SECTION 2

CHAPTER 1
PRIMARY HYDRAULIC POWER SUPPLIES
Contents
Para
1 Introduction
6 Self idling power circuit
7 Non-self idling power circuit
Hydraulic power supply components
8 Self-idling pump (variable delivery)
10 Non self-idling (constant delivery) pump
11 Automatic cut-out valve (ACOV)
12 ACOV operation
14 Accumulator
17 Reservoirs
18 Unpressurised reservoirs
19 Pressurised reservoirs
20 Gas pressurised reservoirs
21 Hydraulic system pressurised reservoirs
22 Pressure relief valve
24 Pressure maintaining valve
26 Non-return valve (NRV)
27 Filters
29 Low pressure filter
30 High pressure filter
31 By-pass filters
32 Ground test connections
34 Pressure relief valve
35 Power supply circuits
36 Two pump systems
Figure Page
1 Self-idling pump and hydraulic symbol 4-2-1-4
2 Non-self idling (constant delivery) pump and hydraulic symbol 4-2-1-5
3 Automatic cut-out valve (ACOV) and hydraulic symbol 4-2-1-6
4 ACOV operation 4-2-1-7
5 Accumulator and hydraulic symbol 4-2-1-8
6 Unpressurised reservoir and hydraulic symbol 4-2-1-9
7 Pressurised reservoir hydraulic symbol 4-2-1-9
8 Gas pressurised reservoir 4-2-1-10
9 Hydraulically pressurised reservoir 4-2-1-10
10 Pressure relief valve (PRV) and hydraulic symbol 4-2-1-11
11 Pressure maintaining valve and hydraulic symbol 4-2-1-12
12 NRV and hydraulic symbol 4-2-1-13
13 Filter hydraulic symbol 4-2-1-13
14 By-pass filter and hydraulic symbol 4-2-1-14
15 Ground test connection (Push type) and hydraulic symbol 4-2-1-15
16 Pressure relief valve hydraulic symbol 4-2-1-15

Contents (continued)
Figure Page
17 Pressure switch and hydraulic symbol 4-2-1-16
18 Single pump self-idling power circuit 4-2-1-17
19 Single pump non self-idling power circuit 4-2-1-18

PRIMARY HYDRAULIC POWER SUPPLIES
INTRODUCTION
1. A power supply circuit controls and governs the hydraulic flows and pressures
required to operate the individual hydraulic operating circuits (services) installed on
the aircraft.
2. It would be impractical due to the high flow rates (speed of operation), high
pressures required and physical effort needed, to operate the hydraulic systems in
flight using a hand pump. Hand pumps fitted to aircraft are normally for ground
maintenance or emergency use. Therefore powered hydraulic pumps are utilised.
3. Aircraft hydraulic systems may have one or more engine driven pumps
(EDPs), which are driven by the aircraft engine accessory gearbox. Pumps are
simply fluid movers; they generate a flow of fluid. Pressure is generated when there
is a restriction to flow.
4. A hydraulic pump is a device for the conversion of mechanical energy into
hydraulic energy. The mechanical action of the pump traps the fluid within the
pumping cavities, transports it through the pump, and forces a flow of fluid into the
hydraulic system. By repeating this operation a continuous flow of hydraulic fluid is
produced.
5. Supply circuits fall into two main categories, which are dictated by the type of
pump used:
Self-idling (variable delivery).
Non-self idling (constant delivery) - pumps constantly provide a flow of
fluid.
Self-idling power circuit
6. In a self-idling power circuit, the pump is self-regulating and provides variable
flow at constant pressure to meet the requirements of the system without the need
for an external pressure-regulating device.
Non self-idling power circuit
7. In a non self-idling power circuit, the pump is not self-regulating and provides
a continuous flow of fluid to the pressure line. To prevent over pressurisation, an
automatic cut-out valve (ACOV) is fitted in the circuit to off-load the pump when the
pre-determined system pressure has been built up. An accumulator is also fitted in
the circuit to provide a backpressure to ensure that the ACOV operates efficiently.

