 0 = 600 fpm).

  • Rate of descent (RoD) in ft/min should be equal to 5 times the ground speed in knots (same as above but different calculation).

  • To maintain a stabilized approach, add a zero to your indicated air speed and divide by two (150 kias + 0 = 1500 / 2 = 750 fpm).

  • To determine distance from threshold to start a 3 degree glideslope, take the height above ground level and divide by three hundred (600 ft AGL / 300 = 2 nm).

  • To maintain a 3 degree glideslope (ILS), multiply your ground speed by 5.  The resulting number is the rate of descent to fly (110 kias x 5 + 550 fpm on 3 degree glideslope).

  • If the glideslope is not operational on an ILS approach with DME, multiply the distance ‘to go’ by 300.  This will provide the height in feet above the threshold of the runway (4 nm to the threshold; multiply x 300 = 1200 ft).

Flight crews today, especially those flying in and out of busy intercity hubs, rarely execute step down approaches as computer and GPS-orientated systems have replaced traditional methods of navigation.  However, as the flight into Canberra revealed, the best system may at times be inoperative or fail and it is good airmanship to understand and be able to remember one or more of the above equations. 

Today's systems provide a high level of redundancy and the Boeing 737-800 NG incorporates a number of integrated aids to assist a flight crew during descent and approach.  In this post some of less commonly understood aids will be discussed.

CDU showing DES Page, waypoint/altitude and VBI interface (Key RSK3 & RSK4)

Vertical Bearing Indicator (VBI))

A tool often overlooked with regard to positional awareness is the Vertical Bearing Indicator (VBI). The VBI display is accessed and displayed in the CDU. 

The VBI can calculate an accurate rate of descent to a particular spatial point.  It is basically an angle calculator that provides ‘live’ vertical speed information based upon a desired descent angle, the current speed of the aircraft and an end location.

A flight crew enters into the VBI the final altitude that the aircraft should be at (for example, the Final Approach Fix or runway threshold). This figure is determined by consulting the appropriate approach chart for the airport.  The CDU will then calculate the descent rate based on flight variables.  As the aircraft descends, the VBI readout will continually update the descent rate based upon aircraft speed and rate of descent.

The flight crew can either manually fly the descent rate or use part or full automation to maintain the rate of descent.  A common method is to use the Vertical Speed (V/S) function on the MCP.

It is important to understand that the VBI has nothing to do with VNAV.  The VBI takes the raw distance between the aircraft and a selected altitude point and calculates a vertical bearing to that point.  If that point is part of a route in the CDU, then the next altitude constraint will be displayed, unless the user changes this.

Accessing the VBI

Navigate to Descent page on the CDU by pressing the DES key.

At lower right hand side of the DES page you will see the following: FPA, V/B, V/S.  This is the Vertical Bearing Indicator.

Key RSK3 (right line select 3) allows manual entry of a waypoint and altitude or altitude restriction.  Type the waypoint and altitude separated by a / slash symbol into the scratchpad of the CDU and upload to the correct line. (for example, MHBWM/200).

The VBI provides three fields:

  1. FPA (Flight Path Angle). This is the vertical path in degrees (angle of descent) that the aircraft is currently flying.

  2. V/B (Vertical Bearing). This is the computed vertical path in degrees that the aircraft SHOULD be flying to reach the CDU waypoint or altitude restriction.

  3. V/S (Vertical Speed). This is the vertical bearing (V/B) converted into a vertical speed (RoD) for easy input into the MCP.  The V/S is the vertical speed (RoD in feet per minute) required to achieve the displayed vertical bearing (VB).

Observe the vertical bearing.  The idle descent in a 737 is roughly 3.0 degrees.  Wait until the V/B moves between 2.7 and 3.0 degrees (or whatever descent angle you require based upon your approach constraints) and note the descent rate (V/S).  At its simplest level, the V/S can be entered directly into the MCP and is the rate of descent required to achieve the computed vertical path. 

If using automation, it will attempt to follow the vertical bearing calculated and displayed on the CDU. For example, if a VNAV descent is activated before the Top of descent (ToD) is reached, the Flight Management System (FMS) commands a 1250 fpm descent rate until the displayed V/B is captured. This is done while maintaining a VNAV connection.

Important Points:

  • The VBI can be used for any waypoint, fix and altitude and acts in conjunction with the AFDS

  • The vertical bearing when the aircraft is on final approach calculates data from the Final Approach Fix (FAF) to the runway threshold.

737-800 Altitude Range Arc and Vertical Deviation Scale and Pointer

Other Approach Aids

Altitude Range Arc (ARA)

A handy feature often overlooked is the Altitude Range Arc (ARA).  The ARA is a green coloured half semicircle which can be viewed on the Navigation Display (ND).  The ARA indicates the approximate map position where the altitude, as set on the mode control panel is expected to be reached.  Once the aircraft is well established on the vertical bearing (V/B) calculated by the CDU, the ARA semicircle should come to rest on the targeted waypoint.  

Vertical Deviation Scale and Pointer (VDS)

The Vertical Deviation Scale is another feature often misunderstood.  The scale can be found on the lower right hand side of the Navigation Display (ND).

