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A380

TECHNICAL TRAINING MANUAL


MAINTENANCE COURSE - T1 & T2 (RR / Metric)
LEVEL I - ATA 49 Airborne Auxiliary Power
This document must be used for training purposes only

Under no circumstances should this document be used as a reference

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without the prior written permission of AIRBUS S.A.S.
A380 TECHNICAL TRAINING MANUAL

LEVEL I - ATA 49 AIRBORNE AUXILIARY POWER


APU System Introduction (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
APU Installation Presentation (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
APU Controls & Data Processing Presentation (1) . . . . . . . . . . . . . .14
APU Powerplant Presentation (1) . . . . . . . . . . . . . . . . . . . . . . . . . . .18
APU System Maintenance (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) TABLE OF CONTENTS Apr 21, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 1
A380 TECHNICAL TRAINING MANUAL

APU SYSTEM INTRODUCTION (1)


General
The APU system is divided into five main subsystems:
-The APU oil system,
-The APU fuel system,
-The APU air system,
-The APU ignition and starting system,
-The APU shutdown system.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM INTRODUCTION (1) Apr 18, 2006
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GENERAL

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM INTRODUCTION (1) Apr 18, 2006
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APU SYSTEM INTRODUCTION (1)


APU General Architecture
The APU is divided into six main sections:
- The load gearbox, connected to the power shaft. It drives the two
generators to supply the electrical system with AC current.
- The load compressor, which supplies compressed air to the bleed system.
- The accessory gearbox, driven by the High Pressure (HP) shaft. It is
connected to the starter, to the oil pump and to the fuel control unit.
- The core section that uses fuel and external air to supply energy to drive
the load compressor and the generators.
- The oil cooler that uses APU compartment air to cool the APU oil and
generator oil.
- And the exhaust that ejects the hot gas from the power section and air
from the oil cooler overboard.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM INTRODUCTION (1) Apr 18, 2006
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APU GENERAL ARCHITECTURE

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM INTRODUCTION (1) Apr 18, 2006
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A380 TECHNICAL TRAINING MANUAL

APU SYSTEM INTRODUCTION (1)


APU Supplies
The APU can operate up to a maximum altitude of 43000 feet.
It can supply compressed air to the pneumatic system up to 22500 feet.
The two APU generators can provide a full electrical supply to the
electrical system up to around 18000 feet (depending on external
conditions).
Above this 18000 feet limit, only one generator is used and supplies
degraded 120 kVA electrical supply up to around 25000 feet. Above this
altitude power decreases down to 40 kVA at 43000 feet.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM INTRODUCTION (1) Apr 18, 2006
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APU SUPPLIES

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM INTRODUCTION (1) Apr 18, 2006
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A380 TECHNICAL TRAINING MANUAL

APU INSTALLATION PRESENTATION (1)


General
The Auxiliary Power Unit (APU) is installed in a fireproof compartment
located in the fuselage tailcone.
An air inlet, connected to the APU via an air inlet duct assembly, is
installed on the upper right hand side of the tailcone.
The Air Inlet Flap actuator moves the Air Inlet Flap in order to let the
air enter into the inlet duct.
A cooling air duct, connected to the APU compartment, is installed on
the upper left hand side of the tailcone, and is used for compartment
ventilation and supplies air to the oil heat exchanger.
An exhaust muffler, connected to the APU exhaust, and installed at the
rear end of the tailcone, releases the exhaust gas into the atmosphere.
The APU is inclined at 15 degrees from the horizontal axis.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU INSTALLATION PRESENTATION (1) Apr 18, 2006
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GENERAL

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU INSTALLATION PRESENTATION (1) Apr 18, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 9
A380 TECHNICAL TRAINING MANUAL

APU INSTALLATION PRESENTATION (1)


APU Installation
The opening of the maintenance doors gives access to the APU
compartment.
A pressure relief door is used for the opening of the maintenance door
when the APU is running.
An inspection door gives access to the area located above the APU
fireproof compartment for access to the air inlet duct and flap actuator.
This APU is designed so that most of the LRUs are accessible through
the left hand maintenance door.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU INSTALLATION PRESENTATION (1) Apr 18, 2006
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APU INSTALLATION

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU INSTALLATION PRESENTATION (1) Apr 18, 2006
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A380 TECHNICAL TRAINING MANUAL

APU INSTALLATION PRESENTATION (1)


