PBS SAFIR 5L Operation And Attendance Manual

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PG 01-31

AUXILIARY POWER UNIT

SAFIR 5L

OPERATION AND ATTENDANCE MANUAL

ISSUED ON 4/2015

April 2015

Table of Contents

Summary of Contents for PBS SAFIR 5L

Page 1 PG 01-31 AUXILIARY POWER UNIT SAFIR 5L OPERATION AND ATTENDANCE MANUAL ISSUED ON 4/2015 April 2015...
Page 2 Issued on April 2015 This document is the property of PBS Velká Bíteš, a.s. and it is illegal to copy, use or promulgate it as a whole or in parts for any other purpose without prior written consent of the Manufacturer.
Page 3: List Of Changes And Corrections
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL LIST OF CHANGES AND CORRECTIONS Change number Subject of change Validity Pages No. Performed by, date L-KSS-3874 The parameters changing of the control box From seriál 11, 59, 60 Bc. Tučková based on the requirements from the number APU 17.2.2016...
Page 4: Table Of Contents
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL LIST OF CONTENTS LIST OF CHANGES AND CORRECTIONS ........................3 LIST OF CONTENTS ................................ 4 LIST OF ILLUSTRATIONS .............................. 5 INTRODUCTION ................................6 BASIC TECHNICAL DATA ............................ 7 ...
Page 5: List Of Illustrations
Anti-surge valve P/N 490330.03 Ignition exciter P/N 81550.01 Control box LUN 3594.04 APPENDIX No.3 Auxiliary Power Unit SAFIR 5L – Interface Control Document (ICD) LIST OF ILLUSTRATIONS Fig. Page Fuel System Diagram Oil System Diagram Air System Diagram Wiring Diagram with control box LUN 3594.04...
Page 6: Introduction
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL INTRODUCTION This Manual is intended for technicians and mechanics, who support the operation of the Auxiliary Power Unit SAFIR It contains instructions for all work that will occur during the APU operation in the time till the complete overhaul.
Page 7: Basic Technical Data
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1. BASIC TECHNICAL DATA Auxiliary Power Unit Identification, type: SAFIR 5L Description: Turbo-reactive engine with automatic control and air outtake from compressor Compressor: single stage, radial See article 1.4 Technical parameters for standard conditions:...
Page 8: Fuel System
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Fuel System Description: low-pressure, with constant input flow rate, with twelve bypass nozzles and throttled output flow rate: 130±5 l.hour Max. pressure 1,3±0,1 MPа Working fuel temperature -40 ÷ +60 °C Block of Filter and Servo: 490740.01...
Page 9: Oil System
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Oil System Description: autonomous, directly deaeration with open circulation flow rate 45 l.hour oil pressure 210 kPа max. minimum oil pressure 885 kPа operating oil temperature -40 ÷ +140 °C (-40÷284 F) Oil tank: 490620.03...
Page 10: Air System
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Air System Carakteristic Output Air parameters behind anti-stall bleed valve at 100 % speed mode (for ISA, H=0m) air flow ≥1920 kg.h air presure ≥348 kPa 190 С (374 F) warming of the air in the compressor air inlet temperature -60 ÷...
Page 11: Control And Regulation System
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Control and Regulation System Description: electronic Speed transmitter: LUN 1326.03-8 purpose produces the input signal for electronic control type electromagnetic output voltage 1 V on 2145 Hz  5 % location on the APU gearbox...
Page 12: Actuating System
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Actuating System Ignition exciter P/N 81550.01 type high-energy nominal voltage 28 V output voltage 2,5-3 kV number of outputs (for ignition plug) Type of ignition plug 85500.11 The interconnecting conductor (length1100mm) 490510.01...
Page 13: Fuel System Diagram
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1 – BLOCK OF FILTER AND SERVO 490740.01 2 – ELECTRIC FUEL PUMP 490720.01 3 – RETURN FUEL FILTER LUN 7616-8 Fig.1. Fuel System Diagram...
Page 14: Oil Pump Lun 6320-8
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL FILTER 80 μm 1 – OIL TANK 490620.03 2 – OIL PUMP LUN 6320-8 3 – OIL FILTER 490131.01 4 – ELECTROMAGNETIC VALVE 486611.01 5 – ELECTROMAGNETIC FUEL VALVE LUN 2475-8 Fig.2. Oil System Diagram...
Page 15: Air System Diagram
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL ø33 Bleed nozzle ø27 1 – ANTI-SURGE VALVE 490330.03 Fig.3. Air System Diagram...
Page 16 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Fig.4 Wiring Diagram with Control Box LUN 3594.04...
