Airbus A380

Aerospace

• The world's only twin-deck, four-aisle airliner• The airlines' solution to growing demand for

air travel• More fuel-efficient than your car• A dedicated three-deck 150 ton long-range

freighter

EATON CORPORATION AEROSPACE C5-37A June 2006 3

Royce or GP7200 engines

from The Engine Alliance (a

joint venture between

General Electric and Pratt &

Whitney).

The A380, which will seat 555

passengers in a typical three-

class interior layout, will enter

airline service in 2007.

While meeting the most strin-gent international certificationrequirements, the A380 embod-ies the very latest technologiesfor materials, systems andindustrial processes. Offeringabout a third more seating andfar more available floor spacethan its closest competitor, theA380 will deliver an unparalleledlevel of comfort, with widerseats and aisles, open spacesfor passengers to stretch theirlegs and access to lower-deckamenities. The A380's moderntechnology and economies ofscale provide 15% lower seat-mile costs than today's mostefficient aircraft. Consequently,the A380 will offer passengersluxury travel at much moreaffordable prices.

The A380 will carry more pas-sengers further allowing forgrowing passenger numbersand helping to ease an increas-ingly congested environment. Itwill achieve this without increas-ing the number of air trafficmovements and without nega-tively impacting the environ-ment thanks to significantlyreduced noise and emissionslevels. In addition, thanks tonew generation engines andadvanced wing and undercar-

riage design and technology, theA380 will not only comply withcurrent noise limits but will bequieter than today's largest air-liner, meeting strict local regula-tions such as QC2 for departureat London airports. The A380will generate half the noise levelat take-off and carry 35 per centmore passengers than its com-petitor over distances such asfrom London to Singapore.

And the A380's environmentalfriendliness does not stop atnoise reductions. The economicfuel consumption of the A380 -around 13 per cent lower fuelburn than its closest competitor- will also help reduce theimpact of exhaust gases on theatmosphere. Indeed, the A380will be the first long-haul aircraftto consume less than threeliters of fuel per passenger over100 kilometers (95 miles perimperial gallon) - a fuel burncomparable with the best ofsmall modern turbo-diesel cars.

While offering all the advan-tages of a completely newdesign, the A380 will extendthe benefits of Airbus familycommonality to the very largeaircraft sector. Thanks to thesame cockpit layout, proceduresand handling characteristics,pilots will be able to make thetransition to the A380 fromother Airbus fly-by-wire aircraftwith minimal additional training.

Working with some 60 majorairports to ensure airport com-patibility and a smooth entryinto service, the Airbus A380provides the smartest and most

economical solution to growingair traffic and airport congestion.The only alternative, an increasein frequencies of existing air-craft, would not only require bil-lions of dollars of investment byairports (in new runways, termi-nals and even airports) butwould also contribute to greatercongestion and a significantlyincreased impact on the envi-ronment. Airbus' analysis of thisissue has been irrefutably con-firmed, both implicitly, throughindustry-wide participation inthe program from its outset,and explicitly, through thealready immense success ofthe A380 on the market. Todate, eleven customers haveannounced firm commitmentsfor a total of 129 A380s, includ-ing 17 freighter versions.

The A380 Family starts from abaseline passenger aircraft witha capacity of 555 passengers inthree classes, and a range of upto 15,000km (8,000nm). Thefreighter version, the A380F, willcarry a payload of 150 tons(330,000lbs) over 10,400km(5,600nm).

The Airbus A380: The largest,

most advanced and efficient

commercial airliner ever con-

ceived.

The A380 Family starts from a

baseline passenger aircraft

with a capacity of 555 passen-

gers in three classes over a

range of up to 8,000

nm/14,800 km. Larger and

longer range members of the

family are anticipated in the

basic design concept.

Designed in close collabora-

tion with major airlines, air-

port and airworthiness

authorities, the A380 brings

new standards of comfort and

better economics in an aircraft

that is more environmentally

responsible. Whilst doing all

of this, it allows growth and

reduced congestion from

today's airports with mini-

mum change. Most important-

ly, the A380 introduces com-

petition to the large aircraft

sector, completing the Airbus

product portfolio.

While offering all the advan-

tages of a completely new

design, the A380 will extend

the unique benefits of Airbus

family commonality into the

very large aircraft sector.