HYDRAULIC POWER SUPPLY COMPONENTS
Self-idling pump (variable delivery) (figure 1)
8. The most common pumps used in modern aircraft hydraulic systems are of
the piston type with an integral self-idling facility. This type of pump consists of a
multiple bore cylinder block with the cylinder bores parallel to, and symmetrically
spaced around, the pump axis. The cylinder block containing the pistons and the
drive-shaft rotate together. As the cylinder block rotates, the pistons move around
the angled yoke and are drawn in and out once per revolution. This action displaces
fluid into the system. The angle of the yoke can be varied to increase or decrease
pump stroke, so that constant pressure is maintained in the system. This type of
pump is often referred to as a 'swash plate pump'.
9. When system pressure is low, which is the case when a service has been
selected, spring pressure on the control piston moves the yoke to its maximum
angle. The pistons move to full stroke and maximum output is delivered to the
system. As system pressure increases, pressure acting against the control piston
moves the yoke back towards the minimum stroke angle. In this position a small
flow through the pump is maintained to lubricate the mechanical parts, to help
dissipate heat and to ensure a quick response time when a service is operated.
























Outlet

Inlet




Figure 1 - Self-idling pump and hydraulic symbol

Non self-idling (constant delivery) pump (figure 2)
10. The non self-idling pump is similar in design and operation to the self-idling
pump, except that it does not incorporate a control piston assembly. The pump
displaces or delivers a constant fluid output for any rotational speed, e.g. 45 litres of
fluid per minute, (10 gallons/min) at a pump speed of 2800 RPM. As long as the
pump maintains that RPM. it will deliver at that rate, regardless of the pressure in the
system














Inlet
Outlet

Cylinder
block
End view of pump
Fixed angle
swash plate
Drive
shaft
Piston

Figure 2 - Non-self idling (constant delivery) pump and hydraulic symbol


Automatic cut-out valve (ACOV) (figure 3)
11 This component is used in power supply circuits, which employ non-self idling
pumps. The ACOV regulates system pressure by offload flow from the pump to
return when there is no demand from the operating services. The ACOV is sensitive
to system pressure. When system operating pressure has been attained the ACOV
will operate, trapping fluid downstream of the ACOV, and offloading flow back to the
reservoir.








To
Services
Relief to Reservoir
From Pump
Flow
NRV






Figure 3 - Automatic cut-out valve (ACOV) and hydraulic symbol

12. ACOV operation (figure 4) The ACOV operates as follows:
a. Fluid flow from the EDP opens the NRV (B) and flows into the circuit.
b. Springs (F) and (G) keep the spindle valve (D) seated until system
pressure is attained.
c. When system (cut-out) pressure is attained, the spindle valve (D)
moves to the right, compressing springs (F) and (G).
d. As pressure within the ACOV drops, the NRV (B) closes, aided by
spring pressure and the accumulator.
e. Accumulator pressure continues to move the spindle (D) and
compresses spring (G).
f. Pressure acts on the flutter plate (E) displacing it against the spring (F).
g. Fluid then passes to the reservoir via the holes in the flutter plate, thus
offloading flow.
13. As the accumulator pressure falls during initial operation of services, spring
(G) pushes the spindle valve (D) towards its seat. When the cut-in pressure is
reached, the spindle valve (D) engages its seat; spring (F) returns the flutter plate (E)
on to the spindle valve (D), NRV (B) opens and fluid can flow directly from the pump
into the system.

E
F
G
D
C
B
Reservoir
EDP
Accumulator
To system
8
1
4
5
(
8
3


Figure 4 - ACOV operation

Accumulator (figure 5)
14. An accumulator is a cylinder and floating piston assembly with openings on
each end. One chamber contains hydraulic fluid at system pressure and the other
chamber contains gas under pressure. Hydraulic system fluid pressure enters one
port and forces the piston against the gas charge.
Note - An accumulator is always fitted in a non-self idling power circuit.
15. As hydraulic system pressure increases, an increase in fluid within the
accumulator acts to move the piston and compress the gas. This will continue until
gas and hydraulic pressures are equal. As hydraulic system pressure decreases,
the gas will expand forcing fluid back into the system
16. The purposes of an accumulator include:
Providing an emergency store of hydraulic energy.
Giving initial impetus to hydraulically operated components.
Damping out pump pulsations.
Compensating for temporary drop in supply pressure on selection of a
service.
Preventing 'chatter' in the ACOV.
Compensating for thermal expansion of the fluid.

