PBS SAFIR 5L Operation And Attendance Manual Download

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PG 01-31

AUXILIARY POWER UNIT

SAFIR 5L

OPERATION AND ATTENDANCE MANUAL

ISSUED ON 4/2015

April 2015

Summary of Contents for SAFIR 5L

Page 1: ...PG 01 31 AUXILIARY POWER UNIT SAFIR 5L OPERATION AND ATTENDANCE MANUAL ISSUED ON 4 2015 April 2015...

Page 2: ...UNIT SAFIR 5L OPERATION AND SERVICE MANUAL PG 01 31 Issued on April 2015 This document is the property of PBS Velk B te a s and it is illegal to copy use or promulgate it as a whole or in parts for a...

Page 3: ...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 based on the requirements from the operation APU Fr...

Page 4: ...in Use 23 APU Actuation in flight 24 Other Limits 24 4 SERVICE INSTRUCTIONS 25 General Survey 25 Assembly and Operation Instructions 25 Instructions for Replacement of APU In Operation 27 Activation...

Page 5: ...Fuel System Diagram 13 2 Oil System Diagram 14 3 Air System Diagram 15 4 Wiring Diagram with control box LUN 3594 04 16 5 APU Function Flow Chart 17 6 Timing Behavior of APU Start and Operation 18 7 T...

Page 6: ...he time till the complete overhaul The adherence to these instructions is the prerequisite of achieving a reliable operation and endurance of APU The minute command of these instructions is therefore...

Page 7: ...form to the class 10 11 according to GOST 17216 71 or 7 according to NAS 1638 Oil AEROSHELL TURBINE OIL 500 a 560 according to MIL L 23699D MOBIL JET OIL II according to MIL L 23699D IPM10 according t...

Page 8: ...x current consumption 1 5 servo operated valve current consumption 0 150 m modulation 250 Hz 500 mV non return valve opens when pressure exceeds 10 kP thermoregulator 32 89 618 F air relief valve open...

Page 9: ...ubular output filter filter efficiency 80 m Oil pump LUN 6320 8 description single stage drive from APU gear change over ratio 1 7 Oil filter 490131 01 filter efficiency 35 m differential pressure ind...

Page 10: ...or air inlet temperature 190 374 F 60 60 75 982 F 140 018 F Venturi tube purpose 33 mm APU protection part of the anti stall bleed valve restricting the air quantity from the compressor and protect tu...

Page 11: ...d 89 46 400 rpm APU protections levels of setup maximum speed 109 56 660 rpm sub speed 79 41 200 rpm closing during actuation when the exhaust gas temperature does not reach 150 302 F within 13 sec cl...

Page 12: ...2 5 3 kV number of outputs for ignition plug 1 Type of ignition plug The interconnecting conductor length1100mm 85500 11 490510 01 Electric starter type 490110 01 output on 4600 rpm 1 25 kW maximum t...

Page 13: ...13 SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 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: ...RATION AND ATTENDANCE MANUAL PG 01 31 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 Diagr...

Page 15: ...15 SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 1 ANTI SURGE VALVE 490330 03 Fig 3 Air System Diagram 33 Bleed nozzle 27...

Page 16: ...16 SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 Fig 4 Wiring Diagram with Control Box LUN 3594 04...

Page 17: ...ave adequate signal from TP Sub speed reached in 35s ES EU disconected from the power supply Timing 13 s reached at the exhaust gases temperature 150 C 302 F Timing 35 s finished before reaching sub s...

Page 18: ...idling 89 6 Reaching operating speed 100 cold and hot start of the main engines 7 APU cut off by pilot after finishing the main engine starting by switching off the switch DELAY STOP Reaching idle 89...

Page 19: ...APU sub speed within 35 s 4 APU switch off after 35 s resulting from low oil pressure 5 APU switch off resulting from reaching over speed 6 APU switch off resulting from decrease of APU speed bellow t...

Page 20: ...20 SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 1 Electr starter Conversion ratio 1 1 96 2 Oil Pump Conversion ratio 1 7 Fig 8 Kinematic Diagram of APU Gear Box...

Page 21: ...rruption of APU operation exceeding 1 month see Chapter 5 The method of performance is the same as in Item 2 2 without ignition device circuit switched on breaker 5A APU will automatically stop in 13...

Page 22: ...erature of 60 o C 76 o F on the prerequisite that no part of the oil and fuel loop is subcooled to less than 40 o C 40 o F Before actuating APU at temperatures below 40 o C 40 o F on the ground when t...