Thanks to the same cockpit

layout, procedures and han-

dling characteristics through

fly-by-wire, pilots will be able

to transition to the A380 from

other Airbus aircraft with only

minor additional training.

The A380 can be powered by

Trent 900 engines from Rolls-

AAiirrbbuuss AA338800 SSyysstteemm OOvveerrvviieewwEaton’s Aerospace Product

Capabilities

4 EATON CORPORATION AEROSPACE C5-37A June 2006

A380 Hydraulic System Block Diagram

Ailerons Spoilers Rudder Elevators THS Slats/Flaps

Landing Gear actuation

Wheel steering

Braking

EDP Eng. 1

EDP

LIB & RIB LOB & ROB 2, 4, 6, 8 (L&R)

Upper & Lower LOB & LIB

Pitch trim

Slats & Flaps

Nose Gears (ERS) Wing Gears

(ERS)

Wing Gear Brakes

Green System Left Outboard Left Inboard

Right Outboard Right Inboard Priority Valve Pressure Maintaining Valve Electrical Generator Engine Driven Pump Elec . Motor Pump

LOB: LIB:

ROB: RIB: PV: PMV: Gen : EDP: EMP:

PV

PMV

PMF

EDP Eng. 2

EDP

LEHGS

LOB & ROB LMB & RMB 1, 3, 5, 7 (L &R) Upper & Lower

ROB & RIB

Flaps

Body Wheel St i

Body Gears (ERS)

Body Gear B k

Yellow System

PV

PMF

EDP Eng. 3

EDP EDP Eng. 4

EDP

Pitch trim 2

PMV

APU

LMB & RMB 6 (L & R)

Upper & Lower

LIB & ROB

Slats

Electric System 1

Gen1 Gen2

Gen

Gen3 Gen4

LIB & RIB 5 (L & R)

Upper LOB & RIB

RAT

Electric System 2

Isolation contactor (RAT)

Thrust Reversers Eng . 2 T/R Eng . 3 T/R

EMP EMP

EMP EMP

Cargo Doors Back Up

Hand pump

Nose Wheel St i

PV

Left Medium LMB: Right Medium RMB:

BPS BPS BPS LEHGS

Gen

Pitch trim

Lower

The Airbus A380 hydraulic sys-tem consists of two hydraulicsystems (Green & Yellow). Athird hydraulic system used onprevious Airbus aircraft isreplaced by an electro-hydraulicsystem made of a combinationof Electro Hydraulic Actuators(EHA) and Electrical BackupHydraulic Actuators (EBHA).

For the first time in civil aircrafthistory the A380 will use a highpressure 5000 psi- hydraulic sys-tem. The fluid remains a stan-dard phosphate-ester type asused on most civil aircraft.

The A380 hydraulic system inte-grates a total of eight EngineDriven Pumps (EDP). This archi-tecture allows to have one EDPas a go item which means the

aircraft can be dispatched nor-mally with one off-line EDPwhile using the remaining sevenpumps.

On this aircraft the ElectroMotor Pump (EMP) will be usedfor ground purpose only and arelocated by couple in the innerpylon.

EATON CORPORATION AEROSPACE C5-37A June 2006 5

Eaton’s Airbus A380 Components

CFRP Transmission ShaftsHydraulic Sliding Unions

Trent 900 EBUFire Shut-Off ValveEngine-Driven PumpChip CollectorsSight Gauge

Ground Service Panel

Monitoring & Control Protection Units (MCPU)

HP Air Ground Connector

Slat Drive System

CFRP Main Deck StrutsCFRP Upper Deck Struts

GR7200 EBUQDMCarbon Main Breaking Seals

Flexible Hose AssembliesRynglok™ Fittings

APU Pump

Trim Tank Check Valve

HTP Ducting

Supplemental Cooling System

Cabin Water Drain Valve

Trim Pumps

Flexible Hose AssembliesRynglok™ Fittings

Wing Transfer Fuel Pumps

Feed Fuel PumpsPressure Holding ValvesFuel Transfer Jet Pumps

EBH Accumulators

Wing Transfer Fuel Pump

6 EATON CORPORATION AEROSPACE C5-37A June 2006

AC Motorpump

The 21,3 kw 5,000 psi ACMotorpump is the largest devel-oped to date for an aircraft. EachEaton Vickers® brand ACMotorpump is powered by 115VAC 400 Hz constant frequencyand can deliver a max flow of38 l/min (10 gpm) with a con-stant horse power characteristic.The unit is controlled by twoparticular subsystems, theMonitoring and ControlProtection Units (MCPU) andMotor Switching Units (MSU).There are four AC Motorpumpsper aircraft.