The VDI will be displayed when a descent and approach profile is activated in the CDU (such as when using VNAV).  However, the tool can be used to aid in correct glideslope for any type of approach (RNAV, VNAV, VOR, etc).  To display the VDI, an appropriate approach be selected in the CDU; however, the flight crew fly a different type of approach without VNAV engaged).

The Vertical Deviation Scale presents the aircraft’s vertical deviation from the flight management computer’s determined descent path (vertical bearing) within +- 400 feet.  It operates in a similar way to the Glideslope Deviation Scale on the Instrument Landing System (ILS).

The VDS is a solid white-coloured vertical line with three smaller horizontal lines at the upper, lower and middle section, on which a travelling magenta-coloured diamond is superimposed.  The middle horizontal line represents the aircraft’s position and the travelling diamond represents the vertical bearing (V/B). 

When the aircraft is within +- 400 feet of the vertical bearing the diamond will begin to move, indicating whether you are above, below or on the V/B target.  When the aircraft is on target (middle horizontal line) with the indicated vertical bearing, the FMA will annunciate IDLE thrust mode followed by THR HLD as the aircraft pitches downwards to maintain the V/B.

In some literature this tool is referred to as the Vertical Track Indicator (VTI).

Vertical Development (VERT DEV)

The Vertical Development (VERT DEV) is the numerical equivalent of the vertical deviation scale and is found on the Descent Page of the CDU.  The VERT DEV allows a flight crew to cross check against the VBI in addition to obtaining an accurate measurement in feet above or below the targeted vertical bearing. The VERT DEV will display HI or LO prefixed by a number which is the feet the aircraft is above or below the desired glideslope.

The Vertical Deviation Scale and pointer (VDS) will remain visible on the Navigation Display (ND) throughout the approach, and in association with the Vertical Development display on the CDU are important aids to use for Non Precision Approaches (NPA). 

Final Call

The traditional method of a step down approach, which was the mainstay used in the 1970s has evolved with the use of computer systems and GPS.  In the 1980s RNAV (area navigation) approaches with point to point trajectories began to be used, and in the 1990s these approach procedures were further enhanced with the use of Required Navigational Performance (RNP) in which an aircraft is able to fly the RNAV approach trajectory and meet specified Actual Navigation Performance (ANP) and RNP criteria.  From the 1990s onward with the advent of GPS, the method that non precision approaches are flown has allowed full implementation of the RNP concept with a high degree of accuracy.

Although the nature of non precision approaches has evolved to that of a 'precision-like' approach with a constant descent angle, their are operators that widely use these techniques, despite their flaws, weaknesses and drawbacks. Even if modern navigational concepts are used in conjunction with traditional methods, aids such as the VBI, ASR and VDI should not be overlooked.  Appropriate cross checking of the data supplied by these aids provides an added safety envelope and avoids having to remember, calculate and rely on ‘back of the envelope’ calculations.

The flight crew landing in Canberra, Australia did not use all the available aids at their disposal.  If they had, the loss of vertical situational awareness may not have occurred.

Abbreviations

  • ANP - Actual Navigation Performance

  • ARA - Altitude Range Arc

  • CDU – Control Display Unit (used by the flight crew to interface the with the FMC)

  • FAF - Final Approach Fix

  • FMS – Flight Management System

  • FMA – Flight Mode Annunciation

  • FMC – Flight Management Computer (connects to two CDU units)

  • ILS – Instrument Landing System

  • KIAS - Knots Indicated Air Speed

  • MAP - Missed Approach Point

  • MCP – Mode Control Panel

  • ND – Navigation Display

  • NPA – Non Precision Approach

  • RoD – Rate of Descent

  • RNP - Required Navigation Performance

  • RNAV - Area Navigation

  • ToD – Top of Descent

  • V/B – Vertical Bearing

  • VBI – Vertical Bearing Indicator

  • V/S – Vertical Speed

  • VDS – Vertical Deviation Scale and pointer (also called Vertical Track Indicator)

  • VERT DEV – Vertical Development

B737-800 AFDS Unit - Converted and Installed to MIP

OEM AFDS and bracket is a solid piece of engineering.  it looks like a small 'brick'.  The three angled annunciators can easily be seen in the photograph as can the attachment bracket and screws

The Autopilot Flight Director System (AFDS) is located on the Main Instrument Panel (MIP).  There are two identical units; one situated the Captain-side and the other on the First officer-side. 

The AFDS is one of several components belonging to the Automatic Flight System (AFS) and is also referred to as the autoflight annunciator and autopilot/autothrottle indicator.  The FMC annunciator is often referred to as the FMC alerting indicator.

The purpose of the unit is two-fold; to provide the flight crew with a visual warning of disengagement of the Autopilot and Autothrottle, to an alert on the FMC, and to enable the resetting of and testing of the unit (light test). 

The unit has two annunciation colours, red and amber in either a flashing or steady state which correspond to either an alerting or advisory messages.  Red precedes Amber in the level of importance.  The A/P and A/T annunicators have dual colour capability while the FMC annunciator displays only amber.

