Ata 49 Aps
Ata 49 Aps
737--300/400/500
ATA 49
Airborne Auxiliary Power
For training purposes and internal use only.
Copyright by Lufthansa LAN Technical Training
All rights reserved. No parts of this training
manual may be sold or reproduced in any form
without permission of:
GENERAL
49
ATA 49 APU
FWD
APS 2000
For Training Purposes Only
MAX CONTINUOUS EGT 702°C PSIG . . . . . . . . . . . . . . . . . . Punds Per Square Inch Gage
Max EGT 730°C RPM . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions Per Minute
RTD . . . . . . . . . . . . . . . . . Resistive Temperature Detector
SHP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Horsepower
SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch
V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts
GENERAL
49-- 00
For Training Purposes Only
GENERAL
49-- 00
PANEL DESCRIPTION
MAINTENANCE LIGHT ( blue ) APU BLEED AIR SWITCH
ON- Identifies an APU Warning. An Electrical fault has occured , or an APU Oil ON -Opens the APU Bleed Air Valve if the APU is Operating.
Servicing is required . See MCDU Multi purpuse Control Display Unit or OFF- Closes the APU Bleed Air Valve.
FADEC Fault Display for Maintenance Light Reason.
GENERAL
49-- 00
MAINTENANCE LIGHT
FAULT LIGHT
OVERSPEED LIGHT
RECIRC FAN
OFF
L PACK R PACK
ISOLATION
OFF VALVE OFF
AUTO CLOSE AUTO
HIGH AUTO HIGH
ON ON
START 1 APU 2
BLEED
APU EXHAUST GAS TEMPERATURE INDICATOR
POWER PLANT
49-10
ACCESS DOOR
Access to the APU is through an access door, completely enclosing the APU
compartment.
The access door is hinged on the right side and latched on the left side. It con-
sists of skin, ribs and stringers forming the outside contour of the fuselage. On
the inside are two door open holding rods, two drain cups and cooling air ex-
haust. On the outside, is a drain mast connected to the drain cups.
The door can be opened for normal APU servicing, or it can be removed by
unlatching the hinges on the right side. The drain cups should be inspected
periodically for cleanliness.
The exhaust ducting is cooled by four air inlets around the aft end of the ex-
haust fairing.
SHROUD
The APU shroud is a titanium compartment that fully protects the APU power
plant. The APU shroud gives the protection from an APU fire and decrease the
noise from the APU power plant. The APU shroud includes the upper shroud
and the lower shroud. The upper shroud attaches to the airplane structure and
holds the forward end of the APU exhaust duct. The upper shroud and the
lower shroud connect to one another with the shroud latches on the lower
shroud.
Upper Shroud
The upper shroud is installed in the APU compartment. When the APU is re-
moved from the airplane, the upper shroud will stay in the APU compartment.
The upper shroud has openings for the fuel lines, air inlet ducts and bleed
air duct. Three mounting brackets for the APU engine attach to the shroud
rings.
For Training Purposes Only
Lower Shroud
The lower shroud attaches to the upper shroud with ten shroud latches. The
lower shroud has the openings to the filler port for the oil tank and to the over-
board exhaust for the APU cooling air. Also, there is an access panel that is
removed to read the elapsed time indicator. When the lower shroud is re-
moved, you can get access to do maintenance on the APU.
POWER PLANT
49-10
EXHAUST DUCT
UPPER
SHROUD
DRAIN
HOLES DRAIN LINE
FWD
COOLING AIR EXHAUST
FWD
APU ACCESS DOOR LOWER SHROUD
APU COOLING AIR APU DOOR LATCH
TO DRAIN MAST DRAIN FITTING
EXHAUST DUCT (3 PLACES)
APU DRAINS
The APU drains provide means for draining unburned fuel from the engine and
for draining fuel or oil from the shroud in event of leakage inside the shroud.
At the aft end of the shroud, a drain cup with stand--pipe picks up unburned
fuel discharged through the turbine exhaust port. Two fuel drain lines are
manifolded into a fitting on the engine. This fitting mates with a drain cup in the
drain line. The drain line terminates at a fitting at the forward end of the shroud.
Adjacent to the drain line terminal end fitting is another fitting. Through this fit-
ting fuel or oil is drained from the shroud. Both fittings at the forward end of the
shroud mate with drain cups in the APU compartment access door. The drain
cups in the access door are connected to a drain mast.
Drain Valve
The drain valve is a spring- loaded ball device. The drain valve permits fuel that
collects in the combustor to flow to the APU drain mast.
The drain valve is located at the lowest point in the combustor plenum. This
permits complete drainage prior to another attempted start.
The drain valve is spring--Ioaded open until the APU reaches approximately 15
percent RPM. At 15 % RPM APU combustor pressure closes the drain valve.
For Training Purposes Only
APU
ENGINE
FWD
TURBINE EXHAUST
END DRAIN CUP
SHROUD DRAIN
SHROUD
DRAIN CUP
DRAIN CUP
For Training Purposes Only
A09673 91061
Figure 4 Shroud Drains.
SCL VRC/RRH 26.08.2005 Page: 9
AIRBORNE AUXILIARY POWER B737-300/400/500
Lufthansa LAN Technical Training
Operation
When the actuator is powered, the pushrods move the door to the open posi-
tion. Movement of the door deflects the flap on the vortex generator for impro-
vement of air flow into the inlet. When the door is fully open, the door switch
operates. The switch actuation is part of the APU start cycle.
