You are on page 1of 22

Vol.

1 04--00--1
AUXILIARY POWER UNIT
Table of Contents REV 3, May 03/05

CHAPTER 4 ---AUXILIARY POWER UNIT

Page

TABLE OF CONTENTS 04--00


Table of Contents 04--00--1

INTRODUCTION 04--10
Introduction 04--10--1

APU POWER PLANT 04--20


APU Power Plant 04--20--1
Engine 04--20--1
Gearbox 04--20--1

SYSTEMS 04--30
Systems 04--30--1
Lubrication 04--30--1
Fuel 04--30--1
Ignition and Starting 04--30--1
Air Intake and Exhaust 04--30--1

CONTROL 04--40
Controls 04--40--1
Starting 04--40--1
Stopping 04--40--1
Protective Shutdown 04--40--6
System Circuit Breakers 04--40--7

LIST OF ILLUSTRATIONS

INTRODUCTION
Figure 04--10--1 Auxiliary Power Unit -- Introduction 04--10--2
Figure 04--10--2 APU Altitude and Airspeed Envelope 04--10--3
Figure 04--10--3 Pneumatic Flow 04--10--4
Figure 04--10--4 APU Start and Operating Limits 04--10--5
Figure 04--10--5 APU Door Position 04--10--6
Figure 04--10--6 EGT Shutdown Schedule 04--10--7

SYSTEMS
Figure 04--30--1 APU Controls and ECU Interface 04--30--2

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--00--2
AUXILIARY POWER UNIT
REV 3, May 03/05
Table of Contents

CONTROL
Figure 04--40--1 Auxiliary Power Unit -- Control 04--40--2
Figure 04--40--2 EICAS Auxiliary Power Unit Indications -- Primary 04--40--3
Figure 04--40--3 Auxiliary Power Unit and Indications -- Status 04--40--4
Figure 04--40--4 APU Start Sequence 04--40--5

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--10--1
AUXILIARY POWER UNIT
Introduction REV 3, May 03/05

1. INTRODUCTION

The auxiliary power unit (APU) is a gas turbine power plant which drives an electrical
generator. The generator is rated at 40 kVA and produces 115 VAC electrical power for
backup to the main engine generators (refer to Chapter 7). The APU also supplies
compressed air to the pneumatic system for main engine starting and environmental control
(refer to Chapter 19). To prevent compressor surge, some compressor air is vented
overboard by a surge control valve.

The APU is enclosed within a fireproof tailcone assembly. The APU compartment is
composed of an upper section and forward and aft bulkheads made of titanium. Two
clamshell doors made of fireproof composite material enclose the sides and bottom of the
compartment.

An Electronic Control Unit (ECU), located in the aft equipment bay, controls the APU through
all phases of operation. The ECU monitors all sensors and switches, sets up the
appropriate fuel acceleration schedules and relays specific operating data to the engine
indication and crew alerting system (EICAS). The ECU is powered through selection of a
PWR/FUEL switchlight on the APU control panel in the flight compartment.

The APU intake door position is continuously shown on the EICAS status page. The APU
RPM and exhaust gas temperature (EGT) are shown on the EICAS status page, only when
the APU PWR/FUEL switchlight on the APU control panel is selected.

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--10--2
AUXILIARY POWER UNIT
Sep 09/02
Introduction

PNEUMATIC
AIR INLET DUCT

EXHAUST

OIL COOLER SURGE CONTROL


VALVE

GENERATOR

IGNITION
STARTER UNIT

Auxiliary Power Unit --- Introduction


Figure 04---10---1

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--10--3
AUXILIARY POWER UNIT
Introduction REV 3, May 03/05

APU Altitude and Airspeed Envelope


Figure 04---10---2

Flight Crew Operating Manual


CSP C--013--067
LEFT ENGINE RIGHT ENGINE

COWL ANTI--ICE WING WING COWL ANTI--ICE


ANTI--ICE ANTI--ICE

LOW WING WING LOW


PRESSURE A/I VALVE A/I VALVE PRESSURE
PORT PORT
AIR COND BLEED AIR COND
ISOLATION
VALVE

PRSOV STARTER PRSOV


AIR VALVE HIGH
AIR LOAD CONTROL AIR
TURBINE TURBINE PRESSURE
STARTER E VALVE (LCV)
STARTER STARTER VALVE
HIGH AIR VALVE P
PRESSURE GROUND HIGH
VALVE AIR SUPPLY PRESSURE
PORT
Introduction