Page 17 Decrease the rotational from the power supply speed at idle and two minutes waiting at idle - Auxiliary Power Unit SAFIR 5L in order to cool the - Fuel Pump turbine. - Electromagnetic Fuel Valve of Filter and Servo Block - Electromagnetic Valve of Oil Filter - Electromagnetic Valve of Oil Tank - air vent.
Page 18 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL  rpm  56650 51900 46400 41200 Times 1. Initiation of the start APU after switching on of the power supply circuit by switching on the relevant breakers and switches "RUN" and push down the "START BUTON"...
Page 19 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1. APU switch off resulting from inadequate signal level of the speed transmitter or from a speed transmitter circuit failure 2. APU switch off resulting from failure to achieve exhaust gas temperature of 150...
Page 20: Kinematic Diagram Of Apu Gear Box
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Electrоstarter Conversion ratio 1:1,96 Oil Pump Conversion ratio 1:7 Fig. 8. Kinematic Diagram of APU Gear Box...
Page 21: Operation Instructions
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL OPERATION INSTRUCTIONS Pre-Start Preparation Before actuating APU, it is necessary to perform the following: - Check the oil level in the tank - Check the seal of the air line between APU and both turbines for starting of the main engines - Switch on all APU circuit breakers and fuel delivery pump - Other works related to the pre-flight preparation APU are described in Article No.
Page 22: Operative Limits
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 3. OPERATIVE LIMITS Actuation Repeatability After APU shutdown, its next actuation can begin after 60 sec. The number of such actuations is limited till 3, it can be actuate for the 4 time firstly after 20 minutes on the ground, or after 10 minutes in the air.
Page 23: Permissible Overload With Apu Switched Off
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Permissible Overload with APU Switched off Maximum operational multiples in the APU gravity center and the limiting values of angles and angular speeds for the three axis of airplane are: - linear overload nх...
Page 24: Apu Actuation In Flight
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL APU Actuation in flight - scope of airplane instrument speed for reliable APU actuation is depending on the APU installation. This parameter should be verified by test. The common maximum flight speed for successful APU start is 214 ÷...
Page 25: Service Instructions
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 4. SERVICE INSTRUCTIONS General Survey These instructions can be used for routine work related to APU operation. Their aim is to ensure trouble-free operation from activation to complete overhaul. Trouble-free operation of APU depends predominantly on the regular and correct performance of periodic work.
Page 26 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 4.2.2. During APU installation on an airplane and its activation, it is also necessary to adhere to the following instructions:  The installation of APU and the separate devices of APU on an airplane must be approved by the Manufacturer APU.
Page 27: Instructions For Replacement Of Apu In-Operation
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Instructions for Replacement of APU In-Operation Dismantling of APU from aircraft - Perform cold start of APU (preservation) - Empty the oil tank - Dismount connector cable of APU devices, connectors and thermocouple compensation cables of exhaust gas...
Page 28: Definitions Of Periodic Work
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL from idling speed (89%) 45 – 100 sec Record activation into the certification and Engine log book. Perform the control and cleaning of filter elements of Oil filter 490131.01, Filter and Servo Block 490740.01, Return Fuel filter LUN 7616-8 and magnetic plugs in oil drain and in the oil tank after a performed first of the airplane flight-test.
Page 29 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 4.5.3. Periodic Check – work performed after 50 , 100 , 150- service hours from the last performed Periodic Check. Periodic Check of APU Periodic Check – work performed: (1) After 50 service hours or after 300 APU actuations at the latest (the one, which will come first) from the last Periodic Check.
Page 30: Time-Limits Of Activity - Technical Resource
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Time-limits of Activity – Technical Resource After the period of operation specified of Table No.1, it is necessary to dismount the APU devices listed below and to ship them to a specialized machine shop or plant to perform a complete overhaul (GO).
Page 31 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Table No. 2 Flight Preparations Periodic Check After 300 After 650 After 1000 Manual Seq. Article Scope of Work actuations actuations actuations After 100 After 150 After 50 hours of hours of...