For Training Purposes Only
TORQUE BOX
AIR DIFFUSER
DUCT
VORTEX
GENERATOR
COMPRESSOR
AIR DUCT COOLING
AIR DUCT
AIR INLET
DOOR FWD
SET SCREW
(DOOR OPEN)
VORTEX GENERATOR FLAP
VORTEX GENERATOR
(OPEN POSITION)
For Training Purposes Only
DOOR
OPEN
Figure 5 APU Air Inlet
SCL VRC/RRH 26.08.2005 Page: 11
AIRBORNE AUXILIARY POWER B737-300/400/500
Lufthansa LAN Technical Training
ENGINE
49-20
BOROSCOPE INSPECTION
The following components of the turbine assembly may be inspected by the
use of a boroscope: Turbine Blade Tips Combustion Chamber Turbine Nozzle
Vanes Turbine Wheel Blades Compressor Wheel Blades Compressor Diffuser
Legend:
1. BLADES OF THE COMPRESSOR WHEEL
2. LEADlNG EDGE OF THE COMPRESSOR WHEEL
3. EXHAUST SECTlON
4. BLADES AND VANES OF THE TURBlNE WHEEL
5. LEADlNG EDGE OF THE TURBlNE WHEEL (3 LOCATlONS)
6. COMBUSTION CHAMBER (4 LOCATlONS)
7. HAND--CRANK PROVlSlONS (LOCATED ON THE COOLlNG FAN)
For Training Purposes Only
ENGINE
49-20
946555
TURBINE
COMPRESSOR NOZZLE
WHEEL FWD
FWD
COMPRESSOR
BOROSCOPE PLENUM IGNITER
COVER
PLUG PLATE PLUG
6
5 COMBUSTION
1
2 TURBINE CHAMBER
COMPRESSOR WHEEL
DIFFUSER
HAND--CRANK
PROVISIONS LEGEND:
______
COVER
1 BLADES OF THE COMPRESSOR WHEEL
6 COMBUSTION CHAMBER
945054 833716
OIL
49-90
the gearbox. The oil is filtered prior to leaving the pump and then fiows through
the oil cooler. The cooled oil is returned to the gearbox oil passages and jets to
provide Iubrication and cooling of the gears, shafts and bearings.
During operation of the gear system, an oil/air mist is created inside the gear-
box. The oil and air are separated by the action of a mechanical separator that
is part of the generator gear shaft. Oil is returned by gravity to the gearbox oil
sump and the air is vented to the APU exhaust through the gearbox vent sys-
tem.
OIL
49-90
RELIEF
VALVE
45 PSID
OIL COOLER
BYPASS VALVE OIL COOLING
25-45 PSID AIR FAN
COOLER
AIR/OIL MIST
TURBINE ASSEMBLY
FORWARD OVERHEAD PANEL, P5
HIGH OIL OIL FILTER AND
TEMP. SW. PUMP ASSEMBLY
135 C
GEARBOX
OIL TANK > 55% CLOSE CLOGGING IND. 30-35 PSID DRAIN PLUG
S
OIL TYPE
FILL
WHEN AMBER
LIGHT IS ON OIL TANK
SOLENOID VALVE LEGEND
OIL SUCTION
PRESS. FILL OIL PRESSURE
CONNECTION
LUBE OIL PRESS. FILLING
SERVICING PANEL
833776 795131 830931 OIL TANK VENT LINE
Figure 7 Lubrication Schematic
SCL VRC/RRH 26.08.2005 Page: 15
AIRBORNE AUXILIARY POWER B737-300/400/500
Lufthansa LAN Technical Training
OIL
49-90
OIL
49-90
FWD
OIL
FILLER CAP
For Training Purposes Only
MAGNETIC
DRAIN OILLEVEL
PLUG SIGHT GLASS
803803 833776
OIL
49-90
COMPONENT DESCRIPTION
Oil Cooler Oil Pressure Relief Valve
The oiI cooler is installed on the APU below the APU electrical generator. The The pressure relief valve is installed in the lower part of the gearbox housing.
oiI cooler is a rectangular unit made of aiuminum tubes. The oiI cooler receives The pressure relief valve keeps the oil pump pressure below 40 to 45 psig. If
the oil from the oiI pump. In the oil cooler the oil moves through the tubes the pressure relief valve opens, the oil wilI flow back to the oil tank.
where it is cooled by air from the cooling tan assembly. The oil tIows from the
oil cooler to the gearbox assembly and the gears and bearings ot the APU en- OiI Pressure Switch
gine. The oil cooler has a bypass valve that opens if the oil cooler is clogged. The oil pressure switch is installed on the gearbox assembly or on the oil cooler
The bypass valve opens when the differentia! pressure across the oii cooler is The oil pressure switch stops the APU when the APU oil pressure decreases to
25 to 35 psig . The bypass valve is tu!Iy open when the differential pressure is 20+/-2 psig . The signal from the oil pressure switch is monitored by the FA-
45 psig . DEC and the airplane electronics in the control cabin.
De--Prime Valve
The de--prime valve is energized open when the APU is started . When the
APU accelerates to 55% service speed, the de--prime valve is de--energized to
the closed position. This will permit the oil pump to produce oil pressure. When
the APU is stopped the de--prime valve is energized to the open position to
stop the supply of oil to the oil pump. The oil that stays in the APU wiIl drain to
the oil tank. After 5 minutes APU stop the de--prime valve is de-energized to
the close position.The de--prime valve is installed on the oil pump and filter as-
sembly. The de--prime valve operates with a solenoid.