GENERATOR BLEED SOURCE

CSP C--013--067
HIGH BOTH ENG
APU

Pneumatic Flow
PRESSURE

Figure 04---10---3
AUXILIARY POWER UNIT

PORT
L R
EGT ENG

Flight Crew Operating Manual


APU ENG
RPM ELECTRONIC
CONTROL UNIT
(ECU) APU
(AUTOMATIC OR
MANUAL)
ON OFF
APU GEN
GENERATOR OUTPUT GENERATOR OFF/
Vol. 1

TO BUS DISTRIBUTION CONTROL UNIT RESET


(GCU) APU GEN
AUTO
SELECTOR
REV 3, May 03/05
04--10--4
Vol. 1 04--10--5
AUXILIARY POWER UNIT
Introduction REV 3, May 03/05

45,000

APU Generator Loading


40,000
Limit (41,000)
APU Altitude Starting
35,000 Limit (37,000)

30,000
PRESSURE ALTITUDE, FEET

25,000 APU MES and ECS Bleed


Altitude Limit (25,000)

20,000

Surge Valve Closed


15,000 Below 17,000 FT

Ground Starting
10,000 Altitude Limit
(15,000)

5,000

0
(--1,000 feet)

--5,000
--100 --80 --60 --40 --20 0 20 40 60

STATIC AIR TEMPERATURE, CELSIUS

APU Start and Operating Limits


Figure 04---10---4

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--10--6
AUXILIARY POWER UNIT
REV 3, May 03/05
Introduction

DOOR POSITION SCH. (Degrees) 60

50

40

30
ARINC MACH NO = 0.4

ARINC MACH NO = 0.85


20

10

0
0 20 40 60 80 100
N (% speed)

N (% speed) ARINC MACH NO = 0.4 ARINC MACH NO = 0.85


DOOR POSITION SCH. DOOR POSITION SCH
(Degrees) (Degrees)
0 9.0 4.5
10 9.0 4.5
30 45.0 9.0
50 45.0 45.0
70 45.0 45.0
95 45.0 45.0
100 45.0 45.0

APU DOOR POSITION SCHEDULE

APU Door Position


Figure 04---10---5

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--10--7
AUXILIARY POWER UNIT
Introduction REV 3, May 03/05

NOTE
EGT acceleration shutdown limit
increases with higher altitudes.

NOTE
EGT ECS & MES shutdown limits increase with
higher inlet temperatures and higher altitudes.
EGT Shutdown Schedule
Figure 04---10---6

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--10--8
AUXILIARY POWER UNIT
REV 3, May 03/05
Introduction

THIS PAGE INTENTIONALLY LEFT BLANK

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--20--1
AUXILIARY POWER UNIT
Power Plant Sep 09/02

1. APU POWER PLANT

The APU power plant consists of a gas turbine engine and gearbox.

A. Engine

The engine is a single-shaft, constant speed design, consisting of a compressor, a


combustor and a two-stage turbine. The compressor draws large volumes of air
through the inlet ducting and delivers it under pressure to the combustor. Fuel from the
left collector tank is added to the high pressure air and ignited, increasing the energy of
the airflow. The high velocity, high temperature gasses are delivered to the turbine
section. The turbine converts the high velocity gasses into mechanical energy to drive
the compressor and gearbox.

B. Gearbox

The gearbox reduces the turbine shaft rpm to a speed suitable to operate the gearbox
mounted accessories. Accessories include the lubrication module, fuel control unit,
electric starter and generator. The gearbox has an integral oil sump. The oil level can
be checked using a sight glass on the oil filler assembly.

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--20--2
AUXILIARY POWER UNIT
Sep 09/02
Power Plant

THIS PAGE INTENTIONALLY LEFT BLANK

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--30--1
AUXILIARY POWER UNIT
Systems REV 3, May 03/05

1. SYSTEMS

The APU consists of a lubrication system, fuel system, ignition and starting systems, and an
air intake and exhaust.