Page 23: ...angular speeds for the three axis of airplane are linear overload n 5 g n 11 4 g nz 3 g angular acceleration 4 5 rad sec 2 25 rad sec 2 z 15 rad sec 2 APU is resistant to the effect of negative linear...

Page 24: ...reed with original producer of APU Maximal exhaust gas temperature 850 C Nominal net voltage 28 VDC Precondition of successful APU start is that supply conductors of electric starter have the adequate...

Page 25: ...nd fuel pump are located on the airframe separately Return fuel filter and anti stall bleed valve is installed in the piping of the system For correct function of APU the following must be ensured ran...

Page 26: ...oil level There must be adequate space under the oil cleaner 490131 01 for easy dismounting of the filter body free space under filter body min 80 mm There must be adequate space under the Blok of fi...

Page 27: ...cturer Perform the mounting of the ignition plug in accordance with Article 4 8 8 Install APU and other devices on the airplane according to the reference manual Detach the blinding plugs gradually du...

Page 28: ...ssible as replacement Other replacements must be agreed on with the Manufacturer Oils of different types must not be mixed The oil used must be thoroughly drained from all devices of the APU Oil Syste...

Page 29: ...ces The APU 490100 02 The Block of Filter and Servo 490740 01 The Return Fuel Filter LUN 7616 8 The Oil Tank 490620 03 3 After 150 30 service hours or 1000 APU actuations at the latest the one which w...

Page 30: ...16 8 2000 8 300 Control Box LUN 3594 04 2000 8 300 Ignition exciter 81550 01 2000 8 300 Interconnecting Conductor 490510 01 2000 8 300 Ignition Plug 85500 11 1000 4 150 Temperature Transmitter LUN 137...

Page 31: ...oreign matter and the possible products of corrosion by a wiping cloth X X X X 3 Check the leak tightness of the APU fuel oil installation Eliminate the possible presence of working liquids by tighten...

Page 32: ...4 Inspection of Fuel Filter from Block of Filter and Servo in case of signaling of clogging X 12 4 8 5 Inspection of the Return Fuel Filter X 13 4 8 6 Inspection of the Oil Filter in case signaling of...

Page 33: ...lock and unscrew bolts 4 21 pcs using spanner s7 Dismount the combustion chamber drainage valve 5 using spanner s17 Dismantle the fuel supply line 6 on the input to fuel drainage 7 using spanner s17 S...

Page 34: ...essor overhaul with attendance of the production plant service crew Control the deposition Guide Wheel 13 with a 1st stage of Guide Wheel Guide Wheel 13 must freely slip by grooves in the outer rim on...

Page 35: ...th clean petrol or aviation petroleum Clean the filter body with petrol Lubricate the packing rings 3 4 with the APU operating oil If the packing rings are defective it is permitted to use rings from...

Page 36: ...g of the filling opening 1 and full the magnetic plug 2 Drain off the oil Remove the screen from the filler and rinse it in clean petrol Dismount oil filter 4 on output of oil tank see instruction and...

Page 37: ...cap nut against loosening with binding wire NOTE The ignition plug does not require any maintenance during operation It is prohibited to clean the surface of the insulator between the points howsoeve...

Page 38: ...pressure gauge which is mounted in place of the piping between the oil pump and the oil filter d Record the flushing of the oil pump into the oil pump certificate and into the APU Engine log book 4 8...

Page 39: ...ion using distance washers from the set of replacement parts 1 10 Check the condition of the gasket ring If defective replace it with a new one from the set of replacement parts Tighten three M2 5 bol...

Page 40: ...work into the APU Engine log book including values of the measured play V 4 9 Tightening Torque for screws and nuts fastening Thread Part Position Tightening Torque M3 0 8 0 5 Nm M4 3 1 Nm M5 7 1 Nm...

Page 41: ...OPERATION AND ATTENDANCE MANUAL PG 01 31 1 Regulation casing 2 Spring 3 Spring support 4 Piston 5 Bolt 6 Cap 7 Adjusting regulating washers 8 Washer 9 Bolt 10 Plug Fig 9 Oil Pump 486130 01 1 3 4 5 6...

Page 42: ...acking 19 Sealing Washer 20 Oil Filter 21 Suction tube 22 Screw of turned neck 23 Screw of turned neck 24 Exhaust pipe 25 Clutch of exhaust pipe 26 The grounding screw M4 27 The grounding screw M5 28...

Page 43: ...43 SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 Fig 11 Permissible Defects of the Combustion Chamber 10 10 3 6 1 4 5 2 2 4...

