Airbus A318/A319/A320/A321 ATA 51-57

(CFM 56 and IAE V2500) cat. C AIRFRAME STRUCTURES

TRAINING MANUAL

Airbus A318/A319/A320/A321
(CFM 56 and IAE V2500) cat. C

ATA 51 - 57 AIRFRAME STRUCTURE

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Airbus A318/A319/A320/A321 ATA 51-57
(CFM 56 and IAE V2500) cat. C AIRFRAME STRUCTURES

TABLE OF CONTENTS TABLE OF FIGURES

STRUCTURE DESIGN PRINCIPLES ...............................................................3 Figure 1. STRUCTURE DESIGN PRINCIPLES............................................... 4

STRUCTURE ATA BREAKDOWN....................................................................5 Figure 2. STRUCTURE ATA BREAKDOWN ................................................... 6
DOORS .............................................................................................................7 Figure 3. DOORS ............................................................................................. 8
FUSELAGE .......................................................................................................9 Figure 4. FUSELAGE ..................................................................................... 10
PYLONS...........................................................................................................11 Figure 5. PYLONS .......................................................................................... 12
STABILIZERS - HORIZONTAL STABILIZER & ELEVATORS .................................13 Figure 6. STABILIZERS - HORIZONTAL STABILIZER & ELEVATORS ....... 14
WINDOWS........................................................................................................15 Figure 7. WINDOWS ...................................................................................... 16
WINGS FIXED PARTITION.................................................................................17 Figure 8. WINGS FIXED PARTITION ............................................................ 18
WINGS MOVABLE SURFACE ............................................................................19 Figure 9. WINGS MOVABLE SURFACE ....................................................... 20
COMPOSITE APPLICATIONS ............................................................................21 Figure 10. COMPOSITE APPLICATIONS ..................................................... 22
52 DOORS PRESENTATION .........................................................................23 Figure 11. SYSTEM INTRODUCTION ........................................................... 24
SYSTEM INTRODUCTION .............................................................................23 Figure 12. PASSENGER DOORS.................................................................. 26
PASSENGER DOORS....................................................................................25 Figure 13. EMERGENCY EXITS.................................................................... 28
EMERGENCY EXITS......................................................................................27 Figure 14. EMERGENCY EXITS - ESCAPE SLIDE AND SLIDING
ESCAPE SLIDE AND SLIDING WINDOWS ...................................................29 WINDOWS...................................................................................................... 30
CARGO DOOR ...............................................................................................31 Figure 15. CARGO DOOR ............................................................................ 32
AVIONICS COMPARTMENT DOORS............................................................33 Figure 16. AVIONICS COMPARTMENT DOORS......................................... 34
COCKPIT DOOR.............................................................................................35 Figure 17. COCKPIT DOOR - GENERAL ..................................................... 36
GENERAL .......................................................................................................35 Figure 18. COCKPIT DOOR – DOOR ELEMENTS ...................................... 38
DOOR ELEMENTS .........................................................................................37 Figure 19. COCKPIT DOOR - COCKPIT DOOR LOCK SYSTEM................ 40
COCKPIT DOOR LOCK SYSTEM ..................................................................39 Figure 20. COCKPIT DOOR - OPERATING MODES................................... 42
OPERATING MODES .....................................................................................41 Figure 21. COCKPIT DOOR – OPERATING MODES ................................. 43
CONTROL AND INDICATING ........................................................................45 Figure 22. CONTROL AND INDICATING - PASSENGER DOORS ............. 46
PASSENGER DOORS....................................................................................45 Figure 23. CONTROL AND INDICATING - EMERGENCY EXITS ............... 48
EMERGENCY EXITS......................................................................................47 Figure 24. CONTROL AND INDICATING - CARGO DOORS ...................... 50
CARGO DOORS .............................................................................................49 Figure 25. CONTROL AND INDICATING - ECAM DOOR/OXY PAGE ........ 52
ECAM DOOR/OXY PAGE...............................................................................51 Figure 26. MAINTENANCE/TEST FACILITIES............................................. 54
MAINTENANCE/TEST FACILITIES................................................................53 Figure 27. SAFETY PRECAUTIONS ............................................................ 56
SAFETY PRECAUTIONS ...............................................................................55

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(CFM 56 and IAE V2500) cat. C AIRFRAME STRUCTURES

STRUCTURE DESIGN PRINCIPLES

Four typical principles are used in the aircraft design:

- for the fuselage, the skin is attached to the frames and stiffened by stringers,
- for the boxes, the skins stiffened with stiffeners are attached to spars and
ribs,
- the composite parts could be monolithic or sandwich construction.