This unit was removed from an United Airlines Boeing 737.  On inspection, it was observed that the toggle was slightly bent.  The bent toggle may have been the reason why the part was scrapped; it failed certification. The toggle was easily straightened.

Conditions for Operation

There are four operating conditions:

1:    Autopilot (A/P) Disengage Light

The annunciator will flash RED if either the autopilot or autothrottle is disengaged. The former will also trigger the A/P disengaged tone (whoop, whoop, whoop).  To extinguish the flashing light and reset the unit, the flight crew must push either of the two annunciators (A/P P/RST or A/T P/RST) or press the yoke disengage switch twice.

The annunciator will illuminate a steady RED in any of the following conditions:

  • The stabilizer is out of trim below 800 feet RA on a duel channel approach

  • The ALT ACQ mode is inhibited during an autopilot go-around (is stabilizer not trimmed correctly)

  • The disengage light test switch is held in position 2, or

  • The automatic ground system fails.

The annunciator will illuminate flashing AMBER when the autopilot automatically reverts to CWS pitch or roll mode while the in Command (CMD).   To extinguish the light, press either the A/P P/RST annunciator or press another mode of the MCP.

The annunciator will illuminate steady AMBER when the light test switch is held in position 1, or when a downgrade in autoland capability occurs.

2:  Autothrottle (A/T) Disengage Light

The annunciator will illuminate flashing RED if the autothrottle (A/T) is disengaged.

The annunciator will illuminate steady RED if the light test switch is held in position 2.

The annunciator will illuminate flashing AMBER to indicate an autothrottle airspeed error exists under either of the following conditions:   

  • Inflight

  • Flaps not up, or

  • Airspeed differs from the commanded value by +10 or -5 knots and is not approaching the commanded value.

The annunciator will illuminate steady AMBER if the light test switch is held in position 1.

3:  Light Test Switch

The AFDS is not connected to the main light test toggle; therefore, it’s equipped with its own light test switch.  The central spring-loaded toggle is used to determine if the unit is operational. 

If the toggle is pushed toward TEST 1, it will illuminate the autopilot, autothrottle and FMC alert annunciator in a steady AMBER colour.  The FMC alert is delayed a few seconds.

If the toggle is pushed toward TEST 2, it will illuminate the autopilot and autothrottle annunciator in a steady RED colour and the FMC alert annunciator will illuminate steady AMBER.  The FMC alert is delayed a few seconds (see last photograph this page).

4:  FMC Alert Light

The FMC P/RST will illuminate steady AMBER when an alerting message exists on the CDU, the fail light on the CDU is illuminated, or the test switch is in position 1 or 2.  To extinguish the annunciation the flight crew can either clear the message from the CDU scratchpad or push the FMC annunciator.

FCOM - Simple yet Confusing

The above information has been interpreted from official documentation from Boeing and whilst straightforward to understand, can appear confusing because of to the repetitious nature of the information and the similar functionality of the unit.

The AFDS is powered by 28 Volts and when illuminated the legends are exceptionally bright and very sharp

Simply put, The AFDS is a caution and advisory panel that illuminates when there is a change from normal flight operations in the autopilot system.  For example, if VNAV disconnects for whatever reason, the A/P annunciator will illuminate (flashing AMBER) to caution the flight crew that something has disengaged in the autopilot system, in this case VNAV.

Anatomy of the AFDS Unit

The AFDS is a solid piece of engineering that contains it's own logic.  The unit has three buttons (annunciators) that illuminate when specific conditions are met.  Each button can be depressed to either cancel/extinguish a caution.  Interestingly, the buttons on the AFDS are angled downwards and are depressed in this direction - the push to cancel is not a direct push as you would expect with normal style korry (see first photograph).

oem AFDS button partially removed showing location of four bullet-style 28 Volt bulbs.  The button when removed from the lightplate hangs by a plastic ball which allows the button to be rotated in either direction

Each annunciator is fitted with four 28 Volt bulbs and depending upon the ‘caution’ either illuminate an amber of red coloured lens plate in a steady or flashing state.  

Removing the button to replace a bulb or troubleshoot highlights the advanced yet simplistic engineering.  A small insert is located on each side of the button and inserting a flat device such as a blade screwdriver or blunt pen knife bland into the insert allows the button to be slowly loosened. 

The complete button when carefully pulled from the unit will hang vertically from a plastic bracket that has been designed with a ball which allows the korry to be turned 360 degrees for bulb access.

Interfacing and Configuration

A Phidget 0/16/16 card is used to interface the unit with the avionics software.   Phidgets Manager 21 (free from Phidgets) is required to interface between the flight avionics suite and the actual analogue inputs from the unit.  

The AFDS annunciators are powered by 28 Volts and like the annunciators on the Master Caution System (six packs) there are exceptionally bright to ensure a flight crew notices them when they are illuminated.  