A. Lubrication

The lubricating system consists of a mechanically driven lubrication module, oil filter, oil
cooler, low oil pressure switch, oil temperature sensor and a deprime solenoid. The
lube module provides pressurized oil to the power plant, gearbox and generator for
lubrication and heat removal. To ease starting under cold conditions, a de-prime
solenoid allows vent air to enter the lube pump to reduce starter motor drag.

B. Fuel

Fuel is supplied to a fuel control unit from the left collector tank by a dedicated APU fuel
pump (refer to Chapter 13). The fuel control unit starts, stops and modulates the flow of
fuel to the APU in response to commands from the ECU.

C. Ignition and Starting

The ignition and starter systems are controlled by the ECU. The ECU commands the
DC starter motor to rotate the power plant. The starter accelerates the power plant to a
specific speed where the ECU introduces fuel to the combustor. The ignition system is
used to ignite the fuel/air mixture in the combustor which further accelerates the power
plant. As the APU accelerates toward the onspeed condition, the starter is disengaged.
When the APU reaches normal operating speed, the ignition is turned off. At this point
the engine becomes self sustaining.

D. Air Intake and Exhaust

The air inlet door is located in the upper right side of the rear fuselage and is controlled
by the ECU. When open, the door provides ram air for APU operation and oil cooling.
On the ground, the air inlet door has only two positions, closed or open (0 and 45
degrees). In flight, during APU start, the ECU limits the door position in response to
APU engine rpm and aircraft speed. This prevents excessive amounts of ram air which
could cause the APU to flameout. When the APU is not operating, the door remains
closed to prevent windmilling of the compressor. The inlet door also serves as a barrier
in the event of fire. The exhaust duct is composed of stainless steel and is centered in
the tailcone.

Flight Crew Operating Manual


CSP C--013--067
APU
PWR START/
FUEL STOP

LCV POSITION COMMAND (TORQUE MOTOR)


BLEED FLOW
LCV POSITION (RVDT)
START
ON/OFF SURGE VALVE
RUN
BLEED SOURCE INLET DOOR POSITION
BOTH ENG LOAD CONTROL
POWER INLET INLET VALVE (LCV)
TO ECU INLET DOOR ACTUATOR AIR DOOR
L R
ENG ENG
AIR/OIL COOLER
APU INLET TEMPERATURE (T2)
TO EDUCTOR AIR
LCV CLOSE INLET PRESSURE (P2)
T2 SENSOR SURGE VALVE
LCV OPEN SPEED
P2 SENSOR
EICAS GEN. OVERLOAD
STAT PAGE SPEED
GEN. LOAD LEVEL SENSOR
EGT GEARBOX
APU GENERATOR READY TO LOAD
GCU
DCU STARTER VOLTS
Systems

SPEED STARTER
DC POWER 28 VOLTS
ECU
GEN
MDC AC TO AIRCRAFT

CSP C--013--067
AIRCRAFT
BATTERY

Figure 04---30---1
AUXILIARY POWER UNIT

IOC
APU STARTER -- CONTACTOR
FUEL CONTROL OIL

Flight Crew Operating Manual


UNIT UNIT PUMP
ADC APU EGT SENSOR
LOP SWITCH

APU Controls and ECU Interface


IGNITION FUEL
AIR DEPRIME FUEL EXCITER NOZZLE
PSEU SOV ASSEMBLY
GND OIL/GEN. FILTERS DELTA P

OIL TEMPERATURE SENSOR


TORQUE MOTOR MET. VALVE
Vol. 1

EXTERNAL SERVICES FUEL SOLENOID VALVE


PANEL
OIL TEMPERATURE
IGNITION ON/OFF
IGNITION BUILT--IN TEST
EXHAUST GAS TEMPERATURE (EGT)
Sep 09/02

APU COMPARTMENT P
SHUTDOWN SWITCH
04--30--2
Vol. 1 04--40--1
AUXILIARY POWER UNIT
Control REV 1, Jan 13/03

1. CONTROL

The APU electronic control unit (ECU) provides full automatic control of APU starting,
stopping, and protects the APU during all modes of operation. The control system ensures
that priority is given to electrical loads by reducing bleed airflow.