OIL
49-90
OIL COOLER
OIL PUMP
AND FILTER ASSEMBLY
DE--PRIME
VALVE
OIL FILTER
BYPASS VALVE
OIL FILTER
CLOGGING IND.
(RED)
OIL PRESSURE
For Training Purposes Only
RELIEF VALVE
CARBON SEAL
HIGH OIL DRAIN
TEMP. SWITCH WHITNESS
PORT
GEARBOX DO NOT PLUG
OIL FILTER
OIL
49-90
Power
Power for the system is 28 volts dc from the battery bus,switched hot bat bus
or APU G.C.U.
Maintenance Practices
The oil tank is replenished by connecting the oil supply to the pressure fill con-
nection and pumping oil into the tank until the green light ilIuminates. Required
oil supply pressure is 35 psi.
For Training Purposes Only
OIL
49-90
STABILIZER
COMPARTMENT
ACCESS DOOR
OIL TYPE
FWD STABILIZER
COMPARTMENT PRESSURE
DOOR
DOOR OPEN SWITCH
ACTUATING MAGNET
991803
OIL
49-90
OIL
49-90
TO
APU LOW OIL QUANTITY
CONT
MCDU
OFF
BITE CODE LOQ
ON
START
ADD
TO
APU PANEL MAINT
B < 5% RPM
APU
CONT
APU MASTER CONTR. SW. (P5)
FADEC
CLOSE AFT CARGO CPTM
FULL
G
OPEN
DOOR OPEN
SWITCH WHEN OIL LEVEL”ADD”
APU CONTROL UNIT M280 ADD
( E3--3 ) A SIGNAL TO FADEC DURING
APU START AND SHUTDOWN.
28V DC
SWITCHED
HOT BAT BUS APU
CONT FULL
OIL TANK
CIRCUIT BREAKER
SOLENOID VALVE
For Training Purposes Only
PANEL ( P6 --5 )
ADD
28V DC
OIL QTY RELAY OIL LEVEL
SWITCHED R 253 SENSOR
HOT BAT BUS
OPEN: RPM >70% FOR 60 SEC. AND APU SHUT DOWN FOR 30 SEC.
T AMB FROM
BYPASS START
LEGEND P AMB
PURGE
...
VALVE
10 PSID VALVE
LOW FUEL PRESSURE
FILTER FILTER CLOGGING TO DRAIN MAST
HIGH FUEL PRESSURE INDICATOR 6 PSID
APU DC
BOOST PUMP
FUEL
OUTLET
APU FUEL
For Training Purposes Only
SHUTOFF
VALVE
FUEL INLET
MANUAL OVERRIDE LEVER
FWD INBD
INBD FWD
LEFT LOWER
INBOARD TRAILING
EDGE PANEL
997665 ATA28.190608
ON
NORMAL
OFF SHUTDOWN APU AIR INLET DOOR
APU MASTER CONTR. SW. (P5)
28V DC
NORM
DISCH
FIRE DOOR
NC
NOT
CLOSE CLOSE FULLY
APU OPEN
FIRE
HANDLE M M
R FULL
OPEN OPEN
OPEN
NORM
NC
FIRE
APU FUEL SHUTOFF APU AIR INLET DOOR DOOR
VALVE ACTUATOR OPEN
FIRE SWITCH
RELAY
APU FIRE
REMOTE DETECTION 28V DC
CONTROL MODULE
PANEL M 279
For Training Purposes Only
28V DC
SWITCHED
HOT BAT BUS APU MONITOR
APU GENERATOR CONTROL UNIT ( P6 )
APU SHUTDOWN SIGNAL
28V DC
SWITCHED
POWER SUPPLY
HOT BAT BUS APU
CONT
APU CONTROL UNIT M 280
CIRCUIT BREAKER PANEL ( P6 --5 )
FADEC M 3056
Figure 14 APU Fuel Shutoff Valve Control FADEC AFT CARGO CPTM
SCL VRC/RRH 26.08.2005 Page: 28
AIRBORNE AUXILIARY POWER B737-300/400/500
Lufthansa LAN Technical Training
START
BAT BUS
NC
APU FUEL
BOOST PUMP
M
CIRCUIT
ON BREAKER
PANEL ( P6 ) APU FUEL BOOST PUMP
NC
OFF
R 155 APU FUEL
BOOST PUMP RELAY
APU MASTER CONTROL SWITCH
NC
NC
28V DC
SWITCHED
HOT BAT BUS
APU MONITOR
28V DC APU GCU ( P6 )
28V DC
POWER SUPPLY SWITCHED
APU CONT HOT BAT BUS
APU CONTROL UNIT M280 ( E3--3 )
CIRCUIT BREAKER PANEL ( P6 )
FADEC M 3056 AFT CARGO CPTM
FUEL HEATER
The fuel heater is used to prevent ice from blocking the fuel filter.
The heater is a tubular fuel / air heat exchanger. The control valve has a bime-
tallic element for sensing the fuel temperature and allowing bleed air to pass
through the heater.
The fuel heater and control valve with a temperature sensor are attached to the
inside surface of the upper shroud.
FIow Control Valve
When the fuel temperature passing through the valve decreases to
3 C (37 F), the valve modulates to full open. This allows hot air from the APU
bleed duct to pass through the heater and dumps into the shroud. When fuel
temperature increases to 18 C (64 F), the valve closes.
