Neo LEAP-1A - IDG Oil Delta Temp and High Oil Temp Issues

Reference: 24.21.00.061 Issue date: 13-DEC-2022 Last check date: 23-DEC-2022 Status: Open
A/C type/serie: A319, A320, A321 ATA: 24-21
Engine manufacturer: CFMI Supplier: HAMILTON SUNDSTRAND, ...
Purpose / Reason for revision: New mitigating action highlighted: Flushing of the IDG Cooling System
Engineering Support Status: Open
Description
* A320NEO Leap operators have reported recurrent class 2 fault
Message IDGx OIL DELTA TEMP/GCUx recorded in the PFR.

This message is triggered when the difference between the IDGx oil
temperature Out and In is greater than 28°C during 15 seconds. (Oil Out
temp - Oil In temp > 28⁰C for at least 15 sec).

* In addition, the oil at sight glass is frequently observed, short after engine
shutdown, above the green band (middle yellow band) or in the lower red
band to be slowly stabilized in the green band.

Investigation Status Mitigation

laboratory, where an internal IDG “Slow Drain Down” phenomenon is recommend performing a flushing of the IDG if the failure message appears

observed after having disconnected the overflow drain hose. frequently. This will drastically reduce the foaming phenomenon due to silicon
contamination.

* During recent oil sampling campaign, analysis have been showing abnormal Terminating action
levels of Silicon. Silicon contamination has a negative impact on the cooling All improvement avenues (AMM improvements, GCU, FRV logic
system due to foaming. Several cases of High/Delta Temp events have been modification,..) are being evaluated. Once the root cause investigation phase
correlated with a high level of Silicon > 12ppm. is completed (by Q1 2023), the way forward will be communicated to all
A320NEO operators.
* Additional endurance tests are required by Collins in order to check new
brand diode pack Semtech and Power-x installed in old machines already
cleaned. Root cause analysis expected by Q12023.
Applicability:

A320FAM Neo Leap aircraft

Reference / Documentation:

Ref A: AMM Task 24-21-00-920-803-A Drain, Remove and Discard the Scavenge and
Charge Filter Elements and Replenish IDG Oil System.

Ref B: TSM Task 24-00-00-810-812-A & 813-A High-Delta Temperature Condition of the
IDG 1(2) Oil Sensors.

Ref C: AMM Task 12-13-24-612-804-A - IDG Servicing - Filling of the IDG with Oil or
Addition of Oil after a Level Check.

Ref D: AMM Task 24-21-00-612-807-A Servicing of the Integrated Drive Generator (IDG)
after Oil Chemical Contamination.
Ref E: ISI 24.22.00010 - IDG high oil temperature induced by overservicing.

Ref F: AMM Task 71-00-00-700-805 - Dry-Motoring Check.

Description
The class 2 IDGx OIL DELTA TEMP/GCUx message is recurrently displayed, on ground, on
the ECAM Status page and recorded in the PFR mainly during taxi-out, take-off, climb or
just after top of the descent.
By design, this message is triggered when the difference of temperature between Oil-in and
Oil-out ports of IDG is greater than 28°C for at least 15 seconds.
It gives an indication of a possible internal mechanical issue of the IDG. However, in the
case of the A320FAM aircraft with Leap engines, most of the time, the triggering of this
Failure Message is not associated with a mechanical failure of the IDG.
In-flight, on the ECAM ELEC SD page, the IDG temperature will be displayed in green and
flashing if it is above 147°C. The rise of temperature and the cooling of the oil does not last
more than 6-8 minutes with temperatures that can reach 165°C. Some exceptional cases
have been reported with temperatures close to the OVHT condition. Finally the temperature
is stabilized in its nominal range when the FRV is commanded to open.
In addition, some operators have informed Airbus that sometimes, after engine shut down:
- The IDG oil level is above the green band, which can be in the middle or higher on the yellow
band on the IDG sight glass.
 - IDG oil level is initially indicated in the lower red band and slowly stabilizes, around 30 mins
after, in the green band or top of green band of the IDG sight glass.

Consequence
On ground:
In case of log book entry, TSM 24-00-00-810-812-A (813-A) “High-Delta Temperature
Condition of the IDG 1(2) Oil Sensors” need to be applied.
- Disregard if Delta Temp is not accompanied by other ATA24 message and triggered during
flight phase 2, 4, 5 or 6.
- Apply the AMM task Ref D to perform an IDG servicing that includes the oil circuit flushing
procedure.

In-flight:
The IDG 1(2) continues to operate and the aircraft electrical network is supplied normally.
The Crew may decide to apply the ELEC Advisory FCOM procedure if the IDG temperature
is observed flashing (T°> 147°C) at the ECAM SD ELEC Page.