The AFDS, as with many OEM parts, is fitted with two Canon plugs on the rear of the unit (left image).  These plugs make connecting the unit to the Phidget card very easy – provided you know the plug pin outs.  The benefit of using the default Canon plugs are seven-fold: the connection is very good, they are the plug designed for the unit, they look neat and lastly, the plugs are easy to separate if you need to remove the unit for whatever reason.

I am not going to explain how to determine the pin outs.  This information has been documented several times in earlier posts.  For a detailed review see this link - How To Determine Connectivity.

Another post of interest is Using Interface Cards & Canon Plugs to Convert OEM 737 Parts.

Configuration in ProSim737

It is a two-step process to configure the AFDS unit.  First, the Phidget Manager 21 software must be opened to check the 0/16/16 card designation number and to determine the digital output numbers for the three AFDS switches.  To find the outputs, press any of the switches on the AFDS and note the output number.

Next, open the configuration menu in ProSim737.  You need to configure both switches and indicators (lights).  Find the specific switch in the switches menu and push one of the three switches on the AFDS and assign this to the Phidget 0/16/16 card in the drop down menu.  The output for the switch can be seen at the top of the configuration screen.  ProSim737 also has a very easy to use auto find option.  Press the AFDS switch followed by F and the software automatically assigns this switch to the correct

Interface Card and Outputs

Then in indicators, use the same card designation used in switches and assign the digital output (found in the Phidget Manager 21 software).  ProSim737 has an automated method for determining the lights/indicators.  Open the configuration menu and selecting the letter F opposite the function required.  The software will then do a sweep of all lights and functions determining the appropriate setting.

Whilst this sounds confusing, it’s very straightforward and comparatively easy to accomplish.

Matching OEM AFDS units.  The marks on the glass are scuff marks only and were subsequently cleaned

Although the hole for the AFDS can be enlarged with the MIP plate in-situ, any filing will result in a fair amount of waste filings.  The AFDS MIP plate should be removed to facilitate easier cutting and enlargement of the hole (if necessary)

Installation to MIP

It’s not difficult to mount the unit to the Main Instrument Panel (MIP) as there is already a gap in the MIP where the reproduction unit was fitted.  Depending upon which MIP type you are using, the hole may have to be enlarged with a dremel or a number 2 ‘bastard’ metal file before being finely finished using to remove any sharp edges.

The size of the hole should allow the AFDS unit to be firmly placed in the MIP so that the switches and buttons can be firmly pressed without the unit being dislodged. 

The difference in the length of the unit compared with a reproduction unit is obvious, which is why a secure method of attachment is paramount.  There are several methods in which to secure the unit; the best method to use is the original attachment bracket (seen in the first image).  If the bracket is missing, a solid sealant works well.

AFDS Bracket and Screws

The bracket is a specialist bracket designed to hold the AFDS unit securely to the MIP.  Once the unit is fitted to the MIP, the bracket is slid over the AFDS unit until snug with the rear of the MIP.  The four screws are then placed through the MIP from the front and tightened against the bracket.  This ensures that the unit will not dislodge.  Note that the screws are of two sizes. 

There is strong possibility that the MIP used will not feature the four holes to secure an OEM AFDS unit to the bracket and MIP.  These holes must be drilled into the MIP.  This task requires a solid eye as if the screw holes are not aligned correctly with the bracket, the unit will not fit correctly.

The AFDS units in these images lack the scews as the bracket has yet to be fitted.

OEM Verses Reproduction

First off, most the reproduction units are very good.  There is not a lot to the ADFS unit - basically three push annunciators and a two-way toggle.  The main difference between OEM and reproduction units is:

  • Brightness of annunciations and spread of light – 28 Volt bulbs verses the lower brightness and light spread of LEDS;

  • annunciator legends are laser engraved and are easy to read;

  • feel of the actual annunciators and toggle;

  • the outside appearance of the unit; being OEM, the unit cannot look any better than what it does…;

  • power Consumption and Heat Generation; and, the

  • the four screws on the front of the MIP which secure the bracket to the MIP.  These are rarely replicated correctly on reproduction AFDS units or MIPs.

oem AFDS with three annunciators illuminated during daylight by pressing test 2.  The 28 Volts provides ample power to allow the lights to be seen easily during daylight flying.  Note that the four screws are not visible in the photograph as the the bracket still needs to be fitted. 

As with most OEM parts the AFDS units are not brand new but exhibit the usual expected service wear.  This second-hand look may not 'appeal' to everyone.

Power Consumptions (bulbs and LEDS)

It is often said that a benefit of using LEDS is the saving of power and generation of less heat.  Whilst this is definitely true for items that are permanently on and illuminated, such as backlighting, many Korrys only illuminate when a specific event triggers them, and then they are only lit up for a very short period of time.  Therefore; the amount of heat and subsequent power draw is negligible.

Another point in question is the use of bulbs and LEDS in the same airframe.  Whilst it is true that LEDS are replacing bulbs in more modern airframes, it is not unrealistic to have a B737-800 with a collection of bulbs and LEDS.  As modules are replaced with newer units, LED technology will slowly creep into the older style flight decks.  

If you are having difficulty coming to grips with using either bulbs or LEDS be assured that both are realistic.