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(CFM 56 and IAE V2500) cat. C AIRFRAME STRUCTURES

Figure 1. STRUCTURE DESIGN PRINCIPLES

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STRUCTURE ATA BREAKDOWN

The structure of the aircraft is broken down as follows:

ATA 52 for the doors,
ATA 53 for the fuselage,
ATA 54 for the pylons,
ATA 55 for the stabilizers,
ATA 56 for the windows,
ATA 57 for the wings.

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Figure 2. STRUCTURE ATA BREAKDOWN

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DOORS

The passenger/crew doors and the emergency exit doors are of same
aluminum alloy design comprising skins, edge members, horizontal beams and
vertical frames.

There are three cargo compartment doors installed on the right side of the
fuselage. The forward and the aft cargo doors are also aluminum alloy structures
consisting of skins, edge members, corner pieces, horizontal beams and
vertical frames.

The bulk cargo door is of plug type design opening inside the fuselage. The
primary structure comprise skins, edge members and horizontal beams both
being made from aluminum alloy.
The main landing gear doors are located in the lower part of the center
fuselage.

They have:
- two main doors, hinged to the two longitudinal boxes of the keel beam,
- two hinged door,
- and two leg fairing doors.
All doors are of composite construction, including carbon fiber skins. The nose
landing gear doors have two forward doors, two aft doors and one fixed door.
The fixed door is made of aluminum alloy, the other doors are made of sandwich
type CFRP composite

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Figure 3. DOORS

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FUSELAGE

Within the technical documentation the fuselage is divided into five main parts
which are also divided into sections mainly for production purpose:
- the nose forward fuselage covered by chapter 53-10-00 and containing
sections 11 and 12,
- the forward fuselage covered by chapter 53-20-00 and containing the
sections 13, or 13/14, depending on A/C model,
- the center fuselage covered by chapter 53-30-00 which is also the section
15/21,
- the rear fuselage covered by chapter 53-40-00 and containing the sections
16, 17 and 18,
- the rear/cone fuselage covered by chapter 53-50-00 and containing the
sections 19 and the tail cone, section 19.1.

The A321, A320, A319 and A318 have the same fuselage sections. The A321
is a stretched version of the A320 with 8 frames added FWD of the center
section and 5 frames added AFT of the center section.

The A319 is a shortened version of the A320 with 3 frames removed FWD of
the center section and 4 frames removed AFT the of the center section.

The A318 is a shortened version of the A319 with 1.5 frames removed FWD
of the center section and 3 frames removed AFT of the center section.

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Figure 4. FUSELAGE

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PYLONS

The pylon box is the primary structure of the pylon. The secondary structure
comprises the forward, the lower and the aft fairings and the pylon to wing
center fillets.

The pylon box is an assembly of titanium alloy and steel parts which includes
spars, ribs, side panels, engine attachment, pylon to wing attachment fittings.

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Figure 5. PYLONS

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STABILIZERS - HORIZONTAL STABILIZER & ELEVATORS

The horizontal stabilizer main structure includes center joint and two outer
spar boxes.
On each side, the horizontal stabilizer also includes a leading edge, a trailing
edge structure, both being mainly made from Carbon Fiber Reinforced
Plastic (CFRP) and a tip which is made of aluminum alloy. The elevators are
basically CFRP structure including top and bottom skin panels, ribs and front
spar. The hinge and actuator fittings and the trailing edge profile are from
aluminum alloy.
The vertical stabilizer structure has:
- the main spar box,
- the leading edge,
- the tip,
- and the trailing edge.
The main box is an assembly of CFRP ribs, spars and side panels. The
vertical stabilizer structure has also:
- a leading edge made of Glass Fiber Reinforced Plastic (GFRP),
- a tip made from aluminum alloy,
- a trailing edge structure made of aluminum alloy,
- and trailing edge panels made of CFRP. The rudder structure has:
- two side panels made of CFRP,
- a front spar made of CFRP,
- leading edge panels made of CFRP,
- hinge and actuator fittings made of aluminum alloy,
- and the trailing edge profile made of aluminum alloy.