Page 44: ...ION AND ATTENDANCE MANUAL PG 01 31 1 Filter Body 2 Filter Element 3 Gasket Ring 14 6 x 1 9 4 Gasket Ring 47 x 2 5 5 Filter and Servo Block Body Fig 12 Sectional View of the Block of Filter and Servo 4...

Page 45: ...45 SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 1 Filter Element 2 Filter Body 3 Gasket Ring 16 6x1 9 4 Gasket Ring 19 5x2 5 Fig 13 Sectional View of the Return Fuel Filter LUN 7616 8 3 2 1 4...

Page 46: ...SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 1 Main Body 2 Filter Body 3 Filter Element 4 Gasket Ring 14 6 1 9 5 Gasket Ring 47 2 5 Fig 14 Broken out Section of the Oil Filter 490131 01 1 2 3 4...

Page 47: ...1 4 2 10 6 5 8 9 7 13 12 11 1 Filler Neck with Cap and Screen 2 Magnetic Plug 3 Tank Jacket 4 Oil Filter 5 Oil Gauge 6 Safety Valve 7 Exchanger 8 Reaeration Neck 9 Neck Spout 10 Temperature Sensor Bli...

Page 48: ...UAL PG 01 31 1 Ignition Plug 2 Sealing Washer 3 Fuel Ramp 4 Casting Fig 16 Ignition Plug 85500 11 installation 1 Cup Nut 2 Contact Point 3 Terminal Fig 17 Interconnecting Conductor 490510 01 1 3 2 1 H...

Page 49: ...49 SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 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 1 2 3 4 5...

Page 50: ...0 SAFIR 5L OPERATION AND ATTENDANCE MANUAL PG 01 31 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 1 2 3 4 5 6 7...

Page 51: ...vo 490740 01 Oil filter 490131 01 and Filter in Oil tank devices after dewaxing It is recommended to perform this operation also after performing an airplane test flight at the final Manufacturer Firs...

Page 52: ...tive air humidity 65 Do not store APU directly on the ground in open air area or in damp rooms The devices of the Fuel Oil System are not dismounted from the airplane but filled with operating oil acc...

Page 53: ...ing START BUTTON the APU does not start turning APU is running for 2 sec only APU is ronning for 13 20 sec only APU runs for 35 seconds only APU not accelerate to operating speed 100 or after reaching...

Page 54: ...gle way Valve of Block of Filter and Servo Check Valve SDF Signaling Device of Fuel Filter Clogging part of the Block of Filter and Servo SDO Signaling Device of Oil Filter Clogging differential press...

Page 55: ...es the EC Control electronic Faulty operation of the electronic circuit the Control Box APU rotor revolves freely Replace ES APU Board network voltage in order Check the feeding Circuit breakers and f...

Page 56: ...re Little or no signal level of APU speed Board network voltage in order Check the feeding Cables between the pickuk of revolutions and the Control Box in order When checking the Control Box by means...

Page 57: ...ES or APU Fuel air mixture in combustion chamber has been ignited Exiter Device in operation Replace Control Box 150 C NO YES Check EGTP in 13th NO 20 YES YES NO Replace EU Check APU draining Replace...

Page 58: ...in 35th second Replace EC Clean FF Check APU Draining Replace BFS and or FP Check feeding Servovalve circuit of FC Check current at Acceleration Limiter Replace EC Check if OF is clean Replace EC and...

Page 59: ...APU via PC RS232 interface on a COM connector on Control Box and via software SAFIR Monitor Voltage of board electric network is correct Check the carrent of Servovalve Replace EC The exhaust gas tem...

Page 60: ...haust gas is 850 15 C YES NO Replace EC Check if CL and EGTP are free from defects Repair connection of EGTP or CL Replace EGTP and or CL Control lamp light Check compressor and turbine APU Replace AP...

Page 61: ...st Check if the voltage at EV3 and EV4 is correct YES NO Replace EC Check electric connection and operation of EC EV3 EV4 valves when energized are open without energized shut and tight EV2 valve in O...

Page 62: ...eeding Replace EC Check if RFF is clean check if JV serviceable Clean RFF and or JV Replace JV Check free passage of reverse fuel flow pipe Replace BFS Perform the checks error messages the EC via PC...

Page 63: ...speed YES NO Engine failure Piping between APU and ATS isnt tight Check APU rotor speed Remove untightness 95 100 Replace EC Voltage of board electric network is correct NOT TIGHT 133mA YES NO TIGHT V...

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