Acronyms and Glossary

The meaning of the below acronyms are second nature to many of you; however, bear in mind that everyone has to begin somewhere and some readers may not yet understand what each acronym stands for.

  • AFDS - Autopilot Flight Director System

  • AFS - Automatic Flight System

  • ALT ACQ – Altitude Acquisition

  • A/P - Autopilot

  • A/T - Autothrottle

  • CDU – Control Display Unit (used in this website interchangeably with FMC)

  • CMD - Command A or B engagae button on MCP (autopilot activation)

  • CWS – Control Wheel Steering

  • FMC - Flight Management Computer (used interchangeably in this website with CDU)

  • Korry – See Annunciator.  A brand of annunciator used in the Boeing 737 airframe

  • Legend – the engraved light plate on the front of a Korry (for example, FMC P/RST)

  • OEM – original Aircraft Manufacture (real aviation part)

  • Phidget Manager 21 – Software downloadable from Phidgets website that allows card to be interfaced between OEM part and avionics suite

  • RA – Radio Altitude

Using Interface Cards and Canon Plugs To Convert OEM B737 Parts

an example of oem wiring and a canon plug

There is little argument that real aircraft parts add a level of realism and immersion to the flight simulator experience.  Furthermore, real parts (Original Equipment Manufacture/OEM) are built to last and if converted correctly will provide many years of trouble-free operation and enjoyment.

For the uninitiated, conversion of OEM parts can appear problematic.  Where does one begin to convert an aircraft part for simulator use?  

This post will attempt to explain the basics behind converting and connecting an OEM module via an interface card and Canon plug to Flight Simulator using ProSim737.   Additionally, it will introduce and provide a general overview of Phidget Manager 21 (PM-21) software.

Please note, I am not an expert on electronics.  My background is Earth Science (geology) which is far removed from electronics...  Like others, I have learnt how things are done by 'trial and error' and listening to those more knowledgeable than myself in this field.

OEM Parts - Modules and Panels

The first thing you will notice about an OEM part (module/panel) is the build, feel and appearance is much better than a reproduction part.  It is at this stage you will be thinking ‘I don’t really want to destroy the part by opening it and rewiring everything’.  The good news is that, while some parts certainly do need rewiring, many do not.

Fortunately, the process to convert many OEM components is similar.  Granted the pin-outs and wiring are different between units, but the methodology used to determine the pin-outs is identical.  It’s a matter of replicating your methodology with each part.

Canon Plugs - The Interface to a Wiring Maze

If you look inside a OEM panel you will be surprised at the multitude of multicolored wires that connect to various relays, switches, solenoids and circuitry. Moreover you will be very impressed with the neatness and integrity of the wiring harness and as mentioned earlier, you will be loath to destroy the craftsmanship employed.

Twin Canon plugs belonging to a OEM 737 AFDS. The plug on the right is OEM while the left is bespoke

In the real aircraft, a module is connected to the aircraft’s wiring harness by a Canon plug which is a plug with any number of pins; each pin corresponding to particular function.  A Canon plug can be locked in place with the clockwise turn of the locking cap providing a solid yet removeable connection.

The benefit of Canon plugs, amongst others, is that they provide an easy and solid connection to the module’s internal wiring.    Many individuals remove these plugs, pull apart the module and gut the wiring starting afresh.  While this certainly is possible, why do it when all that is required is to ascertain the pin-outs of the Canon plug to connect to the wiring inside the module.  I doubt many of us, with the exception of a professional electrical craftsman, have the ability to duplicate the quality of workmanship seen in an OEM module.

Unfortunately, it is common place to find modules that are sold without the corresponding male or female side of the plug.  In this case the correct male or female plug must be bought separately, an existing plug converted, or a new plug fabricated.  If you have the opportunity to use a Canon plug, always try to use it before cutting the plug from the unit.  

Determining Pin outs - The Value of a Good Multimeter

The crux of converting an OEM module is to understand the functionality of the module in question.  The best place to begin learning how a module operates is the latest FCOM.  OEM modules are made for real aircraft and as such often have functions that may not be incorporated into flight simulator.  After arming yourself with 'operator knowledge', the next step is to decipher the often cryptic maze of pins in the Canon plug.  Once this is understood, the conversion is relatively straightforward with the addition of an interface card and power supply (if needed).

oem Canon plugs showing the snake-like pattern of pin location and numbering.  This module uses two Canon plugs marked J1 and J2

The pins of a Canon plug will provide at the minimum: functionality for the part, an earth (common) and a pin (s) dedicated to power.  Traditionally, all modules have used incandescent bulbs for backlighting which is powered by 5 Volts.  Depending upon functionality, some modules require different voltages with 28 Volts being the norm.

It’s important to be able to decipher which pin does what to ensure correct functionality within Flight Simulator.  This involves logical thinking and little bit of trial and error.  It is a high probability that not all the pins in the Canon plug will be used or needed in Flight Simulator.  Remember, that in a real aircraft there are multiple systems and some wires and pins will connect with these 'unneeded' systems.  

