PHENOM 100 TECHNICAL SESSION. SAMUEL PECCI OCTOBER 14 th, PDF Free Download

PHENOM 100 TECHNICAL SESSION SAMUEL PECCI OCTOBER 14 th, 2011

PHENOM TECHNICAL SESSION AGENDA Subject Air management system (AMS) Ice and rain protection system Brake system updates Tire wear update Flap system updates Electrical system contactors Starter generator update Engine start failures Pratt & Whitney Canada updates

TECHNICAL ITEMS AIR MANAGEMENT SYSTEM New Solutions for Phenom 100: Compressor Drive Module (CDM) Ground Cooling Fan (GCF) Temperature Controller (TC) Air Conditioning Hoses Flow Control and Shut-off Valve (FCSOV) Upper Air Distribution Ducts

AIR MANAGEMENT SYSTEM COMPRESSOR DRIVE MODULE (CDM) Description CDM P/N 1133630-9 introduced in April 2009 Increased reliability with respect to CDM -8 Still presenting reliability issues

AIR MANAGEMENT SYSTEM COMPRESSOR DRIVE MODULE (CDM) Investigation Moisture inside the controller affects Printed Circuit Board (PCB) Solution Increased CDM controller sealing and new protective material over controller PCB against humidity SB500-21-0005 Compressor Drive Module (CDM-10) rework, issued on May 18, 2011 Action plan Factory incorporated since 500-00256 SB with retrofit campaign (~22% done, 97 affected aircraft)

AIR MANAGEMENT SYSTEM GROUND COOLING FAN (GCF) Description Original GCF was P/N 1133710-4 Upgrade to P/N 1133710-5 via AIPC since acft 500-00016 Investigation Low GCF controller reliability

AIR MANAGEMENT SYSTEM GROUND COOLING FAN (GCF) Solution Improved GCF controller Printed Circuit Board (GCF -15) Action plan GCF -15 available via AIPC for exchange replacement (on attrition) Additional improvement (optional) GCF -6 factory incorporated from S/N 500-00270 Same GCF PCB and improved rotor (quieter) Upgrade available through chargeable SB 500-21-0008, Ground Cooling Fan Replacement, issued on October 13, 2011

AIR MANAGEMENT SYSTEM TEMPERATURE CONTROLLER (TC) Description TC -10 introduced fault log download capability, improved printed circuit board (PCB) Incorporated via SB 500-21-0003 and from S/N 500-00174

AIR MANAGEMENT SYSTEM TEMPERATURE CONTROLLER (TC) Investigation TC -10 still presented spurious failures related to Flow Control and Shut Off Valve (FCSOV), Pressure Regulating and Shutoff Valve (PRSOV), red X on synoptic page and BLEED 1(2) FAIL CAS messages. Solution TC -11, available through SB 500-21-0007, Replacement of the ECS Temperature controller, issued on October 11, 2011. Corrects spurious messages Action plan SB with retrofit campaign

AIR MANAGEMENT SYSTEM AIR CONDITIONING HOSES Description Leakages reported on CDM outlet hose, on the Heat Exchanger Pack (HXP) inlet fitting This is the most critical hose as it handles high pressures and high temperatures of refrigerant fluid delivered by the CDM to HXP HXP CDM Connection subjected to leakage from CDM

AIR MANAGEMENT SYSTEM AIR CONDITIONING HOSES Investigation Leakages caused by quality escapes on supplier s hoses Solution All hoses will be supplied only by Enviro Systems (P100 & P300) New hoses available via AIPC 21-52-06-03, Hoses instl, vapor cycle system, rear fuselage Action plan Replacement of hoses on attrition basis New hoses will be factory-installed from December 2011

AIR MANAGEMENT SYSTEM FLOW CONTROL SHUTOFF VALVES (FCSOV) Description SB 500-21-0001, Replacement of the flow control shutoff valve (FCSOV), introduced FCSOV -15/-25 Retrofit completed August 2011 (112 aircraft) Fixed controller printed circuit board (PCB) resin issues