FueI Heater Check Valve
A check valve is installed in the fuel Iine upstream of the heater to retain fuel in
the pump. This ensures a positive prime for starting.
FUEL HEATER
CHECK VALVE
UPPER
SHROUD
FUEL HEATER
OVERBOARD
DUMP LINE
FOR THE
BLEED AIR
ACTUATOR
FLOW CONTROL
FUEL HOSE CHECK VALVE
997661
The start fuel solenoid gets a signal from the FADEC to permits unmetered fuel
flow through the start fuel nozzles.
opens, if RPM > 2% ( FF ca 10 kg/h)
closes, if RPM > 70%.
GEARBOX
FWD
FUEL SERVO
VALVE
MAIN FUEL
SOLENOID VALVE
For Training Purposes Only
FUEL DRAIN
TUBE FWD
DIFFERENTIAL
PRESSURE VALVE
IGNITOR
FUEL FILTER
ASSEMBLY
FUEL FILTER
For Training Purposes Only
803431
FUEL FILTER FITTING MAIN CHECK VALVE MAIN FUEL MANIFOLD COMBUSTION
CHAMBER
DRAIN LINE 997645
49
38
AMBIENT TEMPERATURE OF ( C )
27
16
--7
--18
--29
For Training Purposes Only
--40
710 715 720 725 730 735 740
MAXIMUM EGT C
EGT Limit -- APU Speed more than 98%
AIR
49-50
AIR
49-50
ON S
BLEED
SERVO ACTUATOR
OFF
VALVE CLOSED
APU APU BLEED REG
BLEED 28 AIR VALVE
AIR SWITCH VDC FILTER
OPEN
P 5 FWD VENT
OVERHEAD M280 APU M278 MISC APU BLEED
PANEL CONTROL UNIT SWITCHING AIR DUCT
E3-2 MODULE E3-2
MAIN ENGINE
START ( GRD ) TO FUEL
TO DUAL
HEATER
BLEED BLEED LIGHT
CHECK
98% RPM VALVE
AND 2 SEC AIR
INLET
OPEN SIGNAL
RPM
FILTER
T AMB
P AMB
COOLING AIR ACTUATOR CHECK
EGT SHUTOFF VALVE VALVE
FADEC
AFT CARGO CPMT
GENERATOR
LEGEND
For Training Purposes Only
OIL COOLER
A56082
AIR
49-50
When the APU is operating above 98% RPM and the APU bleed air switch is
’ON’, the bleed servo valve changes control pressure to the APU bleed valve.
The FADEC controls the bleed servo valve as a function of APU EGT. When
APU EGT Iimits are approached, the FADEC signals the bleed servo valve to
vent control pressure. This modulates the APU bleed valve closed.
AIR
49-50
ELECTRICAL
CONNECTOR
TURBINE
PLENUM FWD
FWD
BLEED AIR
VALVE SOLENOID
APU
BLEED
AIR DUCT
For Training Purposes Only
BLEED
AIR VALVE
INBD
PRESSURE
REGULATOR
833545
AIR
49-50
AIR
49-50
OFF
VENT
ON
PNEUMATIC
NC D ACTUATOR
TO PNEUMATIC
SYSTEM
ENGINE START
FILTER
INTERLOCK RELAY PRESSURE
REGULATOR
M278 MISC SWITCHING
MODULE (E3--2)
OPEN
TO DUAL BLEED
LIGHT CIRCUIT CLOSED
APU BLEED AIR VALVE TO FUEL
HEATER
98% RPM RPM AIR
AND 2 SEC INLET
T AMB
OPEN SIGNAL FILTER
P AMB COOLING AIR
TO BLEED SHUTOFF VALVE
For Training Purposes Only
AIR
49-50
an APU fire occurs. The shutoff valve has a butterfiy mounted on a shaft. The
butterfiy is installed in the cooling air duct. The pneumatic actuator controls the
shutoff valve.
AIR
49-50
AIR
INLET
CHECK
ACTUATOR FILTER VALVE
COOLING AIR
SHUTOFF VALVE
GENERATOR
OIL COOLER
S
AIR
49-50
AIR
49-50
PRESSURE LINE
TO THE PNEUMATIC
ACTUATOR
UPPER
SHROUD
CHECK VALVE
(TO FUEL HEATER)
767835
AIR
49-50
COOLING FAN
The cooling fan supplies a positive, cool airflow through the oil cooler and the
APU electrical generator. The cooling fan is a gear--driven, mixed flow fan. The
cooling fan has a shaft impeller that is installed in a shroud. A housing holds
the baiI bearing for the impeller shaft. The housing also moves the air to and
from the shaft impeller. The cooling fan inlet duct and the exhaust scroll for the
cooling fan move the air into and out of the cooling fan assembly. The fan inlet
screen stops aII unwanted materials before they go into the components of the
cooling fan that turn.
