49 Apu PDF
49 Apu PDF
49 Apu PDF
APU
G5707111 - G3GT0M0
TABLE OF CONTENTS
SYSTEM OVERVIEW
The Auxiliary Power Unit (APU) is located in the unpressurized tail cone.
The APU is a self-contained unit, which lets the aircraft be independent
of external pneumatic and electrical power sources. The APU is mounted
in a fireproof compartment located in the fuselage tail cone. Two access
doors give access to the APU compartment for inspection and maintenance
task. The APU is hanged in its compartment by shock-mounts. An exhaust
duct releases the APU gas into the atmosphere.
The APU is a constant-speed gas turbine engine. The constant-speed gas
turbine engine drives the accessory gearbox and a load compressor. The
APU provides:
- electrical power for the aircraft systems,
- bleed air for engine starting and air conditioning on the ground,
- bleed air for air conditioning / pressurization and wing anti-ice in flight.
The APU air intake flap is mounted on the lower fuselage forward of the
APU. The intake flap opens when the APU master switch is selected ON
and closes when the master switch is selected OFF. When open, it supplies
air to the APU inlet for combustion and pneumatic supply.
The APU operation is controlled and monitored by the Electronic Control
Box (ECB). The ECB has full authority over the following APU functions:
- starting,
- acceleration,
- speed governing,
- indication,
- fault monitoring,
- interface with A/C systems.
The APU is designed to operate throughout the entire flight envelope.
Electrical power is available whenever the APU operates, but bleed air
is limited by the demand and is shut off above 25.000 ft.
SYSTEM OVERVIEW
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
SYSTEM OVERVIEW
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
The APU cowl doors are secured with three quick-release hook latches
fasteners and four pin latches. The hook latches secure the doors
together and the pin latches secure the doors to the aircraft structure.
Procedure to open the doors:
- release 3 hook latches,
- support the door and release the 2 pin latches of each door,
- use support struts to secure the doors.
To close the access doors, release the support struts. Support the doors,
close the hook latches and then close the pin latches.
NOTE: Note: The APU Master Switch must be selected ON for this
indication to be displayed.
The APU LOW OIL LEVEL message agrees with the ADD mark on
the oil reservoir (gearbox) sight glass. With no oil leakage, sufficient
oil is available (4 L) to let the APU operate for 60 hours.
Prior to servicing, shut down the APU and open the APU access doors.
Make sure to use the operator-approved oil for servicing (operators
may be selected from the approved list). The oil may be serviced by
the gravity (most common) or pressure fill procedure (OPTIONAL).
NOTE: Note: To get an accurate oil level indication, do not wait
longer than 5-15 minutes after the APU shutdown before
checking the APU oil.
Gravity procedure:
- open the lock and slowly loosen the oil filler cap to release remaining
pressure from the oil reservoir,
- check sight glass for level,
- slowly add oil until the level is at the FULL mark on the sight glass,
- close and lock the oil filler cap.
Pressure fill procedure:
- check sight glass for level,
- connect pressure and overfill hoses to the APU gearbox,
- slowly pump oil into the gearbox until the level is at the FULL mark
on the sight glass,
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
In case of an APU inlet actuator failure, the APU may be dispatched per
Minimum Equipment List (MEL) with the inlet CLOSED or OPEN. If
the inlet is deactivated CLOSED, the APU will not be operational. The
APU is only operational with the inlet deactivated OPEN - limited to 10
days as per the MEL.
The air inlet flap actuator has a manual drive. In case of failure the manual
drive may be used to move the inlet to the required position prior to the
deactivation. Access to the actuator is through an access door near the
APU inlet on the left hand side of the fuselage. The actuator requires 87
turns of the manual drive for one full travel of the inlet flap.
Deactivation procedure:
- get access to the actuator,
- disconnect the actuator electrical connector from the fixed connector
on the frame and install a blanking cap,
- use the manual drive to move the inlet to the required position. Use a
torque wrench to avoid damage to the actuator.