AIR MANAGEMENT SYSTEM FLOW CONTROL SHUTOFF VALVES (FCSOV) Investigation -15/-25 presented poor electromagnetic interference (EMI) protection Solution New FCSOV s -17/-27 added a seal in the electrical connector Rework of existing FCSOV s is possible

AIR MANAGEMENT SYSTEM FLOW CONTROL SHUTOFF VALVES (FCSOV) Action plan Retrofit campaign for FCSOV -17/-27 Expected availability date October 2011

AIR MANAGEMENT SYSTEM UPPER AIR DISTRIBUTION DUCTS Description Water dripping from cockpit overhead panel gasper Investigation Duct configuration may accumulate condensed water from bleed system Depending on aircraft attitude, this water may fall over pilot or copilot head

AIR MANAGEMENT SYSTEM UPPER AIR DISTRIBUTION DUCTS Solution Duct outlet to cockpit overhead gasper re-located Drain attachment fitting chamfered LH View from AFT PRE-MOD POST-MOD

AIR MANAGEMENT SYSTEM UPPER AIR DISTRIBUTION DUCTS Action plan Factory incorporated from S/N 500-00264 Replacement on attrition basis

TECHNICAL ITEMS ICE & RAIN PROTECTION SYSTEM New Developments: De-ice System Modifications Dual Static Ports Standby (Pitot-Static) Probe Windshield Heating Control Unit (WHCU)

ICE & RAIN PROTECTION SYSTEM DE-ICE SYSTEM MODIFICATIONS Description 500-30-0004, De-ice line modification, was issued on January 31, 2011 Elimination of water accumulation spots on tubing Re-positioning of valves to keep water away Retrofit campaign ongoing (~27% done)

ICE & RAIN PROTECTION SYSTEM DE-ICE SYSTEM MODIFICATIONS Description (cont.) PRE-MOD SB500-30-0004 POST-MOD SB500-30-0004

ICE & RAIN PROTECTION SYSTEM DE-ICE SYSTEM MODIFICATIONS Investigation The electronic flow control valves (EFCVs) that supply air to the inboard boots are affected by moisture in the system Solution Installation of a water separator upstream of the EFCV to purge water from the system

ICE & RAIN PROTECTION SYSTEM DE-ICE SYSTEM MODIFICATIONS Solution (cont.) RH Point of water accumulation upstream EFCV Inboard EFCV POST-MOD SB500-30-0004 RH POST-MOD SB500-30-0004 with Water Separator installed - PRELIMINARY

ICE & RAIN PROTECTION SYSTEM DE-ICE SYSTEM MODIFICATIONS Action plan Water separator Service Bulletin under development Expected availability for 1Q2012 Note: Water separator is a complementary solution to de-ice lines re-routing

ICE & RAIN PROTECTION SYSTEM DUAL STATIC PORTS Description ADS 1-2 HTR FAULT or ADS 1-2 HTR FAIL CAS messages Investigation Heating system subject to failure due to a supplier surface finishing quality escape

ICE & RAIN PROTECTION SYSTEM DUAL STATIC PORTS Solution SB 500-34-0006, Replacement of the dual static ports, issued on March 21, 2011 New dual static ports -106/-107 with improved hardware, not affected by quality escape Action plan Factory installed from S/N 500-00236 Retrofit campaign ongoing (~63% complete, 97 affected aircraft)

ICE & RAIN PROTECTION SYSTEM STANDBY (PITOT-STATIC) PROBE Description STBY HTR FAIL message on display Investigation Heating system subject to failure due to supplier assembly process (sensor heating element - original probe -002)

ICE & RAIN PROTECTION SYSTEM STANDBY (PITOT-STATIC) PROBE Solution SB 500-34-0007, Replacement of the pitot-static probe, issued on April 14, 2011, introducing probe -003 Improved hardware made the assembly process more robust Action plan Factory installed from S/N 500-00236 Retrofit campaign ongoing (~44%, 97 affected aircraft)

ICE & RAIN PROTECTION SYSTEM WS HEATING CONTROL UNIT (WHCU) Description SB 500-30-0001, Replacement of the WHCU, issued on October 16, 2009, introduced WHCU -2 Supplier improved electromagnetic interference (EMI) resistance Retrofit campaign completed December 2010 (64 aircraft) Spurious messages still appearing