Gauge
Nitrogen
Connection
Piston
Fluid
Connections
8
1
4
5
(
2
0


Figure 5 Accumulator and hydraulic symbol
Reservoirs
17. Reservoirs can be divided into two main groups:
Unpressurised.
Pressurised.
18. Unpressurised reservoirs (Figure 6). Unpressurised reservoirs are
normally fitted vertically and higher than the EDPs, relying on gravity to feed the
pumps. This type of reservoir is often fitted to transport aircraft and helicopters.

Figure 6 - Unpressurised reservoir and hydraulic symbol
19. Pressurised reservoirs (figure 7) Pressurised reservoirs subject the stored
fluid to pressure. This ensures that the pump, regardless of aircraft attitude or
altitude, is always being positively supplied with fluid. Reservoirs are pressurised by
one of two methods:
Gas pressure.
Hydraulic system pressure taken from the power supply circuit.










Hydraulic symbol
Figure 7 - Pressurised reservoir hydraulic symbol

20. Gas pressurised reservoirs (figure 8). In a gas-pressurised reservoir, one
method of pressurisation is accomplished using air bled from the engine. An air
pressure regulator valve is used to control the engine bleed air to a desired range.
Another method involves pre-charging the reservoir with pressurised nitrogen on the
ground.



Figure 8 - Gas pressurised reservoir
21. Hydraulic system pressurised reservoir (figure 9). The reservoir is
constructed with a piston rod assembly, with two pistons of differing surface areas.
System pressure acts upon the small piston in a chamber separated from the main
reservoir body. This pressure generates a force, which is transmitted to the larger
piston within the main reservoir body. The transmitted force acts on the surface area
of the larger piston producing a low pressure within the fluid. As system pressure is
applied to the small piston, the piston assembly tries to move. However, as hydraulic
fluid is virtually incompressible, this movement will be small. As the piston assembly
moves it pressurises the fluid in the reservoir. Pressure ratios between the small
(inlet) piston and the larger reservoir piston are usually in the order of 60:1. This
means that a 3000-psi inlet pressure is reduced to about 50 psi in the main reservoir.

System
Pressure
Return
Supply
8
1
4
5
(
7
7

Figure 9 - Hydraulically pressurised reservoir
Pressure relief valve (figure 10)
22. A pressure relief valve (PRV) is fitted to protect a circuit or component from
possible damage caused by hydraulic over pressurisation.
23. Should system pressure exceed the spring loading, the ball valve will be lifted
off its seat allowing excess fluid pressure to be relieved to return.


























To return
High
pressure

Figure 10 Pressure relief valve (PRV) and hydraulic symbol

Pressure maintaining valve (figure 11)
24. The function of the pressure maintaining valve (also referred to as a pressure
regulator or priority valve) is to cut off the supply of fluid to those services deemed
to be non-essential and to ensure that the available fluid pressure is directed to
those services deemed to be essential in the event of hydraulic pressure failure.
25. With normal system pressure available, the spring loading is overcome and
the valve opens to allow pressure to all services. If system pressure drops below a
predetermined level, the pressure-maintaining valve closes under spring pressure to
isolate the non-essential services, thus directing all available pressure to the
essential services.



















Normal system pressure Low system pressure
Non - Essential
Essential


Figure 11 - Pressure maintaining valve and hydraulic symbol
Non-return valve (NRV) (figure 12)
26. Non-return valves permit full flow in one direction, and block any flow in the
reverse direction. Due to their flow characteristics, NRVs are used to isolate
components or sub-systems from each other. An arrow on the valve body indicates
the direction of free flow through the valve.






Figure 12 - NRV and hydraulic symbol
Filters (figure 13)
27. In a hydraulic system, moving parts such as pumps and valves will wear, and
as such will introduce metallic and non-metallic debris into the system. If such
material is not removed, it may cause the failure of a component or of the entire
system, therefore, particles are removed from the fluid by a filter screen.
Figure 13 - Filter hydraulic symbol
28. Filters are divided into two distinct groups:
Low pressure or suction filters.
High pressure filters.
29. Low pressure filter. Low pressure filters are normally fitted between the reservoir
and the hand pump or engine driven pump. They are often of simple design and offer
minimal resistance to flow. This is essential to minimise cavitation at the pump.