NOTE: Note: If the inlet is deactivated CLOSED, no further action is
needed other than to placard the APU inop. If the inlet is
deactivated OPEN, the following procedure has to be
accomplished.
When the inlet is in the OPEN position, a jumper lead needs to be installed
to close the circuit and allow the APU to start. Make a dummy connector
and paint it red for easy identification.
Close the access door and make the APU operational test:
- make the BITE test,
- check SERVICE DATA,
- start the APU and check for normal parameters.
MEL/DEACTIVATION
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
MAINTENANCE TIPS - BLEEDING OF THE APU FUEL LINE CONTROL AND INDICATING
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
GENERAL
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
LOAD COMPRESSOR
The power section of the GTCP331-350 system supplies the shaft power
to drive:
- the load compressor,
- the accessory drive gearbox and the electrical generator. It is built up
by the static structure and the rotating group. The static structure
comprises the engine compressor case and the combustion chamber.
The rotating group, including the centrifugal compressor and turbine, is
a single shaft assembly supported with a ball bearing located at the FWD
end and a roller bearing located at the aft end. Both bearings are designed
with a lubricated outer race to damp vibrations. Their 100% operation
speed is 41730 rpm.
ENGINE COMPRESSOR
The engine compressor is a two-stage centrifugal compressor. Each
compressor stage has an impeller and a diffuser. The role of the engine
centrifugal compressor is to increase and to guide the air pressure
through deswirl vanes into the combustion chamber.
COMBUSTION CHAMBER
The combustion chamber is of a reverse-flow annular design and
surrounds the turbine hub containment. While the compressed air is
in the combustion chamber, fuel is atomized and mixed into the air.
During the combustion, the expanded gas stream is directed to the
turbine where it changes its energy into rotational movement.
TURBINE
SCROLL
The scroll collects the bleed air at the diffuser outlet and supplies it
to the bleed air duct.
The air intake system supplies ambient air to the plenum chamber of the
APU. The main components of the air intake system are:
- the air intake diverter,
- the air intake assembly, with an air intake nose, an air intake flap and
an air intake flap actuator,
- the air intake duct.
The Electronic Control Box (ECB) supplies the necessary electrical power
for the operation of the air intake flap actuator. The two limit switches
and the two position switches control the position of the air intake flap
actuator. When the A/C is on the ground with no electrical power available
or in case of flap actuator failure, the air intake flap can be operated
manually by a manual override device.
DRAIN SYSTEM
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
The APU exhaust system ducts the APU GTCP331-350 exhaust gases
overboard; its secondary function is to decrease the exhaust noise level.
The exhaust system is made of two main components:
- the exhaust muffler assembly,
- the suspension.
The exhaust muffler assembly directs the exhaust gas flow to the ambient
air, reducing the exhaust noise. It is composed of a flexible connection,
which compensates expansion and contraction between the APU and the
exhaust muffler caused by changes in temperature. The exhaust muffler
suspension has two guide rails, which are part of the exhaust muffler
compartment structure. They have a U shape. On the exhaust muffler
there are four mount brackets. These fit into guide rails allowing thermal
expansion. The exhaust muffler has a thermal insulation. It keeps the
temperature at the external surface of the exhaust muffler to a limit of
200C.
EXHAUST
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
The Auxiliary Power Unit (APU) fuel system supplies metered fuel to
sustain combustion. It is also used for Inlet Guide Vane (IGV) and surge
control valve actuators operation.
APU fuel system indications are displayed on the EWD and the SD.
GENERAL
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
FUEL DISTRIBUTION
The Fuel Control Unit (FCU) supplies the fuel quantity which is necessary
for the APU operation. It also supplies the necessary fuel to operate the
IGV and the SURGE CONTROL VALVE actuators.
The FCU is composed of:
- an inlet filter,
- a high pressure pump,
- a high pressure filter,
- a torque-motor metering valve,
- a shut-off valve.
FUEL SCHEDULE
The Fuel Metering Valve (FMV) is a torque-motor metering valve.