ICE & RAIN PROTECTION SYSTEM WS HEATING CONTROL UNIT (WHCU) Investigation Root cause was WHCU-2 software (messages logic) Solution Improved part WHCU -3 Improved mechanical robustness Correction of software logics (including CMC messages) Action plan Replacement via AIPC 30-42-01-01, Control unit instl, windshield heating, rack cockpit, on attrition basis Expected for December 2011

TECHNICAL ITEMS BRAKE SYSTEM UPDATES New Developments: Brake Control Unit (BCU) -5 Brake Control Valve (BCV) -2 Brake pedal assembly

BRAKE SYSTEM UPDATES BRAKE CONTROL UNIT (BCU) -5 Description (Vail, 2010) SB 500-32-0001, Replacement of Brake Control Unit (BCU -1/-2 to -3), issued on February 10, 2010, introduced BCU -3 Retrofit campaign finished March 2011 (123 aircraft) Improved left/right oscillating behavior during landing Reduced BRK FAIL messages due to monitors

BRAKE SYSTEM UPDATES BRAKE CONTROL UNIT (BCU) -5 Investigation High rate of early unscheduled removals of BCU -3 due to supplier quality and manufacturing issues Interim solution: implementation of a stress screening test Tested units were re-identified as BCU -4 No software nor hardware changes BCU -4 available through AIPC in February 2011

BRAKE SYSTEM UPDATES BRAKE CONTROL UNIT (BCU) -5 Solution New BCU -5, with upgraded software and hardware Further improvements on anti-skid releases (oscillating behavior) Enhanced protection from wheel speed transducers spikes Delay on in-flight built-in test to reduce possibility of spurious messages Improvement of CMC messages Action plan SB availability expected for December 2011 SB with retrofit campaign

BRAKE SYSTEM UPDATES BRAKE CONTROL VALVE (BCV) -2 Description BRK FAIL messages associated with BRAKE LH/RH CONTROL VALVE FAIL CMC messages

BRAKE SYSTEM UPDATES BRAKE CONTROL VALVE (BCV) -2 Investigation BCV failures were due to supplier manufacturing issues Solution SB 500-32-0004, Brake Control Valve replacement, issued on December 21, 2010, introduces BCV -2 Revised manufacturing process Action plan Factory incorporated from S/N 500-00234 Retrofit campaign ongoing (~69%, 97 affected aircraft)

BRAKE SYSTEM UPDATES BRAKE PEDAL ASSEMBLY Description Reports of left/right tendency during main brake application Investigation Pedal ergonomics affects braking control Same force applied to LH/RH pedals cause different pedal readings and different pressures applied to brakes

BRAKE SYSTEM UPDATES BRAKE PEDAL ASSEMBLY Solution Modification of pedal angle Replacement of pedal feedback springs Addition of a pedal end-of-travel stop

BRAKE SYSTEM UPDATES BRAKE PEDAL ASSEMBLY Solution (cont.) These modifications are complementary to SB 500-27-0013, Modification of the pedal position transducer stops, issued on January 13, 2011 Action plan SB availability expected on or before December 2011 SB with retrofit campaign

TECHNICAL ITEMS TIRE WEAR UPDATE Description Premature tire removals Investigation Service Letter (SL) 500-32-0005 was issued on March 04, 2011, with the intent of collecting more information on tire changes Tire service life is mainly dependent on operational aspects

TECHNICAL ITEMS TIRE WEAR UPDATE TIRES REPLACEMENT 250 225 200 175 150 CYCLES 125 100 75 50 25 0 Dec-09Jan-10 Jan-10 Feb-10 Feb-10 Mar-10 Mar-10 Apr-10 Apr-10 May-10 May-10 Jun-10 Jun-10 Jul-10 Jul-10 Aug-10 Aug-10 Sep-10 Sep-10 Oct-10 Oct-10 Nov-10 Nov-10 Dec-10 Dec-10 Jan-11 Jan-11 Feb-11 Feb-11 Mar-11 Mar-11 Apr-11 Apr-11 May-11 May-11 Jun-11 Jun-11 Jul-11 Jul-11 Aug-11 Aug-11 MONTH BLOW CUSTOMER REQUEST CUT LEAKING N/A WEAR OUT OF BALANCE