AIR
49-50
COOLING FAN
INLET SCREEN
INSPECTION TUBE COOLING AIR
SHUTOFF VALVE
PNEUMATIC
PNEUMATIC PRESSURE LINE ACTUATOR
ACTUATOR
STABILIZER
COOLING AIR COMPARTMENT
SHUTOFF VALVE AREA
ACTUATOR RETRACTED
COOLING AIR DUCT
UPPER
SHROUD COOLING FAN
INLET SCREEN
PRESSURE LINE
APU INLET
GEARBOX
COOLING FAN DRIVEN
For Training Purposes Only
ACTUATOR EXTENDED
OPEN POSITION
COVER
AND LOCATION
TO MANUALLY
COOLING AIRFLOW TURN THE APU
TO GENERATOR COOLING AIR SHUTOFF VALVE TEST
AND OIL COOLER
767825 767831 767832
IGNITION / STARTING
49-40
IGNITION / STARTING
49-40
START RELAY
START R5 APU
NC BATTERY
28 V DC
STARTER
ON
IGNITER
PLUG
IGNITION
OFF TD 1 SEC
EXCITER IGNITER
APU MASTER CONTROL SWITCH PLUG
( P5 )
FULL OPEN
>
= 55 % RPM
28V DC
SWITCHED
HOT BAT BUS
28V DC
SWITCHED POWER SUPPLY
HOT BAT BUS APU APU CONTROL UNIT M280 ( E3--3 )
CONT
APU GENERATOR CONTROL UNIT ( P6 )
FADEC M 3056 AFT CARGO CPTM
IGNITION / STARTING
49-40
Ignition Exiter ( 1 )
The ignition exciter supplies the high voltage current necessary to cause the
igniter plugs to make the sparks. The ignition exciter has a transformer, in-
verter, rectifier, booster coil and capacitors. These components are hermeti-
cally sealed in a metal container on the APU. The ignition unit is an LRU.
Igniter Plugs ( 2 )
The ignition system has two igniter plugs, left and right. The igniter plugs have
an outer casing, center electrode and ceramic insulator. The igniters screw into
mounting bosses on the combustor case. The igniters are LRU’S.
WARNING: MAKE SURE YOU REMOVE THE ELECTRICAL POWER
FROM THE IGNITION AND START SYSTEM. LET 5 MIN-
UTES GO BY BEFORE YOU REMOVE THE IGNITER
CABLE. GROUND THE IGNITER CABLE AGAINST THE
SHELL OF THE IGNITER PLUG BEFORE YOU REMOVE
THE IGNITER CABLE. MAKE SURE THAT THE IGNITION
EXITER IS FREE FROM ELECTRICAL POWER BEFORE
YOU REMOVE THE IGNITER CABLE. THE ELECTRICAL
POWER TO THE IGNITION AND START SYSTEM IS AT A
VERY HIGH VOLTAGE. THE ELECTRICAL POWER TO THE
IGNITION AND START SYSTEM CAN CAUSE INJURY TO
OR KILL PERSONS.
For Training Purposes Only
IGNITION / STARTING
49-40
COMBUSTION
CHAMBER
HOUSING
IGNITER
FWD PLUG
ELECTRICAL
CONNECTOR
IGNITER
CABLE
IGNITION
EXCITER
For Training Purposes Only
IGNITER CABLE S
768571
IGNITION / STARTING
49-40
IGNITION / STARTING
49-40
START
RELAY R5
For Training Purposes Only
FWD
803778
IGNITION / STARTING
49-40
Location
The starter is mounted on the accessory drive section.
Physical Description
The starter consists of an electric motor, a starter motor shaft assembly with an
internal sprag clutch.
Power
The power supply to the starter is 28 volt dc from the battery or external dc
power connection.
Operation
The starter is energized by the action of the APU switch. !t wiIl continue to
drive the APU until 55% RPM. The power supply to the starter is controlled by
the FADEC. The starter brushwear switch is located inside the starter. This
switch is Iocated inside the starter. This switch electrically signals the FADEC
when 75% brushwear occurs.
Monitor
The starter operation is monitored by the dc ammeter on the P5 panel in the
flight compartment and the FADEC located in the aft cargo compartment.
IGNITION / STARTING
49-40
FWD
FWD
GEARBOX
APU CONTROLS
49-60
APU CONTROLS
The APU control system consists of manual and automatic controls for
Start Sequence.
Speed Governing.
Load Control.
Shutdown.
Fault Detection and Indication.
Fault History and Memory.
APU control during all phases of operation is primarily the function of the FA-
DEC, however, other components are also active in controlling operation.
System Description
The primary APU control system consists of the following:
--Full Authority Digital Electronic Control (FADEC)
--APU Control Unit ( M28O Module )
--Speed Sensors (2)
--Ambient Temperature Sensor
--Ambient Pressure Sensor
For Training Purposes Only
APU CONTROLS
49-60
APU
CONTROL UNIT
FWD OVERHEAD PANEL P 5
EMU
FLIGHT DATA
AQUSITION UNIT
( FDAU )
AIR /GRD
APU CONTROL
FADEC
ON
For Training Purposes Only
OFF
FWD OVERHEAD
PANEL P5
APU CONTROLS
49-60
Load Control.
APU CONTROL UNIT M280 FADEC M3056
Shutdown.
Fault Detection, Protection and Indication.
Fault History.
Recording of engine operating history and provisions for communicating the
engine functional status, fault assessment, and operating history to the Digital
Flight Data Acquisition Unit. The DFDAU compiles this information and then
For Training Purposes Only
APU CONTROLS
49-60
AFT CARGO
E 3 ELECTRONIC SHELF
DOOR
AFT CARGO
COMPARTMENT
CIRCUIT BREAKER
For Training Purposes Only
769273
APU CONTROLS
49-60
FADEC DESCRIPTION
The FADEC will conduct a self--test and initialization procedure. Following a of view. You can then push the FAULT DlSPLAY switch on the FADEC and still
successful self--test, the FADEC wilI enter into a watch state in which it moni- see the FADEC BITE code for the last auto shutdown.
tors APU startup and continuous operation. If a component fails, depending on
the severity of the situation, the FADEC will either shutdown the APU with a Start Prepare Test.