Motor Switching Unit (MSU)

There are two Eaton Vickers®

brand Motor Switching Units perA380 aircraft. Each MSU com-prises two Eaton power contac-tors, carrying electrical power totwo Electro Motor Pumps. Thecontactors of the MSU are con-trolled by the Motor Control andProtection Unit and are used tostop the EMP in the event ofany fault condition being detect-ed.

Engine Driven Pump

On the A380 there are eight EatonVickers brand Engine DrivenPumps (EDP) which provide themain hydraulic power for the 5000psi system. Each EDP is poweredby the engine accessory gear boxand delivers a rated flow of 160l/min (42 gpm) at 3775 rpm. Thepump integrates an 11 piston rotat-ing group coupled with a sphericaltype attenuator, a boost impeller,an electrical de-pressurizationvalve, and a scavenge pump. Thepump also includes a clutch mech-anism which allows disconnectionof the pump from the engine gearbox in flight or on the ground.

Ground Service Panel

Eaton's Ground Service Panel issituated in the hydraulic bay ofthe A380 aircraft and integrateseleven different equipment pack-ages, which are used to monitorand maintain the two hydraulicsystems. The main componentsof the system include the pres-sure and level gauges used tomonitor the reservoir air-pressur-ization and fluid levels, a handpump used to refill the hydraulicreservoir, and some valves usedto control the fluid and the airpressurization during the refillingoperation of the hydraulic reser-voirs.

Fire Shut-Off Valve (FSOV)

The A380 is fitted with four FireShut-Off Valves. The valves areused to shut-off the hydraulicline at the pump inlet in theevent of major system or enginefailure.

The FSOV is fitted with size 32hydraulic ports and is designedfor a nominal flow of 350 l/minunder a pressure of 220 psi.

The unit integrates a high preci-sion electrical motor which ispowered under 28Vdc. Themotor has been specially opti-mized for very low electricalconsumption, allowing a signifi-cant weight reduction of the air-craft cabling.

ReservoirGreen Circuit

ReservoirYellow Circuit

ReservoirGreen Circuit

ReservoirYellow Circuit

ReservoirAir Pressure

Gauges

ReservoirLevel Adjustment

Indicator

Reservoir Filling Selector Valve

RSVR Filling Filter

Hand Pump, Handle & filling coupling

Filling Hose

Green & Yellow System Pressure Gauges

ReservoirAir Pressurisation

Valve

Reservoir AirDepressurisation

Switches

Reservoir Filling Protection Coupling

Ground Pressure Supply

EATON CORPORATION AEROSPACE C5-37A June 2006 7

Power Contactor

The A380 is supplied with threepole single throw 115VAC 400HzAC contactors. Four PowerContactors are integrated in eachMotor Switching Unit to controlthe starting sequence of the ACHydraulic Pump Motors.

Oil Filler

Eaton’s Oil Filler provides a high secu-rity oil fill cap for the auxiliary powerunit on the A380.

Oil Fill Valve

When the A380’s oil level in the aux-iliary power unit reaches valve seat,Eaton’s Oil Fill Valve closes to holdthe oil level at the preset point.

Sight Gauge

Eaton’s Tedeco® brand sight gauge ismounted to the exterior of a tank orhousing to provide visual indication ofa liquid over a wide range.

Quantitative Debris MonitorSystem & Lubriclone®

Eaton’s QDM® Sensors are provid-ed for the GP7200 engine used onthe A380 aircraft. Tedeco brandQDMs® generate an electrical pulseproportional to the mass of ferrouswear particles to signal an earlywarning of potential failure of lubri-cated engine gears and bearings.The sensor is mounted in aLubriclone®cyclonic separator thatremoves entrained air from thescavenged oil while providing a qui-escent area for the sensor to cap-ture the debris with high efficiency.

Chip Detector

Eaton’s Tedeco® brand chipdetectors are provided for theTrent 900 jet engine. The ChipDetectors detect and collect fer-rous wear particles in the enginelubrication system.