30. High pressure filter. In a high pressure filter, fluid is forced through the filter
element and any foreign matter will be removed. The effectiveness of a filter is
determined by the size of the smallest particle that it can remove and is referred to
as the filter rating. Particle size is measured in microns and the manufacturer
determines the filter rating for a particular system. Filters, which have this ability are
often referred to as 'micronic filters'
31. By-pass filters (figure 14). In the event of a filter element becoming blocked
no fluid would be able to enter the system. To prevent this, many filters
incorporate a relief valve that opens in the event of a blockage to allow
unfiltered fluid to by-pass the element. To indicate to the groundcrew that the
filter has become blocked, a tell tale indicator is activated. This indicator
takes the form of a red warning button, which protrudes, from the filter
assembly.



















Filter
Housing
Telltale indicator
Filter element
Figure 14 By-pass filter and hydraulic symbol
Ground test connections (figure 15)
32. To enable hydraulic system testing without using the engine driven pumps, a
ground maintenance trolley can be connected to the aircraft hydraulic system
through ground test connections. The ground test connections are composed of two
half couplings; one integral to the aircraft hydraulic system and the other on the
ground maintenance trolley hose.
33. These connections are self-sealing couplings, which allow the maintenance
trolley to be connected quickly and easily. Each coupling is in effect a shut-off valve,
which is opened as the male and female portions are mated together. They come in
a variety of forms, one of which is illustrated in figure 15.


Aircraft half coupling
Maintenance trolley hose
half coupling

Figure 15 - Ground test connection (Push type) and hydraulic symbol

Pressure release valve (figure 16)
34. Before carrying out certain hydraulic maintenance tasks or procedures, it is
essential to ensure that system pressure is dissipated. To facilitate this, some
aircraft are fitted with pressure release valves. Pressure release valves allow
system pressure to be dissipated to return and are manually operated.
Figure 16 - Pressure release valve hydraulic symbol

Pressure switch (figure 17)
35. The pressure switch is an electro-hydraulic component that uses hydraulic
pressure to operate a micro-switch. If the system pressure falls below a pre-
determined level the micro-switch will 'make', illuminating a warning light in the
cockpit.


Figure 17 - Pressure switch hydraulic symbol















POWER SUPPLY CIRCUITS
36. All of the components covered so far form the basis of a hydraulic power
supply circuit. A single pump self-idling power circuit is shown at figure 18 and a
single pump non self idling power circuit is shown at figure 19.
1
2
3
4
5
6
7
8
9
10
Essential
Services
11
17 16
15
14
13
Non-essential
Services
12
8
1
4
5
(
8
1

1
2
3
4
5
6
7
8
9
Reservoir (pressurised)
Ground test connection
Pump (self-idling)
Non return valve
Filter
Ground test connection
Pressure switch
Accumulator
Accumulator pressure gauge
10
11
12
13
14
15
16
17
Accumulator charging point
Pressure maintaining valve
Pressure release valve
Pressure relief valve
By-pass filter
Hand pump
Non return valve
Filter

Figure 18 Single pump self-idling power circuit

1
16
2
3 4
5
6
18
17
14
15
13
12
11
10
9
8
7
8
1
4
5
(
8
2
Essential
Services
Non-essential
Services

1
2
3
4
5
6
7
8
9
Reservoir (pressurised)
Pressure switch
Accumulator
Accumulator pressure gauge
Accumulator charging point
Pressure maintaining valve
Pressure release valve
Ground test connection
Automatic cut out valve (ACOV)
10
11
12
13
14
15
16
17
18
Filter
Non return valve
Pump (non-self idling)
Ground test connection
Pressure relief valve
By-pass filter
Hand pump
Non return valve
Filter


Figure 19 Single pump non self-idling power circuit
36. Two pump systems. It is common for two pumps to be fitted into a circuit, to
provide back up in the event of a pump failure. Under normal conditions both pumps
will operate with a combined flow and a common regulated pressure. However, if
one pump fails:
Pressure remains the same, governed by the ACOV in a non-self idling
system or by the control piston in the remaining pump in a self-idling
system.
Flow rate is reduced in a self-idling circuit or halved in a non-self idling
circuit.
Services operating times may be extended.