FAULT light displayed on the overhead P5 or illuminate a MAlNT light also on When you move the APU master switch from ON to START then to ON, the
the P5, but continue to operate. fault display will show the result of the start prepare test. When the APU oper-
ates, the fault display will show the condition of the APU system continuously.
LED Display
If the airplane is on the ground and the APU does not start or has an automatic
Faults and warnings are displayed on the alpha numeric display on the front of shutdown, do not try a subsequent start until you look at the FADEC. When
the FADEC. Faults/warnings are displayed in the order of occurrence with criti- you move the APU master switch to the OFF position and then to START, the
cal faults taking precedence over warnings. This data is just for the present FADEC BITE code from the last auto shutdown will not show. The problem
APU cycle. Historical data can be accessed via the Fault Data switch. The fault from the first start can possibly not occur again on the subsequent start.
indication will be cleared once the fault condition has been corrected and a new
You must have the APU Master switch in the OFF position to make the FADEC
APU cycle is initiated. It is not until the FADEC senses the fault again, that it
BITE code from the last auto shutdown show.
will display it on the LED.
For the situation in which a fault occurs, and power is removed from the air- Nonvolatile Memory
plane (Bat switch is placed to the OFF position), the FADEC will retain the Five categories of data will be transmitted to the DFDAU as part of the APU
fault(s). condition monitoring. These are:
FADEC BITE Test Procedure CATEGORY PARAMETER
Set the APU Master switch to the OFF position. Life Cycle Engine I.D. Number
Set the BAT switch to the ON position. Data Hours of Operation
Push the FAULT DISPLAY switch on the FADEC. Number of Starts
The fault display on the FADEC will show firstly the APU Identification Number Real Time EGT
( ENID ). Then the fault display will show the FADEC BITE code (s) of the Operating Speed
given faults of the last APU auto shutdown or maintenance data ( first history
Parameters Fuel Flow
record ) or OK if there were no FADEC BITE code (s) found by the FADEC.
Inlet Pressure
Following comes 11 history records (second history records ), a FADEC BITE
For Training Purposes Only
Inlet Temperature
code or maintenance data or OK will show for five seconds. After one compled
cycle the FADEC BITE code ( first hystory record ) from the last APU auto Real Time 3 Fault Codes
shutdown or maintenance data or OK will show again for 10-15 seconds. After Fault Data 12 History
10-15 seconds the fault display go out of view. The ARlNC 429 transmission take place in the continuous broadcast mode
and shall commence when the FADEC is powered up through the APU switch
Power Up Self Test.
or the display power switch.
When you move the APU Master switch from OFF to ON, the FAULT DISPLAY
will show the result of the power-up self-test of the FADEC. lf you move the
APU master switch from ON to OFF and you did not move it to START, the re-
sult of the power-up self-test for the FADEC will show for 5 minutes then go out
APU CONTROLS
49-60
RN 09 RN 02
FADEC BITE CODE DECCODING LABEL
FADEC
IDENTIFICATION RN 08 RN 03
PLATE
FADEC
DATA RN 07 RN 04
For Training Purposes Only
CONNECTOR
RN 06 RN 05
FADEC M3056
FADEC DISPLAY SEQENCE WHEN FAULT DISPLAY SWITCH IS PUSHED.
1 THE FAULT DISPLAY WILL SHOW THE LAST FOUR NUMBERS OF THE IDENTIFICATION NUMBER ( ENIT )
2 THE FAULT DISPLAY WILL SHOW ”OK ” WHEN NO FAULTS OR MAINTENANCE DATA ARE IN MEMORY.
3 THIS IS THE SECOND HISTORY ( RN ) RECORD. UP TO 11 HISTORY RECORDS ARE POSSIBLE. THE FAULT
a53173 DISPLAY WILL SHOW ”N/A” WHEN NO HISTORY RECORDS ARE IN MEMORY.
APU CONTROLS
49-60
APU CONTROLS
49-60
MOUNTING FLANGE
FWD
AMBIENT PRESSURE
TRANSDUCER
MOUNTING FLANGE
For Training Purposes Only
AMBIENT
TEMPERATURE
SENSOR
FILLER PORT
FOR THE OIL TANK
FWD
833587 833686
APU CONTROLS
49-60
SPEED SENSOR
Speed Sensor ( 2 )
The two speed sensors deliver analog signals to the FADEC for speed sensing.
The FADEC uses this information to operate start sequencing, condition moni-
toring and provides overspeed and underspeed control.
The speed sensors are located inside of the engine air intake muff and are
mounted on the intake-housing.
The magnetic probe of each sensor extends through the housing and aligns
with the Iobes on the oil impeller. As the turbine/compressor shaft rotates, the
Iobes on the oil impeller pass by a magnetic probe on each speed sensor. This
generates a sinusoidal output signal which is then sent to the FADEC.
The loss of speed sensor will signal the FADEC to give a MAINT light on the
P5 panel. The loss of both speed sensors will result in an automatic shutdown
and a FAULT light.