Page 32 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Table No. 2A Flight Preparations Periodic Check After 300 After 650 After 1000 Manual Seq. actuations actuations actuations Article Scope of Work After 50 After 100 After 150 hours of APU hours of APU...
Page 33: Checking Techniques
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Checking Techniques 4.8.1. Check of the Compressor Blades Only one defect on one blade and two defects altogether for the whole compressor are permissible, when checking the entering edge of compressor blades.
Page 34 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Note: Cracks of type (1) and (2) must end at the root by a bored apertures with ø1,5 mm. The apertures must be debured.  Clean the caps a faces of the fuel nozzles (11), including the internal area between the cap and the nozzle body, by a wiping cloth,.
Page 35 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL  After two minutes of running at idle, make new check of the magnetic plugs. After that plugs mount back and secure by binding wire.  In case repeat of the chips occurrence is necessary to terminate the operation of the APU and make an entry in the log-book.
Page 36 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 4.8.6. Inspection of the Oil Filter Inspection is performed according to the following procedures: (The description is related to Fig. 14) Remove the binding wire, screw off the filter body (2) from the main body (1).
Page 37 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 4.8.8. Ignition System Inspection Inspection is performed according to the following procedures: (1) Ignition Plug (The description is related to Fig. 16)  Dismount the Interconnecting Conductor and screw off the ignition plug (1) from its casing (4) on the fuel ramp (3).
Page 38 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 4.8.9. Flushing of the Oil Pump Relief Valve If foreign matter gets under the seat of the relief valve or between the piston and the regulation casing, 81130.01 oil pump does not deliver the required oil pressure to the APU. It is necessary to flush the relief valve according to the procedure described below either directly on the APU without dismounting of the oil pump (according to Article 4.8.9.1), or on a dismounted oil pump - i.e.
Page 39 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 4.8.10. Check of the Electromagnetic Valve 486611.01 Perform the following operations during the check: а) Insulation Resistance Check - using an insulation tester with direct voltage of 100 V at relative humidity of 30 ...
Page 40 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL  Brushes shorter than 11 mm must be changed for new from set of spare parts;  The brushes put back inside in opposite sequence;  Check the free moving of brushes and right position of springs;...
Page 41: Oil Pump
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Regulation casing Spring Spring support Piston Bolt Adjusting (regulating) washers Washer Bolt Plug Fig. 9. Oil Pump 486130.01...
Page 42 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Magnetic Plug 19. Sealing Washer Magnetic Plug 20. Oil Filter Spout with Exhaust Cone and covers 21. Suction tube Bolt 22. Screw of turned neck Drainage Valve II 23. Screw of turned neck Screwed Fitting of return fuel Piping 24.
Page 43: Permissible Defects Of The Combustion Chamber
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Fig. 11. Permissible Defects of the Combustion Chamber...
Page 44: Sectional View Of The Block Of Filter And Servo 490740.01
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1. Filter Body 2. Filter Element 3. Gasket Ring 14,6 x 1,9 4. Gasket Ring 47 x 2,5 Filter and Servo Block Body Fig. 12. Sectional View of the Block of Filter and Servo 490740.01...
Page 45: Sectional View Of The Return Fuel Filter Lun 7616-8
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1. Filter Element 2. Filter Body 3. Gasket Ring 16,6x1,9 Gasket Ring 19.5x2,5 Fig. 13. Sectional View of the Return Fuel Filter LUN 7616-8...
Page 46: Broken-Out Section Of The Oil Filter 490131.01
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1. Main Body 2. Filter Body 3. Filter Element 4. Gasket Ring 14,6 х 1,9 5. Gasket Ring 47 х 2,5 Fig. 14. Broken-out Section of the Oil Filter 490131.01...
Page 47: Oil Tank 490620.03
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1. Filler Neck with Cap and Screen 9. Neck Spout 2. Magnetic Plug 10. Temperature Sensor Blind flange 3. Tank Jacket 11. Gasket Ring 16,6x2,5 4. Oil Filter 12. Gasket Ring 10,6x1,9 5.
Page 48: Interconnecting Conductor 490510.01