Investigation Status

As Highlighted during the latest A320NEO webinar, Laboratory tests performed at the
beginning to verify whether fill pressure can open the Cooler Bypass Valve during IDG
servicing were inconclusive, in fact, the bypass valve remains closed even at pressures
above 35psi. AMM recommendation to service the IDG at less than 35 psi remains valid.

During the second part of the tests, different external circuit configurations were tested in
the laboratory, where an internal IDG “Slow Drain Down” phenomenon is observed after
having disconnected the overflow drain hose. This situation will increase the oil level in the
sight glass and can be considered stable 2 hours after the engine shutdown. An
Overserviced condition is frequently reported from the field showing the level above the
middle of the yellow band. A slight IDG overserviced condition would increase the IDG heat
rejection, resulting in an increase in temperature when engines are set to idle.

During recent oil sampling campaign, analysis have been showing abnormal levels of Silicon.
Silicon contamination has a negative impact on the cooling system due to foaming. Several
cases of High/Delta Temp events have been correlated with a high level of Silicon > 12ppm.
Flight testing was successful in highlighting contributors and understanding the system.
High oil volume is a contributor.
Several Lab tests launched, in supplier side, using the knowledge gained in the Airbus
investigation. To understand servicing oil volume variation, Heat Rejection and IDG silicon
release.
Complementary tests performed by Collins using brand new Semtech and Power-X diode
packs installed in already cleaned machines did not permit to conclude that the source of
Silicone is the diode pack itself. This requires to formalize additional endurance tests for
which the result are expected by Q1-2023.

Mitigation / Interim Plan

Oil circuit flushing recommendations

- Based on Neo Leap fleet data, the maximum number of Delta Temp messages are triggered
during the second month of operations to decrease thereafter. Therefore, it is recommended
to perform the flushing procedure as per Ref D during the first IDG servicing (MPD ref.
242000-24-1) which is required at 150FH after A/C delivery, then 800FH if the Delta Temp
message is still observed. Experience shows that Silicon is accumulating with hours of
operations and, the higher the level of Silicon, the greater the probability of IDG system
thermal issues. 150FH servicing is a very suitable moment to clean the system with an oil
flushing.

Oil level check recommendations

Considering the current system behavior, Airbus makes the following recommendations:

- During IDG servicing (Ref C & D) it is recommended to check IDG oil level within 30 min to
60 min after an engine rotation. This is valid at any time when IDG oil level needs to be
checked.

- If within 30 min to 60 min after an engine rotation the oil level should be adjusted, it is
recommended to perform an oil servicing as per Ref C (instead of an IDG draining by
connecting only the overflow drain hose). Indeed, both filling pressure & overflow drain hoses
have to be connected and pump oil into the circuit repeating steps 4.A to 4.D of the AMM
Task Ref C.

- After 60 minutes, the oil level could be found within the yellow band with cold oil due to the
slow drain down phenomenon as explained above. In that case, it is recommended to
perform a dry-motoring as per Ref F and to check again the oil level.
Note: ISI Ref E provides additional information on key points of good practices when the
servicing of the IDG is performed.

Operational Recommendations

Refer to the Flight Operations & Training section of this TFU.

Permanent Solution

All improvement avenues (AMM improvements, GCU modification,…) are being evaluated.
Once the root cause investigation phase is completed by Q1-2023), the way forward will be
communicated to all A320NEO operators.
 Survey for the Engineering Support section

Flight Operations and Training Status: Open Modification on Operational Impact: NO

Applicability:

A320FAM Neo Leap aircraft

General Overview

IDG OIL TEMP ≥ 147°C may trigger in flight.

Mitigation Mean

The QRH and FCOM ECAM Advisory IDG OIL TEMP procedure will be replaced with the following:

An IDG oil temperature increases could be related to the IDG oil cooling system.
To reduce IDG oil temperature increases before limits are reached, the following is recommended:
1. Low Speed – Increase engine speed to increase fuel flow, and thereby cool IDG oil
2. High Speed – Reduce IDG load, if possible (GALLEY or GEN OFF). If required, restore when the temperature has dropped. Restrict
generator use to a short time, if the temperature rises again excessively.

Additional Note

QRH and FCOM will be updated at the next suitable opportunity.

Survey for the Flight Operations and Training section

General Information
Potential impact: Maintenance, Operational Reliability
Key information: In-Service Issue
Solution benefit:
First issue date: 30-JAN-2017 Issue date: 13-DEC-2022 Last check date: 23-DEC-2022

Technical parameters
ATA: 24-21
A/C type/serie: A319, A320, A321
Engine: LEAP-1A26
Engine manufacturer: CFMI
Fault code/ECAM
IDG1 (E1-4000XU) OIL DELTA TEMP/ GCU1 (1XU1)
warning:
FIN: 4000XU
Part Number: 1718205, 1721152
Supplier: HAMILTON SUNDSTRAND, HAMILTON SUNDSTRAND CORPORATION

Attachments
N/A

Links
Other articles (ISI/TFU):
- 24.22.00010
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