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Figure 6. STABILIZERS - HORIZONTAL STABILIZER & ELEVATORS

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WINDOWS

The ATA 56 chapter describes the cockpit, cabin and door windows. The
cockpit windows include the windshield, the sliding windows and the side
fixed windows.

The cabin windows include an inner and an outer pane installed in a seal. This
assembly is installed in the window frame from inside the fuselage and held
in position by a retainer ring

The door windows are of the same design principle as for the cabin windows.

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Figure 7. WINDOWS

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WINGS FIXED PARTITION

The wings consist in a center wing box which is installed in the center fuselage
section and which provides the cantilever attachment of the outer wings. The
center wing box is an assembly of aluminum alloy parts, located between
frames 36 and 42. Each outer wing has a main box (outer wing box), which is
the main load carrying structure. The main box supports a fixed leading edge
structure, a fixed trailing edge structure and a wing tip.

The fixed leading edge structure has leading edge ribs, attached to the main
box front spar, and which support the "D-nose" structure.

The fixed trailing edge structure includes hinge fittings and actuator fittings for
the movable surfaces, and intermediate ribs. The access panels are made of
CFRP.

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Figure 8. WINGS FIXED PARTITION

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WINGS MOVABLE SURFACE

Each outer wing is fitted with:

- five slats made of aluminum alloy,
- an inboard flap and an outboard flap with a CFRP structure and a sandwich
aluminum trailing edge structure,
- five CFRP spoilers,
- and one aileron, mainly made from CFRP.

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Figure 9. WINGS MOVABLE SURFACE

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COMPOSITE APPLICATIONS

The illustration shows the main application of composite materials on

A320 (same materials for other aircrafts).

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Figure 10. COMPOSITE APPLICATIONS

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52 DOORS PRESENTATION

SYSTEM INTRODUCTION

The different doors are:

- passenger doors,
- emergency exits,
- cargo doors,
- avionics compartment doors,
- cockpit door.

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Figure 11. SYSTEM INTRODUCTION

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PASSENGER DOORS

The single aisle family is equipped with two forward and two aft passenger
doors.

The normal door operation is fully manual.

They are plug type doors, which open upward, outward and forward parallel to
the fuselage.

The door can be operated from inside or outside the aircraft. Each door is
equipped with an emergency opening system:
- an escape slide or slide raft stowed in a container attached to the inboard lower
side of the door,
- a door damping and emergency operation cylinder that assist normal door
operation, but in an emergency acts as an actuator for automatic door
opening,
- a slide ARMING/DISARMING lever.

When the slide arming lever is in the ARMED position, the slide is connected
to the floor.

When the door is opened, the escape slides inflates automatically. Opening
the door from the outside will disarm the door and the escape slide.

The ECAM page indicates the door locking/unlocking and the escape
slide/slide raft armed/disarmed condition.

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Figure 12. PASSENGER DOORS

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EMERGENCY EXITS

The A318 and A319 have two overwing emergency exits (one on each side).
The A319 can also have four overwing emergency exits optionally (two on each
side).

The A320 has four overwing emergency exits (two on each side). The A321
aircraft has four emergency exits doors (two on each side) located forward and
aft of the wing.

On the A318, A319 and A320 aircraft, for emergency evacuation the exit can be
opened from inside or outside the cabin to activate the evacuation system.

For normal operation, they are always armed.

To open the exit for maintenance work, authorized personnel must disarm it from
inside the cabin.

The A321 exit can be opened from inside or outside.

These emergency exits are armed in flight but disarmed on ground.

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Figure 13. EMERGENCY EXITS

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EMERGENCY EXITS (continued)

ESCAPE SLIDE AND SLIDING WINDOWS

On the A318, A319 and A320, an overwing escape slide is installed on each
side of the aircraft.

Each slide is stowed in a compartment at the wing root.

On the A321, an escape slide packed in a container is installed in the fuselage

under each emergency exit.

The slide is deployed automatically as soon as a door is opened in armed

configuration.

The ECAM page indicates the emergency exit locked/unlocked and escape
slide armed/disarmed condition.

The two cockpit sliding windows, one on each side, provide emergency exit from
the cockpit.