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL min 0,5 1. Ignition Plug 2. Sealing Washer 3. Fuel Ramp 4. Casting Fig.16. Ignition Plug 85500.11 installation Hexagon 22 Hexagon 22 1. Cup Nut 2. Contact Point 3. Terminal Fig.17 Interconnecting Conductor 490510.01...
Page 49: Speed Transmitter Lun 1326.03-8
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1. Speed Transmitter 2. Tooth-Wheel 3. Gear-Box Body 4. Adjusting Washers 5. Gasket ring 12,6x2,5 Fig. 18. Speed Transmitter LUN 1326.03-8...
Page 50: Electric-Starter 490110.01
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 1. Collector Casing 2. Starter Wheel 3. Clutch Body 4. Cage 5. Flange 6. Gasket Ring 48x2 7. Screw 8. Brush Fig. 19. Electric-Starter 490110.01...
Page 51: Dewaxing And Preservation In Operation
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 5. DEWAXING AND PRESERVATION IN OPERATION Dewaxing – on Delivery from the Manufacturer (replacement parts, after repair, etc.)  Unpack APU and the accessory devices. Verify identity according to assembly document. Wash the external surfaces, if they are preserved, with petrol –...
Page 52: Preservation Valid For 1 Year
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Preservation Valid for 1 Year  If even after this time, i.e. 6 months total, the APU will not be put into operation, it must be dismounted from the airplane after performing a similar internal preservation as according to item 5. All its connections must be immediately plugged.
Page 53: Defects And Troubleshooting
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL 6. DEFECTS AND TROUBLESHOOTING General Survey This chapter lists all the typical defects that can occur during the first actuation or during APU operation. The schematic diagrams can be used to determine in a stepwise manner the most probable cause of a defect and the method of eliminating it.
Page 54: Explanatory Notes To The Schematic Diagrams
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL Explanatory Notes to the Schematic Diagrams Auxiliary power unit Fuel Pump 490720.01 Block of Filter and Servo 490740.01 Fuel Cleaner of Block of Filter and Servo Return flow fuel filter LUN 7616-8...
Page 55: List Of Algorithms For Apu Function Monitoring And Troubleshooting
PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL List of Algorithms for APU Function Monitoring and Troubleshooting After the switch is set to position „RUN“ and is pressed the „START“ button, APU does not start turning Perform the checks error messages the EC via PC, RS232 interface on a COM port and software "SAFIR Monitor"...
Page 56 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL APU is running for 2 sec. only Perform the checks error messages the EC via PC, RS232 interface on a COM port and software "SAFIR Monitor" Error messages the EC – Speed signal failure...
Page 57 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL APU is ronning for 13÷20 sec. only Perform the checks error messages the EC via PC, RS232 interface on a COM port and software "SAFIR Monitor" Error messages the EC – Not igniting of Chamber...
Page 58 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL APU runs for 35 seconds only Perform the checks error messages the EC via PC, RS232 interface on a COM port and software "SAFIR Monitor" Error messages the EC- speed signaling failure- Little or no signal level of APU speed.
Page 59 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL APU not accelerate to operating speed 100 %, or after reaching the operating speed they come up for decline. Perform the checks main parameters APU via PC, RS232 interface on a COM connector on Control Box and via software "SAFIR Monitor"...
Page 60 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL During start of the APU and main engines light signal lamp „HIGH TEMPERATURE EXHAUST GAS“ for more than 5 seconds TEST During the check EC is initiation of signaling high-temperature exhaust gas is 850±15°C...
Page 61 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL APU is exessively oiled. Excessived oil consumption detected. Smoke and blasts visible in APU exhaust TEST Check tightness of oil instalation Check if the voltage at EV3 and EV4 is correct Check electric...
Page 62 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL APU operation cut off due to APU rotor overspeeding Perform the checks error messages the EC via PC, RS232 interface on a COM port and software "SAFIR Monitor" Error messages the EC- exceeding of the overspeed- The operating APU speed exceeds the set limit.speed.
Page 63 PG 01-31 SAFIR 5L OPERATION AND ATTENDANCE MANUAL The engine do not achieve 49% RPM during the time of 45 sec. since the beginning of start Voltage of board electric network is correct Check feeding voltage The APU cranks the engine...