If you carefully study the pin layout in a Canon plug you will note it is not random – there is a definite order in how the pins are presented.  You will note that in all probability some pins are numbered, but not all.  The numbers move sequentially so the pin beside the pin marked ‘5’ will either be pin ‘4’or pin ‘3’.  The snake-like pattern printed on the inside of the plug is there for good reason - it acts as map guiding you from the highest number to the lowest.

By far the easiest way to determine pin-outs for functionality and power, if you do not have a wiring schematic, is to use a multimeter set to continuity mode (beep mode). 

Phidget card 0/16/16 (one of several types).  Phidgets are a proven way to convert many OEM components; the 0/0/4, 0/16/16, 1066 analogue and servo cards are mainstays.

Which Interface Card

Most parts require an interface card of some type to allow communication between the part and flight simulator.  There are several cards that, depending upon the part’s functionality, can be used: Leo Bodnar joystick cards and PoKeys cards are commonly used while Phidget cards have been the mainstay for quite a few years.  Flight Deck Solutions also produce some excellent system cards while Polulu is another manufacturer.

Which interface card is used will depend on the functionality of the module.  A simple on/off switch or a rotary knob can be interfaced using a PoKeys, Leo Bodnar Joystick or another similar 'button-type' card.  If you have a lever that needs calibration then a potentiometer will be needed.  The Leo Bodnar card is an excellent choice and will automatically register the potentiometer’s movement as an axis when the card is activated in Windows.  A light indication (korry), or a more complicated module may require a card such as Phidget 0/16/16 or 0/0/4 card.  Throttle automation and motor activation will need additional cards such as a Phidget Advanced Servo card or Polulu card.

Phidget Cards

Phidget cards, or Phidgets, have been around for a considerable time and have been the mainstay for enthusiasts wishing to control robots, cars, airplanes and the like.  Phidgets produce several cards; however, the core cards used in flight simulation are the Phidget advanced servo cards, 0/16/16, 0/0/8 and 0/0/4 cards.  To read more about Phidget cards, navigate to the the Phidget website and enter the card type into the search bar.

What Does the Interface Card Do?

The interface card is placed between the computer and the OEM module and the wires from the Canon plug are fed directly to the card (power wires usually do not connect with the card).  The card provides you with three things: an input, an output and a USB connection to the computer (or a powered hub that is then connected to the computer). Once connected, the card acts as an interface which converts an inbound analogue signal (For example, the upwards or downwards ‘throw’ of a switch) to an outgoing digital signal. For every analogue input there will be a corresponding digital output. 

An interface card requires software/logic which either comes with the card (embedded) or is downloaded from the developer’s website.  Some cards utilize Windows and the process of plugging the card into the computer will initialize the card allowing the embedded software of the card to be viewed from in Windows.  The software is found by opening the  joystick controllers menu - type ‘joy’ into the search tab of the computer to be directed to this joystick wizard. 

An example of a card that has embedded software and comes pre-calibrated is the Leo Bodnar Joystick card.  The 'Leo' card uses the joystick controller menu in Windows to allow access to the card logic. Other cards such as Polulu require calibration and programming in their own software and without calibration and programming will appear unresponsive when first connected to a computer.  Phidget cards utilize their own software (Phidget Manager 21) downloadable from the Phidgets website.

If using multiple cards of the same make and type, each card will be assigned a dedicated number allowing you to know which card controls what module.

To connect a function (for example a switch) to the Interface card you run the wire from the Canon plug/terminal to the input terminal on the card.  This process is replicated for each function of the module, bearing in mind that some functions on the Captain and First Officer side may be duplicated.  If this is the case, the wires from the module are connected into the same input terminal on the card. 

If power is required to operate the module's function or for backlighting of the panel, then a wire from the power supply will need to be connected to the correct pin in the Canon plug of the OEM module.  The usual method is to connect  power from the power supply to a solid high amperage terminal block and then to the OEM module.  Power is not normally connected directly to an interface card, unless the card has this particular capability. 

The connection of the wires to the card and connection of the card to the computer provides the link to enable the various inputs and outputs to be read either by standalone software, Windows, or directly in ProSim737.

Phidget Manager 21 User Interface.  Each serial number is specific to an individual card that is allocated when configuring the output in ProSim737

Phidget Manager 21 (PM-21) - The Bare-shell Basics

PM-21 is the replacement for the older styled Phidget’s Library.

Phidget Manager 21 (PM-21) software when installed to your computer generates a list indicating which Phidget cards are currently connected to the computer.  Each connected Phidget card can be opened individually from this list. Selecting a card will open a sub-window providing set-up information and the inputs and outputs for the selected Phidget card. 

There is also a testing area to check the functionality (inputs & outputs) of the module in addition to several other specialist features.

It is a little difficult to explain, but when this screen is open you can as in the above example, manipulate the switch up or downwards and a corresponding tick (check mark) will be seen in the input.  PM-21 will then assign this item (switch) to a dedicated output number specific only to this card.  The output number is what is used when configuring the device in ProSim737.