For Training Purposes Only
APU CONTROLS
49-60
PACKING
BOLT
ELECTRICAL
CONNECTOR
833716
APU CONTROLS
49-60
5. AT 5% SPEED
MAIN FUEL VALVE OPENS WHEN EGT RISE > 28 C.
FUEL SERVO VALVE MODULATES.
FADEC ACTIVATES TEMPERATURE CONTROL CIRCUIT.
HOUR METER ON.
START COUNTER PULSE.
APU CONTROLS
49-60
100% 10
98% 9
90%
80% 8
70% 7
APU 60%
MOTOR 55% 6
RPM%
50%
40%
30%
20%
10%
5% 5
For Training Purposes Only
2% 4
1 2 3 TIME
83952
APU CONTROLS
49-60
APU FUEL SHUT OFF VALVE CLOSE.( ONLY WHEN : FIRE DETEC-
TION.)
APU AIR INLET DOOR CLOSE. ( ONLY WHEN : FIRE DETECTION ).
HOUR METER OFF
APU CONTROLS
49-60
1
MASTER CONTROL SWITCH OFF
OR AUTO SHUT DOWN
APU
MOTOR
RPM%
For Training Purposes Only
TIME
83952
E. G. T. INDICATING SYSTEM.
EGT Indication provides a means of monitoring the efficiency of the APU dur-
ing Startup, run (Ioaded or unloaded) and shutdown.
The EGT Indicating system consists of:
2 Thermocouples, located in the exhaust duct.
Event Monitoring Unit, mounted on the cooling air duct.
FADEC, mounted in the aft cargo compartment.
Balancing Resistor, located in the forward right sidewall of the flight deck. .
EGT Indicator, mounted in the P5 panel on the flight deck.
Once the APU switch has been placed to the START position, 28v dc is pro-
vided to the FADEC, which will then allow an EGT signal to be sent to the indi-
cator on the flight deck. Indication wilI continue during operation and until five
minutes after shutdown. At this time, the time delay will prevent 28v dc to the
FADEC.
The thermocouples sense the exhaust gas temperature and convert it to an
electrical signal. This signal is sent to the Event Monitoring Unit (EMU), and
then to the FADEC. The FADEC uses EGT to modify fuel scheduling and mod-
ulate the Bleed Air Valve. The signal is also sent through a balancing resistor to
the EGT indicator on the PS panel.
For Training Purposes Only
EGT
INDICATOR
COCKPIT
P5 O/H PANEL
COCKPIT
EGT THERMOCOUPLE 1
BALANCING
APU RESISTOR
EXHAUST COCKPIT
EGT THERMOCOUPLE 2
FADEC
THERMOCOUPLES ( 2 )
The chromel / alumel thermocouples extend into the exhaust stream to sense
APU exhaust gas temperature. The milli--volt output of the thermocouple is
transmitted to the FADEC which analyzes the signal for appropriate scheduling
of fuel and control of bleed air.
Event Monitoring Unit ( EMU ).
The Event Monitoring Unit (EMU) houses the resistive temperature detector
and also provides indication of APU hours and starts.
The EMU is located on the cooling air duct forward of the cooling fan.
EGT signals are sent to the EMU before going to the FADEC. The resistive
temperature detector in the EMU provides cold junction compensation for the
EGT thermocouples. Displayed on the EMU are the number of APU hours and
starts. Hours are not recorded until 98% RPM is accomplished.
FADEC
EGT input to the FADEC affects fuel scheduling. The EGT signal is also pro-
vided through a balancing resistor to the flight deck.
For Training Purposes Only
FWD
FWD
COOLING
AIR
DUCT
For Training Purposes Only
EVENT
MONITORING
THERMOCOUPLES UNIT
01901 03688
833726 STARTS HOURS 803964
0.05Q 0.05Q
EGT INDICATOR 7
A9
SPOOOL B8 6
THERMOCOUPLE
0.05Q B9 18
D1 4
CH 1
39 1
0.15Q 0.15Q 0.15Q 0.15Q 5
C1 20 2
D2 12 E1 AL
38 3
EGT RESISTOR
THERMOCOUPLE
C2 22 3 CH
2
D3 40 6
1
C3 21 7
2
AL
EVENT
FADEC MONITORING
UNIT
For Training Purposes Only
STATION 851
AIRPLANE
WIRING APU ENGINE HARNESS
795321
EGT Indicator
shows the APU Exhaust Gas Temperature in Celsius
compensates and correct cockpit temperature changes.
is located in the Cockpit P5 Overhead Panel
For Training Purposes Only
FLIGHT COMPARTMENT
APU EGT
BALANCING
RESISTOR
FWD
AIRPLANE LEADS
VERNIER COURSE EGT
ADJUSTMENT ADJUSTMENT APU
TERMINAL TERMINAL EGT
INDICATOR
ID-MODULE
49-70
ID-MODULE
The Engine Identification Module is installed on the APU and provides a resis-
tance value to a microprocessor. The microprocessor interprets this value and
enables the FADEC to identify the APU by a number from 0 to 2047.
The Engine Identiflcation Module can be physicalIy altered to select a desired
ID number. This is accomplished by removing the ID module protective cover
exposing a small printed wiring assembly. By cutting one or more copper clad
circuits, resistance is modified, which represents a number and is assigned to
that particular APU.
Location
The Engine Identification Module is installed on the left side of the APU below
the ignition exciter.
Example
The engine identification number can be represented from 0 to 2047 by physi-
cally cutting the appropriate copper clad circuits.