Monitoring and ControlProtection Units (MCPU)

The A380 has two EatonVickers® brand MCPUs per air-craft. The system integrates par-ticular protection functions toensure total safety during oper-ation of the unit as well as acontrol system managing thestarting sequence of the unit.

Slat Drive System

Eaton’s Vickers® brand Slat DriveSystem integrates a bi-directionalvariable displacement hydraulicmotor and sensors to provideclosed loop motor control, and abrake release mechanism withan associated control valve.

The A380 aircraft is the firstcommercial aerospace platformusing variable displacementhydraulic motors to drive thesecondary flight controls.

8 EATON CORPORATION AEROSPACE C5-37A June 2006

Flexible Hose Assemblies

Eaton’s Aeroquip® brand assem-blies are utilized extensivelythroughout the A380 aircraft.The standard wire braided tech-nology is being used for the lowand medium pressure hoseassemblies and the Kevlar®

braise technology is being usedfor the high pressure hoseassemblies.

Check Valves

A new generation of Eaton’sAeroquip® brand Check Valveshave been designed and quali-fied for the A380. These checkvalves are optimized for very lowpressure drops in a reducedenvelope and weight, whilemaintaining extra long life.

Rynglok Fittings

Eaton’s Aeroquip® brandRynglok™ type fittings are all per-manent high pressure connec-tions for the A380 hydraulic sys-tem, which are also qualified asa repair method for the opera-tors.

High Pressure MaintenanceFree Accumulator (HPMFA)

These accumulators are pre-charged with Helium and areoperating with either 5000 psior 6000 psig of hydraulic fluid.Located in various areas of theA380, the accumulators are partof the hydraulic generation ofthe A/C. In addition to dampen-ing the pulsations of the pumpsand absorbing the pressurespikes which are inerrant to anyhydraulic circuit, they alsorespond to the instantaneousflow demands that the systemis not able to supply.

The accumulators are also pri-marily used to maintain thebrakes of the aircraft duringparking mode and are used as abackup solution for the emer-gency braking of the BodyLanding Gear and the WingsLanding Gears. As well, theyare used on the Steering LocalElectro-Hydraulic GenerationSystem (LEGHS) of the aircraft.

Rudder Electric Back-upHydrostatic Actuator Reservoir

Eaton supplies four maintenancefree reservoirs per A380. Theseare part of the Rudder ElectricBack-up Hydrostatic Actuator(EBHA).

These are metal bellow reser-voirs that are pre-charged with33 cu.in of helium and are work-ing at 350 psig max. They aredesign to operate 5000 psig ofhydraulic pressure.

Electro-Hydraulic Reservoir

Eaton supplies maintenance freereservoirs for the A380. Theseare part of the Aileron and theElevator Electro-HydraulicActuators (EHA).

These are metal bellows reser-voirs. They are pre-charged withhelium and are working at 870psig max. They are design toopeate at 5000 psig of hydraulicpressure.

Steering Reservoir

Eaton supplies one steeringreservoir per A380. It is part ofthe Steering Local Electro-Hydraulic Generation System(LEGHS). This reservoir uses ametal bellow to separate thegas from the fluid. It is Heliumpre-charged and sealed atEaton for the life of the aircraft.The reservoir is equipped witha dual electrical and visual levelvolume indicator. The electricalinformation is transmitted tothe Electric Control Unit (ECU )that will automatically controlthe fluid refilling of the reservoirwhen a low level is reached.

Centurion™ Mechanical Seals

Eaton provides Centurion™Mechanical Seals for theGP7200 engine. These are sta-tionary, “face” type sealsdesigned for managing highspeed, large axial movementand high pressure applications.

EATON CORPORATION AEROSPACE C5-37A June 2006 9

Engine Feed Fuel Pump

Eight engine feed pumps areused to supply fuel to theengines.

Wing Transfer Fuel Pump

Ten wing transfer pumps arefitted in the wings of the A380to transfer fuel between thedifferent fuel tanks.

Trim Transfer Fuel Pump

Two trim transfer pumps aremounted in the horizontal tailplane to move fuel betweenthe centre tank and the tailtank to help trim the aircraft.

APU Fuel Pump

One fixed frequency APUpump is fitted to supply fuel tothe Auxiliary Power Unit.