APU Mounts
The APU is attached to the ceiling of the fireproof compartment by three
mounts: two at the front and one at the rear. The three mounts maintain
the engine in the compartment and supply vibration insulation.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU INSTALLATION PRESENTATION (1) Apr 18, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 12
A380 TECHNICAL TRAINING MANUAL
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APU MOUNTS

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU INSTALLATION PRESENTATION (1) Apr 18, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 13
A380 TECHNICAL TRAINING MANUAL

APU CONTROLS & DATA PROCESSING PRESENTATION (1)


General
The components used for the control, monitoring and power supply of
the APU are the following ones:
Cockpit APU Controls
The following controls are located on the cockpit overhead panel:
APU pushbutton switch is used to start and stop the APU.
The APU FIRE pushbutton switch is used to trigger an emergency
shutdown in case of a fire.
The APU BLEED pushbutton switch is used to supply APU bleed air
to the pneumatic system.
The two APU GEN pushbutton switches are used to manually unload
the two APU generators.
External Emergency Shutdown Controls
Two external emergency shutdown controls let an emergency
shutdown of the APU from the ground.
One APU SHUT OFF pushbutton is located on the nose landing gear
control panel and one APU EMERGENCY SHUTDOWN pushbutton
is located on the Integrated Refuel Panel (IRP).
Electronic Control Box
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The Electronic Control Box (ECB) is a digital controller used to


automatically control and monitor the APU from start to shutdown.
It is installed in the electronic rack 5000VE located at the rear part of
the pressurized fuselage.
APU Battery
The APU battery is used to give an autonomous power supply to the
APU start. It is installed in the bulk cargo compartment.

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU CONTROLS & DATA PROCESSING PRESENTATION (1) Apr 18, 2006
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GENERAL - COCKPIT APU CONTROLS ... APU BATTERY

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU CONTROLS & DATA PROCESSING PRESENTATION (1) Apr 18, 2006
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APU CONTROLS & DATA PROCESSING PRESENTATION (1)


Control And Data Processing
The APU operation is fully controlled and monitored by the ECB.
The ECB is connected to the other aircraft system via the ADCN.
The APU P/BSW and the three emergency shutdown P/BSWs are all
connected to the ECB.
The ECB controls the Inlet Flap Actuator by sending an opening or closing
command to the motor.
A Data Memory Module (DMM), located on the left hand side of the
APU, stores data concerning the APU life (e.g. cycles, operating hours,
health monitoring data).
The crew via the CDS ECAM APU page can view data from the APU.
Maintenance data can be accessed through the Onboard Maintenance
System (OMS).
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU CONTROLS & DATA PROCESSING PRESENTATION (1) Apr 18, 2006
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CONTROL AND DATA PROCESSING

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU CONTROLS & DATA PROCESSING PRESENTATION (1) Apr 18, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 17
A380 TECHNICAL TRAINING MANUAL

APU POWERPLANT PRESENTATION (1)


APU Architecture
The PRATT & WHITNEY CANADA PW980A engine is a twin-shaft
Auxiliary Power Unit (APU). It has a High Pressure (HP) shaft (N2), and
a load shaft (N1).
The APU is divided into six main sections:
- The load gearbox, connected to the load shaft. It drives the two
generators to supply the electrical system with AC current.
- The load compressor, which supplies compressed air to the bleed system.
- The accessory gearbox is driven by the HP shaft through the tower shaft.
The starter, the oil pump and to the fuel control unit are connected to the
accessory gearbox.
- The core section that uses fuel and external air to get the energy to drive
the load compressor and the generators.
- The oil cooler that uses APU compartment air to cool the APU oil and
generator oil.
- The exhaust that ejects overboard the hot gas from the core section,
surge air and air from the oil cooler.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
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APU ARCHITECTURE

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
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APU POWERPLANT PRESENTATION (1)


APU Oil System
The oil system supplies oil to lubricate and cool the APU bearings, gears
and generator drive splines.
It has two segregated systems:
- The main oil system and
- The Generator oil system.
Oil used in both systems is stored in 2 independent compartments of the
oil tank that can be filled through a common oil filler neck. The generators
oil tank is filled first and then, the main oil tank is filled by the overflow
of the generators oil tank.
Oil level in each oil tank compartment can be checked by the maintenance
crew through an oil level sight glass for the main oil system and through
a bull-eye sight glass for the generators oil system.
Scavenge oil from both oil systems goes back to its dedicated tank.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
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APU OIL SYSTEM

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 21
A380 TECHNICAL TRAINING MANUAL

APU POWERPLANT PRESENTATION (1)