The values are as follows:
W1 =1
W2 =2
W3 =4
W4 =8
W5 =16
W6 =32
W7 =64
W8 =128
For Training Purposes Only
W9 =256
W10 =512
W11 =1024
APU SN Nr. 296 is installed
Cut W9 = 256
Cut W6 = 32
Cut W4 = 8
ID-MODULE
49-70
ELECTRICAL
CONNECTOR
PRINTED
WIRING
BOARD
PAD
REMOVABLE
PROTECTOR
COVER
Figure 41 ID-Module
SCL VRC/RRH 26.08.2005 Page: 81
AIRBORNE AUXILIARY POWER B737-300/400/500
Lufthansa LAN Technical Training
INDICATING
49-70
SRVB
LOP
STRT
INDICATING
49-70
RELATED APU INDICATING LIGHT TROUBLE SHOOTING FAULT INDEX AMM 49-00-00 PAGE 108 TABLE 101
*(1) IF BOTH SPD1 AND SPD2 ARE SET, *(2) IF BOTH TC1 AND TC2 ARE SET, *(3) IF ECU SHOWS AFTER REPLACE-
THE FAULT LIGHT WILL SHOW. THE FAULT LIGHT WILL SHOW. MENT OF THE FADEC, DO THESE
MCDU DISPLAY: BOTH N SENSORS FAIL MCDU DISPLAY: BOTH TC FAIL. PROCEDURE ”SPD 1”( FIG 121) AND
FADEC ”SPD 2” ( FIG 122 ).
INDICATING (MCDU)
31-10
A Current Transformer measures the Gen. Load. The wires are routed . 0 +/-- Z DEL / CLR
via a solid state circuit (installed in the Misc. Switching Unit) to the
MCDU.
For Training Purposes Only
INDICATING (MCDU)
31-10
MENU
NEXT
PAGE
B737
TABLE OF CONTENTS
ATA 49 APU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 APU SHUT DOWNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
E. G. T. INDICATING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
APS 2000 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 THERMOCOUPLES ( 2 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
PANEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 EGT BALANCING RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ACCESS DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ID-MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
APU DRAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FADEC BITE CODES AND LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
AIR INLET DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MCDU, APU DATA PAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
BOROSCOPE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
APU LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OIL TANK DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OIL TANK SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OIL SYSTEM SCHEMATIC DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 22
APU FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
APU FUEL SHUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ELECTRONIC FUEL CONTROL AND PUMP ASSEMBLY . . . . . . . . . 32
START PURGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FUEL SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
APU AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
APU BLEED BLEED AIR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
BLEED AIR VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
APU COOLING AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
APU COOLING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
IGNITION AND START SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
IGNITION COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 52
STARTING COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 54
STARTING COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 56
APU CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
APU CONTROL UNIT/FADEC DESCRIPTION . . . . . . . . . . . . . . . . . . 60
FADEC DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
AMBIENT PRESSURE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . 64
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
APU START SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
B737
TABLE OF FIGURES
Figure 1 APS 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 36 Normal/Auto Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 2 APU Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Figure 37 EGT Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 3 APU Access Door and Shroud. . . . . . . . . . . . . . . . . . . . . . . 7 Figure 38 Thermocouples and Event Monitoring Unit. . . . . . . . . . . 75
Figure 4 Shroud Drains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Figure 39 APU E. G. T . System Schematic . . . . . . . . . . . . . . . . . . 77
Figure 5 APU Air Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 40 EGT Balancing Resistor and Indicator . . . . . . . . . . . . . . 79
Figure 6 Boroscope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Figure 41 ID-Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 7 Lubrication Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 42 LOP FADEC Bite Code Indication. . . . . . . . . . . . . . . . . . . 83
Figure 8 Lubrication System Components . . . . . . . . . . . . . . . . . . . . 17 Figure 43 MCDU APU DATA Display . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 9 Lubrication System Components . . . . . . . . . . . . . . . . . . . . 19
Figure 10 Oil Tank Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 11 Oil Servicing System Schematic . . . . . . . . . . . . . . . . . . . . 23
Figure 12 Fuel System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 13 APU Fuel Shutoff Valve and DC Fuel Boost Pump . . . . 27
Figure 14 APU Fuel Shutoff Valve Control . . . . . . . . . . . . . . . . . . . . 28
Figure 15 DC Fuel Boost Pump Control . . . . . . . . . . . . . . . . . . . . . . 29
Figure 16 Fuel Heater and Flow Control Valve . . . . . . . . . . . . . . . . 31
Figure 17 Fuel Control and Pump Assembly . . . . . . . . . . . . . . . . . . 33
Figure 18 Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 19 APU--MAX. EGT CHART . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 20 Bleed Air Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 21 APU Bleed Air Components . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 22 APU Bleed Air Valve Schematic . . . . . . . . . . . . . . . . . . . . 43
Figure 23 APU Cooling Air Schematic . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 24 Cooling Air Components . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 25 Cooling Air Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 26 Ignition / Starting Schematic . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 27 Ignition Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 28 Start Relay Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 29 Starter Motor and Shaft Assembly . . . . . . . . . . . . . . . . . . 57
Figure 30 APU Control Sytem Schematic . . . . . . . . . . . . . . . . . . . . . 59
Figure 31 APU Control Unit and FADEC Component . . . . . . . . . . . 61
Figure 32 FADEC Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 33 Amb. Press. Transducer and Amb. Temp. Sensor . . . . 65
Figure 34 Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 35 APU Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69