A. Starting

When the PWR FUEL switchlight, on the APU panel, is selected:

S The ECU is powered

S The air inlet door opens (position is displayed on the EICAS status page)

S The APU RPM and EGT gauges are displayed on the EICAS status page

S The fuel pump comes on

When the START/STOP switchlight, on the APU control panel, is selected:

S The ignition is activated

S The starter motor is energized

S The fuel shutoff valve opens

S The START legend on the APU panel comes on

S The APU START status message is displayed

The starter motor is deactivated at 46% rpm on the ground or at 60% rpm if in flight and
the START legend goes out. When the APU reaches 95% rpm, ignition is turned off.
Two seconds after the APU reaches 99% rpm, the AVAIL legend, in the START/STOP
switchlight, illuminates to notify the crew that the APU is ready for loading.

B. Stopping

To shutdown the APU, the crew pushes the START/STOP switchlight on the APU
panel. The APU will automatically shed its loading and shutdown. The PWR/FUEL
switch is deselected to close the fuel shutoff valve and to remove primary electrical
power to the ECU.

In the event of an emergency, the flight crew can press the APU FIRE PUSH switchlight
on the glareshield. On the ground, the APU can be shut down by pushing an APU
emergency stop button located in the APU compartment or by selecting an APU
shut--off switch on the external services panel on the RH forward fuselage. Either
selection sends a signal to the ECU to carry out an immediate shutdown.

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--40--2
AUXILIARY POWER UNIT
REV 3, May 03/05
Control

PWR FUEL START/STOP


When pressed, APU When pressed in:
fuel pump is energized Start motor on
and APU fuel shut--off START light (white)
valve opens, APU EICAS comes on
gauges and APU IN BITE At 60% rpm, START
message are displayed. light goes out
On the ground, air inlet AVAIL light (green)
door is scheduled to comes on 2 seconds
open. APU Control Panel
Overhead Panel after APU reaches
PUMP FAIL (amber) 99% rpm.
light comes on to When pressed out:
indicate that APU fuel Fuel shut--off valve
pump has failed. BRT

closes
SOV FAIL (amber) APU shuts down
light comes on to AVAIL light goes out
indicate that the APU Air inlet door closes
fuel shut--off valve has
failed.
When pressed again,
APU fuel pump is
de--energized.

APU Symbol
White -- APU not running
Half--Intensity Cyan --
APU ready to load
Half--Intensity Magenta --
Invalid data

Fuel Page

APU Emergency Stop


Used by maintenance personnel
to shut down the APU.

APU SHUT--OFF (Guarded)


Used by maintenance personnel
to shut down the APU.
APU Compartment External Service Panel
Forward Firewall Right Forward Fuselage

Auxiliary Power Unit --- Control <1001, 1205>


Figure 04---40---1

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--40--3
AUXILIARY POWER UNIT
Control Sep 09/02

APU OVERSPEED warning (red)


Indicates that APU overspeed
condition exists. APU shuts down
automatically. APU

APU OVERTEMP warning (red)


Indicates that EGT overtemperature
shutdown limit exceeded. APU APU
shuts down automatically on the
ground.
NOTE:
If overspeed or overtemperature
occur during flight, do not restart APU.

APU DOOR OPEN caution (amber)


Indicates that APU door failed to close
after APU shutdown.

APU ECU FAIL caution (amber)


Indicates that no data is received from
the ECU with PWR FUEL selected on.

APU FAULT caution (amber)


Indicates a fault requiring the APU to
be shutdown. APU shuts down
automatically on the ground.

Primary Display

NOTE:
For pneumatic messages refer to Chapter 19.

EICAS Auxiliary Power Unit Indications --- Primary Page <1001>


Figure 04---40---2

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--40--4
AUXILIARY POWER UNIT
Sep 09/02
Control

APU ALT LIMIT status (white)


Indicates that surge control valve BRT

has failed.

APU FAULT status (white)


Indicates loss of redundancy in
sensors, impending filter bypass or
fuel valve has failed open.

APU IN BITE status (white)


Indicates air inlet door not in
position with PWR FUEL
selected on.
APU START status (white)
Indicates that starter motor is
engaged.