TECHNICAL ITEMS TIRE WEAR UPDATE Investigation Revised AMM tire removal criteria Issued SL 500-32-0007

TECHNICAL ITEMS TIRE WEAR UPDATE Investigation Tire service life (%) Test conditions: 35,000ft taxi cycles at 40mph, at standard load, with different tire sizes Underinflation (%) Source: Goodyear Aircraft Tire Care and Maintenance (Out/2004)

TECHNICAL ITEMS TIRE WEAR UPDATE Solution Sep/2010 May/2011 4Q2012 AMM revised SL 500-32-0007 New tire Original average tire life Revised removal criteria Tire care recommended actions Increased rubber on tread

TECHNICAL ITEMS FLAP SYSTEM UPDATES Phenom 100 Flap Position Sensor Unit (FPSU) attachment link Flap actuator jams

FLAP SYSTEM UPDATES FPSU ATTACHMENT LINK Description FLAP FAIL messages on ground Investigation FLAP FAIL messages caused by position sensor attachment

FLAP SYSTEM UPDATES FPSU ATTACHMENT LINK Solution SB 500-27-0015, Replacement of the bolt that attaches the link arm to the flap position sensor, issued on Aug 25, 2011 Action Plan Retrofit campaign

FLAP SYSTEM UPDATES FLAP ACTUATOR JAMS Investigation Supplier teardown reports revealed internal corrosion

FLAP SYSTEM UPDATES FLAP ACTUATOR JAMS Investigation (cont.) Actuator internal material is prone to corrosion Solution Under development, will include material change Action Plan To be confirmed after solution definition Expected by 2Q2012

TECHNICAL ITEMS ELECTRICAL SYSTEM CONTACTORS Description Contactors are located in the Power Distribution Units (LPDU, RPDU, EPDU)

TECHNICAL ITEMS ELECTRICAL SYSTEM CONTACTORS Description Contactors P/N SM400D117 presenting erratic behavior and quality escapes

TECHNICAL ITEMS ELECTRICAL SYSTEM CONTACTORS Investigation Reports of unusual behavior in the electrical system Displays blanking out during engine starts Aircraft not entering electrical emergency during pre-flight test Hot/hung starts Engine not starting Conflicting indications in the system synoptic page Loss of hydraulic pump power

TECHNICAL ITEMS ELECTRICAL SYSTEM CONTACTORS Solution Upgraded contactor P/N SM400D117-1 SB 500-24-0008 Replacement of LPDU, RPDU and EPDU contactors, issued on August 26, 2011 Action plan Retrofit campaign will resume by the end of October 2011 (supplier parts availability)

TECHNICAL ITEMS STARTER GENERATOR UPDATES Description Reports of failed starter-generators were received

TECHNICAL ITEMS STARTER GENERATOR UPDATES Investigation During removal and inspection of affected starter-generators, the following conditions were identified: Supplier bearing failure and commutator brazing quality escape

TECHNICAL ITEMS STARTER GENERATOR UPDATES Interim solution SB 500-24-A007 Replacement of the starter-generators, issued March 29, 2011 Starter-generators below 350FH shall be replaced before they reach 400FH Starter-generators above 350FH shall be replaced in the next 50FH Parts availability is defined by Embraer in accordance with aircraft utilization. Highest-time aircraft will have priority for the replacement of starter-generators

TECHNICAL ITEMS STARTER GENERATOR UPDATES Final solution New starter-generators are under development Availability scheduled for 3Q2012

TECHNICAL ITEMS ENGINE START FAILURES Description Difficulties to start the engines (on ground) Three possible scenarios Engine does not respond to start command Hot start Engine starts with low fuel flow

ENGINE START FAILURES ENGINE DOES NOT RESPOND TO START COMMAND Investigation When a start attempt is requested, there is no response from the engine Generator Control Unit (GCU) hangs in initialization - PBIT Solution New GCU under development by the supplier, expected for November 2011