It is controlled by the Electronic Control Box (ECB) which schedules
the fuel flow for start sequence, on-speed operation and shut-down
sequence.
MUSCLE PRESSURE
Fuel muscle pressure is used to operate the surge control valve actuator
and the load compressor IGV actuator.
FUEL SHUT-OFF
The ECB controls the fuel solenoid valve for positive fuel shut-off.
The valve is controlled open during the start sequence, and closed
during the stop sequence.
FLOW DIVIDER
The flow divider divides fuel into primary and secondary flows. During
the start sequence, only the primary flow is supplied.
At the APU shutdown, compressor discharge stage 2 air blows out the
residual fuel from the two manifolds during APU shutdown through an
ecologic drain solenoid valve controlled by the ECB.
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
The APU load compressor supplies bleed air to the pneumatic system.
Bleed air quantity is controlled by the load compressor Inlet Guide Vanes
(IGVs) which are moved by a fuel-powered actuator. A bleed air shut-off
valve, pneumatically operated, lets or stops the bleed air flow to the
pneumatic system.
A surge control valve prevents a load compressor surge, by discharging
the excess of air in the exhaust. It is a butterfly-type valve hydraulically
operated by fuel coming from the Fuel Control Unit (FCU). The valve
has a Linear Variable Differential Transducer (LVDT) for position
feedback.
ACCESSORY COOLING
APU bleed air is delivered when all the following conditions are met:
- APU is running above 95% speed,
- APU bleed switch is selected,
- No bleed leak detected by the Bleed Monitoring Computers (BMCs),
- APU inlet pressure (P2) altitude is below 25,000 feet.
By pressing the APU BLEED P/B, if no leak is detected, the BMCs send
a signal to the Electronic Control Box (ECB) which energizes the APU
bleed valve solenoid. Using upstream bleed air pressure, the APU bleed
valve fully opens.
Then, the ECB adjusts the IGVs actuator torque motor current according
to the following parameters:
A gearbox-driven fan draws air from the inlet plenum and forces it to
pass through the oil cooler and from there overboard.
The fan also supplies air to the APU compartment through a pneumatic
cooling valve which is fully closed in altitude. An uncontrolled cooling
orifice is used permanently for the cooling when the APU is running.
GENERAL
The air system delivers compressed air from the Auxiliary Power Unit
(APU) load compressor and cools the accessory. The two subsystems
are:
- bleed and surge air,
- accessory cooling.
The gearbox sump is the oil reservoir. The total capacity of the oil
reservoir is 8.5 liters. The gearbox has:
- a gravity fill port and a pressure fill port,
- an oil level sight glass,
- an low oil quantity switch,
- a low oil temperature sensor,
- an oil heater,
- an electrical chip detector,
- an air/oil separator.
Within the gearbox, the cooling fan pad and the starter motor pad are
internally supplied with oil.
GEARBOX DESCRIPTION
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
VAC power source to increase the oil temperature. The oil temperature
switch is a "thermal temperature-delay switch" which measures the
temperature of the oil in the gearbox sump.
As soon as the aircraft is powered, if the APU master switch is OFF
and the oil temperature is less than 21C, the oil heater is automatically
switched ON. It is deactivated when the oil temperature reaches 43C.
Note that the oil heater has no direct connection to the ECB.
AIR/OIL SEPARATOR
The oil reservoir is vented through an air/oil separator to the exhaust
cone. When the APU operates, the air/oil separator extracts the oil
from the air drawn from the lubrication scavenge pump. Once the
separation is completed, the remaining air is vented through the
gearbox vent line. The air/oil separator is not an LRU. All these
systems are the gearbox accessories.
OIL HEATER
The oil heater is a Line Replaceable Unit (LRU) located on the lower
left side of the gearbox. The APU oil heater has an oil temperature
switch and a nickel-iron alloy coil. It uses an independent aircraft 115
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
GEARBOX DESCRIPTION - GRAVITY FILL PORT, PRESSURE FILL PORT AND OIL OVERFLOW PORT ... AIR/OIL SEPARATOR
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
The same kind of filter is used in the lubrication and in the scavenge
circuits. Both are replaceable and are to be discarded. They are made
of corrugated fiberglass and specified to 10 microns nominal, 25
microns absolute.