If converting an indicator (light) or mechanically-produced sound, the software can be used to determine if the indicator has been wired correctly.  Selecting the input section and placing a tick (check) into the appropriate box will cause the indicator to illuminate or the sound to become audible.

PM-21 UI for Phidget 0/16/16 card that controls fire suppression panel.  Moving a switch on the hardware will show a corresponding tick in the input section.  The output section can be used to test the hardware to ensure the function is working correctly

It is important to remember that the  Phidgets 21 Manager can only read installed cards if ProSim737 is closed (as of ProSim737 Version 1:34).  If the ProSim737 main menu is open, PM-21 cannot obtain the necessary information to read the card correctly.

Configuring the Interface Card in ProSim737

Once the wires from the module have been connected to the inputs of the interface card and inspected (in PM-21, Windows, or whatever software) for correct connection, the output from the interface card must be configured in ProSim737.

Before proceeding further, it is important to determine if the cards you are using are being read by ProSim737.  Open the main ProSim737 menu and select configuration/drivers and confirm that each box corresponding to the card type installed has been checked/ticked.  After this has been verified, the main ProSim737 screen will indicate which cards ProSim737 is reading.  This is a handy way to know if your interface cards are connecting correctly to your computer and are being correctly read by ProSim737.

The process to configure an output is addressed in the ProSim737 manual.  Therefore, the following is an overview.

To configure an output:

  1. Select the appropriate tab in the configuration menu (configuration/switches, configuration/indicators, etc.) that corresponds to the function of the module (i.e. light test switch)  

  2. Scroll down through the list to find the correct function (i.e. light test switch)

  3.  Move the switch on the module noting the input/output variables at the top of the computer screen

  4. From the drop down box beside the function, select the correct interface card type and serial number. (Another method is to press A located beside the function.  This will automatically select the last known position of the switch and automatically assign it).

  5. Beside the interface card drop down menu, there is another drop down menu.  Select this menu and select the correct digital output (variable shown on the screen when the switch was moved)

A similar method can be used for indicators.

Once this is done, close and reopen the ProSim737 main menu.  The function should now be registered in ProSim737. Although this process sounds rather convoluted, once done a few times it becomes second nature.

Conclusion

This is a very simple introduction to the conversion of OEM parts using the Canon plug system and the use of interface cards, in particular Phidget cards and the use of Phidget Manager 21 software. 

In general, PoKeys, Leo Bodnar joystick cards and Phidget cards (type 0/16/16 and 0/0/4) will cover the interfacing of many functions used in real aircraft modules.  However, not every part is as easy as a switch to convert.  Depending upon the complexity of the module, there may be multiple pin outs that need to be deciphered, additional logic needed, and the requirement to use multiple or single interface and/or relay cards before the part will successfully connect with Flight Simulator.

Acronyms and Glossary

  • Canon Plug – A plug made by Canon that allows a secure link between wiring systems.  The plug incorporates any number of pins, each pin corresponding to a particular functionality.  Many Boeing modules incorporate one, two, three or four Canon plugs depending upon the degree of sophistication in the module.

  • Module or Panel – Boeing parts are often called modules or panels (I use both words interchangeably)

  • OEM – Original Aircraft Manufacture (real aviation part).

  • Phidget Manager 21 (PM-21) – Software supplied by Phidgets that provides the logic behind the various Phidget interface cards.

OEM Boeing 737 Stick Shaker - Interfacing and Operation

OEM 737 stick shaker installed to Captain-side column.  The lower section of device is what vibrates

The stick shaker is standard on all Boeing series aircraft; the Next Generation having two units (Captain and First Officer) and the earlier classic series having one unit.  The stick shaker is mounted directly to the control column and is designed to vibrate if air speed degrades to stall speed.  The Stick shaker I am using is manufactured by a company in New York. It is powered by 28 Volts (27.5 Volts to be exact).  

Configuration

Configuration of the stick shaker is a relatively easy task.  The electrical cable from the device is connected to 28 Volts, or if this is not available 12 Volts;  12 Volts still produces enough power for the shaker to vibrate, although the intensity is not as great as if the unit was connected to 28 Volts. 

To allow Flight Simulator to connect to the stick shaker, a relay card is required such as a Phidget 0/4/4 relay card.  A USB cable then connects from the card to the computer.  The stick shaker will vibrate when variables that relate to low air speed are met.  The variables are determined by the flight avionics software (ProSim737 or Sim Avionics).

Phidget 0/0/4 relay card showing the main positive wire (red wire) cut with each end inserted into the correct terminals of the relay card

Interfacing and Wiring

The Phidget 0/0/4 relay card is mounted in-line between the 28 Volt power supply and the stick shaker.    Either of the two wires (+-) from the power supply can be cut to install the in-line relay; however, only one wire is cut; the other remaining unbroken from the power supply to the stick shaker.

The 0/0/4 relay card has four relays of which one is required.  Each relay has three terminals: normally open (NO), common (C) and normally closed (NC).  For the stick shaker the common and normally open terminals are used.