ENGINE START FAILURES ENGINE DOES NOT RESPOND TO START COMMAND Solution (cont.) Interim solution (recommendation) De-energize aircraft and disconnect Ground Power Unit (GPU) cable Re-energize aircraft and attempt to start the engine again

ENGINE START FAILURES HOT START Investigation Possible causes: 1: Battery 2 low charge 2: Generator Control Unit GCU failed 3: Contactor failed

ENGINE START FAILURES HOT START Investigation Battery 2 low charge Start is slow with N2 values taking too long to rise Fuel flow and ITT rise too fast, which may lead to an ENG EXCEEDANCE event Embraer issued two guidance documents FOL PHE500-007/11, Battery recommendations SL 500-24-003, Batteries best practices manual

ENGINE START FAILURES HOT START Solution Perform functional check in accordance with AMM and if the battery does not pass, replace the battery Interim solution (recommendation) Ensure the battery voltage is within specification for engine starts (minimum 24V)

ENGINE START FAILURES HOT START Investigation Generator Control Unit GCU failed Normal start, with fuel flow, N2 and ITT rising normally N2 starts to drop and fuel flow and ITT increase rapidly, which may cause an ENG EXCEEDANCE event Solution Replace the GCU for one with the same part number Interim solution (recommendation) Until the final solution is available, contact Embraer for troubleshooting assistance. Embraer will need the CMC data (CVDR data will speed up analysis)

ENGINE START FAILURES ENGINE STARTS WITH LOW FUEL FLOW Investigation When engine start is attempted, fuel flow, ITT and N2 rise slowly May evolve to an aborted start Solution New Fuel Metering Unit (FMU) made available by P&WC SB66043 Action plan Replace all FMU s in accordance with P&WC s retrofit plan

TECHNICAL ITEMS PRATT & WHITNEY CANADA UPDATES Pratt & Whitney Canada updates Engine No Dispatch / TLD Low Utilization Inspection (LUI) Compressor wash recommendations

PRATT & WHITNEY CANADA UPDATES ENGINE NO DISPATCH / TLD MESSAGES Description ENG NO DISPATCH CAS messages displayed Investigation On Avionics SW LOAD before version 4X ENG NO DISPATCH CAS message triggered by avionics logic. Recent Issues related to FADEC HW (P&WC SB66041) Solution SB 500-31-0006 or -0007, Installation of G1000 load 43 or 43.5 avionics software and CMC load 8 or 9 software, issued on December 21, 2010 and April 7, 2011, respectively New Engine Electronic Control (EEC) hardware P&WC SB66041 Action plan Retrofit campaign ongoing

PRATT & WHITNEY CANADA UPDATES LOW UTILIZATION INSPECTION (LUI) Description The PW617F-E Engine Maintenance Manual (EMM) requires Low Utilization Inspection (LUI) engines to be returned to an overhaul facility Maintenance Update On-wing Low Utilization Inspection (LUI) will be included in the next EMM revision (Nov 11). Additional requirements may be necessary based on inspection findings. Already available in the PW535E

PRATT & WHITNEY CANADA UPDATES COMPRESSOR WASH RECOMMENDATIONS Description Reported corrosion indication following borescope inspection. The condition, as shown in the picture, can be cleaned during engine overhaul as part of the workscope. No action was required. Aircraft had been operated in tropical/salty environment for 1 year without compressor wash Approx. 0.300 Approx. 0.750

PRATT & WHITNEY CANADA UPDATES COMPRESSOR WASH RECOMMENDATIONS Resistance to corrosion and recommendations P&WC position All P&WC engines meet industry standards for corrosion protection. P&WC corrosion mitigation recommendations are appropriate and based on FAA AC 43-4A are similar to other engine manufacturers Maintenance updates Engine Maintenance Manual is being revised (Nov 11) to eliminate need to disconnect P3 during desalination wash to reduce procedure cost. Compressor wash recommendations updated to provide more clarity to operators and maintenance facilities.

THANK YOU!

PHENOM 100 TECHNICAL SESSION. SAMUEL PECCI OCTOBER 14 th, 2011