Jet Pumps

Eaton supplies four jet pumpsper aircraft for some inter-tankfuel transfers. This type ofpump is not as efficient as anelectrical pump but having nomoving parts offers high relia-bility.

Hydraulic Sliding Unions

The A380 Sliding Unions areinstalled in the rear spar areaof the wings and in the innerpylons. Their function is tocater for expansion and con-traction of pipe length due tothermal changes, and move-ments due to significant wingdeflection. They are part of theHydraulic Power DistributionSystem, which delivers thehydraulic pressure to the differ-ent consumers such asailerons, elevators, rudder,landing gear etc.

Collector Cell PressureHolding Valve

The valve prevents flow fromthe collector cell back into thefeed tank following a pumpshut off. It will also act as anon-return valve to prevent re-circulation of flow through thefeed pump that is notoperating.

Horizontal Tail Plane (HTP)Ducting

Horizontal Tail Plane Refuel,Transfer & Vent SystemDucting.

Electrically Driven Fuel Pumps

Eaton supplies a total of 21 electrically driven fuel pumps andassociated canisters for each A380 aircraft. The pumps are used totransfer fuel from the various tanks to the aircraft's engines, andbetween tanks during flight. There are three main different pumptypes - Transfer, Engine Feed and Trim - operating from a variablefrequency power supply which has required the development of new

fuel pump technology. The pumps use brushless dc motors, withpower conditioning and control electronics incorporated in thepumps, and use the fuel itself as a cooling medium. The pumps arefitted in tank mounted canisters which allow them to be removedwithout the need to drain the fuel tank.

10 EATON CORPORATION AEROSPACE C5-37A June 2006

Trent 900 Engine Build-Up(EBU)

Eaton is a key supplier in thedevelopment and manufactureof the EBU for the Trent 900Engine. The EBU has nine subsystems; ECS (Cabin Air),Starter Air, Thermal Anti-ice,Hydraulics, Variable frequencygenerator (VFG) Cables, VFGCooler Pipes, Drains and Fire-extinguishing. The nine EBUsub systems contain morethan 85 Eaton designedcomponents.

Composite Struts

Eaton’s very lightweight andstrong structural struts performtwo primary functions, theystiffen the floor by reducing thefree bending length of thebeams, and working ascantilever pivots, they helpprevent fuselage distortion. Theupper deck longitudinal strutsform part of the connectionbetween the fuselage and thestructural ceiling, performing asimilar job to the main deckstruts. They also triangulate thejoint between the beam andthe ribs stiffening andstrengthening the structure.Eaton supplies a total of 95struts for the main deck floorand 74 for the upper deck peraircraft in a varying sizes

Composite Shafts

Eaton’s very lightweight carbonreinforced plastic tubes, madeusing a filament windingprocess, provide thetransmission shafts for takingpower from rotary actuators tooperate flaps and slats in theaircraft wings. There are 41 flapshafts and 62 slat shafts ofvarying sizes per aircraft.

Water Drain Valve

The water train valve is alightweight compositecomponent designed to drainwaste water in a continuouscycle via the outlet connection.The unit acts as an air stopdevice to prevent loss of cabinpressure through the normallyopen sink, and a backflowprevention device isincorporated within theassembly.

High Pressure Air GroundConnector with Non-ReturnValve

Used for high pressure air sup-ply for engine starting from anexternal compressor — threeinch connector for a standardpneumatic connection, (3 per air-craft).

Supplemental Cooling SystemReservoir

There are two Bellows reser-voirs for the supplemental cool-ing system of the A380. Thereservoirs are used to compen-sate for the thermal expansionof the closed circuit and to pro-vide a minimum pressure to thepumps that will circulate theGalden fluid all over the aircraftin the galleys and the electroniccompartments of the aircraft.These reservoirs are equippedwith a monitoring device thatpermanently controls theremaining fluid volume.

Trim Tank Check Valve

The Trim Tank Check Valve is anon-return valve mountedwithin the Horizontal Tail Plane(HTP), between the Trim Tankand the Trim Vent Tank of allA380 variants. Its mainfunction is to allow thedrainage of the Vent Tank to theTrim Tank.

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© 2006 Eaton CorporationAll Rights ReservedPrinted in USACopying or Editing is ForbiddenForm No. C5-37AJune 2006