APU Fuel System
The two functions of the APU fuel system are:
- To supply metered fuel to the combustion chamber and,
- To supply pressurized fuel for actuation of the Inlet Guide Vanes (IGVs)
and actuation of the Surge Control Valve (SCV).
The fuel coming from the aircraft fuel system goes to the Fuel Control
Unit (FCU) where it is pressurized and supplied to the IGVs and to the
SCV as a muscle pressure and is metered for burning in the combustion
chamber.
The fuel manifold assembly is installed around the combustion chamber.
It is divided into two manifolds: the primary and the secondary fuel
manifolds.
Fourteen fuel nozzles supply fuel to the combustion chamber. They can
be fed by either the primary fuel manifold or by both manifolds
simultaneously through the flow divider valve.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
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APU FUEL SYSTEM

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
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APU POWERPLANT PRESENTATION (1)


APU Air System
The APU air system supplies compressed air to the aircraft pneumatic
system.
APU bleed can be selected in the cockpit by pressing the APU BLEED
pushbutton switch.
Once the APU BLEED pushbutton is pressed in, the APU BLEED
VALVE opens and the Inlet Guide Vanes (IGVs) start to regulate the
airflow through the load compressor.
To avoid load compressor surge conditions, the Surge Control Valve
(SCV) releases excess air to the exhaust when necessary.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 24
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APU AIR SYSTEM

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 25
A380 TECHNICAL TRAINING MANUAL

APU POWERPLANT PRESENTATION (1)


APU Ignition And Starting System
Once the APU P/BSW is pressed in, the ECB opens the Inlet Flap to let
the external air enter the APU inlet plenum.
Once the Inlet flap is open, the ECB energizes the APU starter via the
APU BATtery (up to 25000 ft) or via the aircraft DC supply depending
on the power supply availability.
When compressor speed is sufficient, the ECB energizes the two igniters
via the ignition unit, and the Fuel Control Unit starts to regulate the fuel
flow supplied to the combustion chamber.
When the engine has reached a specific speed, the starter and the igniters
are de-energized and the ECB continues to meter the fuel flow to reach
the APU operation speed.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU POWERPLANT PRESENTATION (1) Apr 18, 2006
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APU IGNITION AND STARTING SYSTEM

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APU SYSTEM MAINTENANCE (1)


APU Safety Items
Here is an overview of main safety precautions relative to the APU
system.
Make sure that you use the correct personal protection when you work
on the APU, as fuel and oil are poisonous.
Do not touch the APU until it is sufficiently cool.
While the APU operates, do not go into these areas:
- The area behind the APU exhaust duct,
- The area around the APU air intake,
- The area of the oil cooler outlet.
If you operate the APU with the APU access doors open or removed,
make sure that you have the correct fire fighting equipment available.
The onboard APU fire extinguishing system is not sufficient when these
doors are not closed.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM MAINTENANCE (1) Apr 18, 2006
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APU SAFETY ITEMS

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM MAINTENANCE (1) Apr 18, 2006
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APU SYSTEM MAINTENANCE (1)


APU Ground Support Equipments
The APU maintenance tasks require some Ground Support Equipments
(GSE's).
The Main GSEs used for the APU maintenance are:
- The APU shipping stand. It is used for APU transport when it needs to
be sent to a shop for heavy maintenance.
- The APU mini-lifts. They are needed for any APU removal or
installation. They are used with the hoist points located in the APU bay
to lift the engine.
- The lifting beam is used to connect the two rear attachment points of
the APU to a mini-lift.
- The APU common trolley is used to hold the APU after removal or
before installation in its compartment. It enables an easy transport of the
APU in the Hangar without any additional lift or tool. Full APU servicing
can be done while the engine is on the trolley as well as other operations
(APU generators removal/installation, removal of shipping brackets,
installation of suspension system...).
Refer to the illustrated Tool and Equipment Manual (TEM) for the
complete list of the tools and to the Aircraft Maintenance Manual (AMM)
for the procedures.
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MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM MAINTENANCE (1) Apr 18, 2006
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APU GROUND SUPPORT EQUIPMENTS

MAINTENANCE COURSE - T1 & T2 (RR / Metric) APU SYSTEM MAINTENANCE (1) Apr 18, 2006
LEVEL I - ATA 49 Airborne Auxiliary Power Page 31
AIRBUS S.A.S.
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REFERENCE L1W06161
APRIL 2006
PRINTED IN FRANCE
AIRBUS S.A.S. 2006
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