APU Inlet Door Status


Indicator (white)
Indicates air inlet door position:
DOOR CLSD
DOOR OPEN
DOOR INHIB/CLSD Status Page
DOOR INHIB/OPEN
DOOR -- -- -- (amber dashes)

NOTE:
Amber dashes indicates position
unknown. Amber DOOR OPEN
indicates door has failed to close
after APU shutdown.

APU

100 430

RPM EGT

APU RPM Readout, scale and APU EGT Readout, scale and
pointer (green) pointer (green)
Indicates percent of APU rpm. Indicates exhaust gas temperature
Readout and pointer turn red in degrees Centigrade. Readout
during overspeed condition. and pointer turn red during
overtemperature condition.

Auxiliary Power Unit and Indications --- Status


Figure 04---40---3

Flight Crew Operating Manual


CSP C--013--067
SWITCH / LIGHT SELECTED

EICAS SECONDARY DISPLAY

APU IN BITE APU START


APU SOV OPEN
Control

CSP C--013--067
READY
TO

Figure 04---40---4
LOAD
AUXILIARY POWER UNIT

RPM

Flight Crew Operating Manual


ECU POWER--UP

Auxiliary Power Unit Start Sequence


DOOR TO
FULL OPEN

PRESS PRESS START


PWR FUEL SW/LT, IGNITION, OIL FUEL SOLENOID STARTER IGNITION STARTER IGNITION
Vol. 1

SW/LT DEPRIME SOLENOID ENERGIZED CUTOUT OFF ON CUTOUT OFF INFLIGHT,


BATTERY GROUND (INFLIGHT), TIME TOTALIZER
MASTER OIL DEPRIME ENERGIZED
”ON” SOLENOID
(CLOSE)
REV 1, Jan 13/03
04--40--5
Vol. 1 04--40--6
AUXILIARY POWER UNIT
Sep 09/02
Control

C. Protective Shutdown

The ECU will shut down the APU (on ground or in flight) if any of the following faults
occur:

S Overspeed -- APU speed exceeded 106 percent.

S Loss of overspeed protection -- A combination of speed sensors or overspeed


circuits fail.

S Loss of speed sensor signals -- Both speed sensor channels failed.

S APU door failed to open within 30 seconds of command.

S APU door was open then closed without command, while the APU was operating.

S ECU internal failure.

S No APU rotation -- During start, speed did not reach 5% within specified time
requirement (12 seconds for warm oil; 50 seconds for cold oil).

S No APU light-off -- Light-off was not detected within specified time requirement.

S Slow start -- Starting time period exceeded.

S No acceleration -- Acceleration during start was less than 0.05% per second for 15
seconds.

S Speed fallback -- The APU speed drops below 50% after starter cutout.

S Loss of DC power -- Battery power lost for more than 200 milliseconds.

S APU fire/emergency -- APU FIRE PUSH switch or one of the emergency shutdown
switches was selected.

S Loss of air inlet door position sensor signal -- Failure of air inlet door position sensor.

The ECU will shut down the APU (on ground) if any of the following faults occur:

S Overtemperature -- APU EGT exceeded schedule limits.

S Low oil pressure (LOP) -- Low oil pressure exists for 15 seconds with the APU
operating.

S Oil pressure switch failed -- Cannot detect a low oil pressure condition.

S High oil temperature -- Oil temperature exceeded 300_F with the APU operating.

S Reverse flow -- APU inlet temperature exceeded 350_F for 5 seconds with with the
APU operating and LCV open.

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--40--7
AUXILIARY POWER UNIT
Control Sep 09/02

S Underspeed -- APU was operating and speed dropped below 80% for 5 seconds.

S Loss of EGT sensors -- Both EGT sensor channels failed.

S APU oil filter in an impending bypass condition.

D. System Circuit Breakers

SYSTEM SUB--SYSTEM CB NAME BUS BAR CB CB NOTES


PANEL LOCATION
APU CONT N7
BATTERY
APU ECU 1
BUS N11
Auxiliary PRIM
Control
Power Unit APU ECU SEC A6
APU BATT
APU DOOR 5
DIRECT BUS B1
ACT

Flight Crew Operating Manual


CSP C--013--067
Vol. 1 04--40--8
AUXILIARY POWER UNIT
Sep 09/02
Control

THIS PAGE INTENTIONALLY LEFT BLANK

Flight Crew Operating Manual


CSP C--013--067

You might also like