LUBE MODULE DESCRIPTION - LUBE PUMP SYSTEM AND SCAVENGE PUMP SYSTEM ... SOLENOID DE-OILING VALVE
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
The oil cooler and the thermal bypass valve are used to maintain a proper
oil temperature during APU operation. The operated Thermal bypass
valve operated is fully open at 60C and fully closed at 77C.
DISTRIBUTION
Oil is pumped by three gerotor pump elements in parallel and goes
through the oil pressure relief valve located in the lubrication module,
which maintains an oil pressure of 65 psig plus or minus 5 psi.
Then, oil goes through the thermal bypass valve.
If the oil temperature is less than 60C, the valve sends the oil directly
to the lube filter.
If the oil temperature is more than 60C, the thermal bypass valve
starts to close and the oil goes through the oil cooler before going into
the lube filter. If the oil temperature is more or equal to 77C the valve
is fully closed.
Finally, oil is supplied to the lubrication points of:
- the APU turbine and mid-frame bearings,
- the load compressor,
- the accessory drive gearbox,
- the APU generator.
During APU start, the de-oiling solenoid valve will be energized
opening in the cold condition.
OIL VENT
Oil scavenged from the oil sumps is highly contaminated by air, which
leaks through the carbon face seals. Consequently, a greater volume
of air and oil mixture flows through the scavenge pump elements and
enters the gearbox. The air/oil separator extracts the air from the
mixture and sends it outside through the exhaust duct.
LOP CONDITION
If the oil pressure decreases to 28 psi plus or minus 2 psi, the LOP
switch transmits a low oil-pressure signal to the ECB which triggers
an APU shutdown.
NOTE: During the flight, the LOP shutdown is inhibited.
HOT CONDITION
Two HOT shutdowns can be initiated by the ECB:
- if the temperature measured by the oil temperature sensor is higher
than 147C, for more than 10 seconds, the ECB triggers a HOT APU
shutdown,
- if the temperature measured by the generator oil temperature sensor
is higher than 185C, for more than 1 second, the ECB triggers an
APU generator HOT shutdown.
The ECB monitors the oil level status when the aircraft is on ground, the
APU is not running and when the power-up initialization is finished, a
few seconds after the APU master switch is pressed in.
Three conditions of the oil level are shown on the EIS and on the
Centralized Maintenance System (CMS):
- if an OIL LEVEL: OK indication is displayed on the APU SERVICE
DATA page of the CMS, and if no indication is displayed on the ECAM
APU page, the oil level is sufficient.
- if an OIL LEVEL: CHECK indication is displayed on the APU
SERVICE DATA page of the CMS, and if a CHECK OIL LEVEL
message appears on the ECAM APU page, the oil level lets the APU
operate for 60 hours with a oil quantity of 4 liters.
- finally, if an OIL LEVEL: LOW indication is displayed on the APU
SERVICE DATA page of the CMS, and if a LOW OIL LEVEL message
appears on the ECAM APU page, the oil level is less than its minimum
and the APU oil reservoir needs to be refilled.
MONITORING
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
DESCRIPTION
The main components of the ignition and starting system are:
- the starter motor and clutch,
- the main and backup contactors,
- the ignition unit,
- the ignition lead,
- the igniter plug,
- the speed sensor,
- the Exhaust Gas Temperature (EGT) thermocouples,
- the memory module,
- the Electronic Control Box (ECB).
IGNITION LEAD
The ignition leads have Teflon-insulated ignition wire covered with
a flexible tube of spirally-wound nickel-iron alloy and an outer
stainless-steel braid. The ignition lead ensures the connection between
the ignition unit and the igniter plug.
IGNITER PLUGS
SPEED SENSORS
The speed sensors are installed between the load compressor and the
air intake housing. Each of the speed sensors is connected to the ECB.