Carefully cut one of the two wires leading from the 28 Volt power supply.  Insert the wire coming directly from the power supply into the terminal marked common (1C, 2C, 3C or 4C).  The other end of the cut wire, which comes from the stick shaker is inserted into the terminal marked NO (normally open) of the same terminal.

If the wires have been inserted into the correct terminal of the relay card, the circuit will be complete only when the parameters established within the flight avionics software are valid.  At all other times the relay will break the circuit by not allowing the power to reach the stick shaker. If you have made a mistake, the stick shaker will vibrate continuously.

Protection

When connecting the stick shaker, it is a good idea to include a diode to protect your computer from any magnetic return signal should the relay fail.  A return signal to the computer may cause problems with the computer, and in it worse instance allow 28 volts to surge into the computer destroying your mother board. 

Positive and negative wires from the stick shaker enter the terminal block on the right.  A diode is placed on the corresponding end of the terminal block prior to the two wires running to the relay (not shown)

A high-end relay, such as a Phidget 0/0/4 relay should not fail, and if it does it should fail in the closed position.  However, if 'Murphy' or 'Sod' is your First Officer then it is better to be safe than sorry, so best install a diode.

A diode is an inexpensive and very simple device that behaves in a similar way to a black hole (astronomy).  In a black hole all matter is sucked into the hole and no matter, including light leaves the hole; it is one way trap.  A diode behaves in exactly the same way.  If a failure of the relay occurs, any power that is being transmitted through the wire from the stick shaker (28 volts) will enter the diode and be trapped.  No current will leave the diode.

Three 6 cm diodes.  The silver spirals indicate the positive side (red tape) while the opposite end is the negative (white tape).  Diodes come in an array of differing shapes, sizes and trapping capacities

The heavy duty diode should be placed in parallel between the stick shaker and the relay card.  It is best to try and place the diode as close to the stick shaker as possible.  Place the positive side of the diode (usually appropriately marked) on the positive side.  The other end of the diode place on the negative side.  If you use a terminal block it is very easy to connect a diode into the circuit (see photograph).

Incorrect Wiring

Do not become concerned if you have connected the wire to the wrong terminal - the stick shaker will not be destroyed.  It will be obvious if you have inserted the wires incorrectly, as the stick shaker will operate continuously as it has unbroken power.

I was debating to re-paint the stick shaker, however, decided to keep it as it is.  I like the used look rather than the pristine 'never been there' look.

Although the stick shaker is not essential, it’s often the smaller things and attention to detail which help bring the simulator to the next level.  I am using OEM control columns and adding a stick shaker enhances the immersion.

OEM and Reproduction

When an OEM stick shaker vibrates, especially when you are not expecting it, the vibrations startle you . The yoke vibrates and the noise of the vibrations is quite loud. In contrast, reproduction stick shakers generate lower vibrations and noise.

Acronyms 

  • OEM - Original Equipment Manufacture (real aviation parts)

BELOW:  A short video demonstrating the noise and vibration made to the control column and yoke by the stick shaker when approaching stall speed.

 
 

V1-Avionics, ARINC 429 Protocol & SIM429-11 Interface - Interfacing OEM Aviation Parts

There’s nothing like using a genuine aviation part in Flight Simulator.  Real parts are made to last, cannot be upgraded, and offer a level of immersion rarely attributable to a reproduction part.  There is also the historical perspective knowing what airframe the part was removed from.  This said, although OEM parts are not difficult to find, a solid level of ability is needed to successfully convert many parts to use in Flight simulator.  

Conversion of an OEM part can involve  re-wiring, determining the pin-outs for each function of the part, interfacing with an appropriate card such as a PoKeys or Phidget card and connecting to a suitable power supply.  OEM parts that are more complicated in nature may involve further work to determine functionality and necessitate several interface cards and relays for correct operation.

ARINC 429 Protocol & SIM429-11 Interface

Put very simply, ARINC 429 is a data communication protocol used on most higher-end commercial, military and transport aircraft.  The protocol defines the physical and electrical interfaces to support an aircraft’s avionics instruments.  

With knowledge of the protocol, many instruments can be converted for flight simulator use if an appropriate avionics interface is used between the simulator and the OEM part.

 V1 Avionics has developed a low-cost interface called the SIM429-11 Interface.  This interface will allow easy connection of OEM instruments avoiding the necessity of rewiring and conversion.

Whilst the Protocol is used by many OEM parts, it is not used by all; therefore, if the Protocol is not supported, conversion of that part to Flight Simulator will still be the traditional way using an interface card.

V1-Avionics

V1-Avionics is the company behind the development of the SIM429-11.  The project team comes from a background in telecommunications, engineering and aerospace applications and is ideally positioned to unravel the intricacies of the ARINC 429 Protocol, to develop, and eventually release the SIM429-11 interface for public use.

LEFT:  SIM 429 enclosure by V1-Avionics - compact and easy to install (image copyright V1 Avionics).

Once the interface is released, conversion of OEM avionics instruments will become easier, more streamline, and within the reach of all flight simulator enthusiasts.

I'll post additional information as this technology unfolds.

Acronyms 

OEM - Original Equipment Manufacture (real aviation parts)