IGNITION UNIT
The ignition unit is located on the rear LH side of the APU inlet
plenum. It is installed in a hermetically sealed nickel-plated aluminum
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
MASTER SWITCH ON
When the MASTER SWitch is set to ON, the ECB is electrically
supplied and the following sequence occurs:
- the ON/R light comes on,
- the ECB starts a power up test and checks the condition of all
necessary items,
- after the power up test the ECB energizes the subsequent systems:
- the surge control valve,
- the APU fuel feed line,
- the air intake flap actuator,
- the Inlet Guide Vanes (IGVs) receive a signal for closure,
- the APU page is displayed on the ECAM.
Then, once the inlet flap is fully open, the FLAP OPEN message
appears on the ECAM APU page and the APU is ready to be started.
ON-SPEED OPERATION
When the APU speed is above 95% the APU is in the normal operation
condition. At that speed, the APU generator can be used and APU bleed
can be switched ON. N >= 95%: dien & bleed co the dung duoc.
During on-speed operation, the ECB compensates the electrical and
pneumatic load effects on speed, by acting on the fuel flow to maintain
an APU constant speed at 100%. ECB dieu khien Fuel-Flow de duy tri speed 100%
The various APU parameters are displayed on the ECAM APU page.
START P/BSW ON
When the START P/B is set to ON:
- the ON light on the P/B comes on,
- the de-oiling solenoid valve, used to unload the lube pump, opens
under specific conditions,
- the main start contactor closes and energizes the start motor, when
the ECB receives the signal that the intake flap is open.
Then, APU speed (N) increases.
At 7% of N, the ECB energizes the ignition exciter, opens the fuel
solenoid Shut-Off Valve (SOV) and the Fuel Metering Valve (FMV)
starts to regulate the fuel flow.
PROTECTIVE SHUTDOWNS
A protective shutdown logic shuts down the APU automatically whenever
continued APU operation would result in damage to the A/C, the APU
or the ECB. The shutdown sequence is the same as the normal shutdown
sequence except that there is no 85 seconds cooling period.
Four shutdown conditions are active at all times:
- the overspeed shutdown, when N is greater than 106%,
- the ECB internal failure shutdown,
- the generator High Oil Temperature (HOT) shutdown, when the
temperature is higher than 185C (365 F),
- the emergency shutdown triggered by:
- the APU fire and overheat detection system (only on ground),
- the APU FIRE P/BSW on the overhead panel,
- the APU SHUT OFF P/BSW, on the external power control panel, at
the fuselage near the NLG,
- the APU EMERG SHUTDOWN P/BSW on the refuel/defuel panel at
the belly fairing.
The other shutdown conditions are inhibited from the start of the first
engine to the shutdown of the last engine (i.e. from flight phase 2 to 9),
AND if the APU speed is above 95% of N. These shutdown conditions
are:
- HOT, above 149C (300,2 F),
- Low Oil Pressure (LOP),
- load compressor reverse flow, based on Pt and delta P data,
- sensor failure: i.e. loss of EGT signal or loss of LOP switch and low
oil quantity signal,
- overtemperature, when EGT exceeds 1,260C (34,27 F) during start
or exceeds 1,232C (34,22 F) during on-speed operation,
- underspeed: i.e. speed < 95% of N for 10 seconds when APU is in the
on-speed governed mode,
- inlet door not fully open,
- no acceleration,
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
- no flame,
- inlet overheats: i.e. APU inlet temperature T2 is above 177C (350,6
F) for 3 seconds,
- clogged oil filter.
The cause of shutdown is stored in the ECB memory.
PROTECTIVE SHUTDOWNS
MAINTENANCE COURSE - T1+T2 (LVL 2&3) (PW 4000/ME)
49 - APU
AIRBUS S.A.S.
31707 BLAGNAC cedex, FRANCE
STM
REFERENCE G5707111
MARCH 2007
PRINTED IN FRANCE
AIRBUS S.A.S. 2007
ALL RIGHTS RESERVED
AN EADS JOINT COMPANY
WITH BAE SYSTEMS