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Figure 14. EMERGENCY EXITS - ESCAPE SLIDE AND SLIDING WINDOWS

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CARGO DOOR

The cargo compartment doors, installed on the lower right hand side of the
fuselage, give access to the forward and aft cargo compartments. They open
outwards and upwards from the fuselage.

They are manually locked and unlocked by a locking handle on the door. The
operation of the door is hydraulically powered by the yellow electric pump.

In case of electrical failure the door can be opened manually by using a hand
pump.

The bulk cargo door is optionally installed for A320 and A321 in the rear of the
aft cargo door and gives access to the bulk cargo compartment. This door is
manually operated and opens into the bulk cargo compartment.

The ECAM page indicates cargo doors closed/locked and unlock condition.

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Figure 15. CARGO DOOR

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AVIONICS COMPARTMENT DOORS

There are four avionics compartment doors in the lower fuselage around the
nose landing gear bay.

These doors are manually operated and open inward. The locking mechanism
is identical on each door.

Each avionics compartment door is monitored by a proximity switch, which

sends a signal to the ECAM system.

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Figure 16. AVIONICS COMPARTMENT DOORS

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COCKPIT DOOR

The cockpit door separates the cockpit from the cabin.

GENERAL
It is an armored and bulletproof door made to prevent a hijacking
attempt and protect the flight compartment against an intrusion.

A Cockpit Door Lock System (CDLS) controls its electrical release

and prevents an unwanted access into the cockpit.

The door also has a door escape hatch, with two pip-pins which
keep the hatch in position.

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Figure 17. COCKPIT DOOR - GENERAL

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COCKPIT DOOR (continued)

DOOR ELEMENTS

The door has an escape hatch which has the same structure as the door. The
hatch is manually operable only from the flight deck for pilot emergency exit in
case of cockpit door jamming.

Three mechanical latches engage in electrical release strikes actuated by

solenoids. The door is always locked when closed and the A/C is powered.

During maintenance activity there is a magnetic door stop to keep the door fully
open.

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Figure 18. COCKPIT DOOR – DOOR ELEMENTS

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COCKPIT DOOR (continued)

COCKPIT DOOR LOCK SYSTEM

The CDLS controls the locking and unlocking of the cockpit door. It also
monitors the door locking and unlocking system for faults. The system has
different parts:
- the control unit on the overhead panel with an integrated pressure sensor
part for cockpit decompression detection and integrated maintenance lights,
- the cockpit door panel on the center pedestal with a toggle switch to control
the cockpit door and a fault indicator,
- the buzzer on the overhead panel,
- the keypad in the cabin for cockpit access authorization,
- three electrical release strikes,
- an optional back-up system may be installed to override an inadvertent mal
function of the CDLS. It has an additional control unit, and a back-up control
panel with a back-up switch and a fault light.

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Figure 19. COCKPIT DOOR - COCKPIT DOOR LOCK SYSTEM

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COCKPIT DOOR (continued)

OPERATING MODES

The CDLS has two access modes.

The first access mode is a Routine Access mode triggered by a single P/BSW
from the cabin keypad (# key), to request entry in the cockpit via a buzzer.

The request can be allowed or denied via the P/BSW of the cockpit door panel
on the center pedestal.

In case of no response, the cockpit door remains closed.

The second access mode is the Emergency Access mode activated by a four-
digit code (plus the # key) entered on the keypad.

If the pilots deny the request, the keypad and the buzzer are inhibited for a
defined time.

In case of no action from the pilots, the cockpit door unlocks after a preset
time.

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Figure 20. COCKPIT DOOR - OPERATING MODES

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Figure 21. COCKPIT DOOR – OPERATING MODES

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CONTROL AND INDICATING

In this topic the door control and indication will be presented.

PASSENGER DOORS
Two different indicating systems are installed on the door:
- a mechanical indicating system,
- an electrical indicating system.
The mechanical indicating are:
- a visual indicator on the top of the door shows if the door is LOCKED or
UNLOCKED,
- a visual indicator on the slide arming lever shows if the slide is ARMED or
DISARMED.
The electrical indicating are:
- two warning lights installed below the door window,
- they are visible from the inside and the outside.

When a person tries to open the door the white SLIDE ARMED light indicates
that the escape slide is in the ARMED mode.

The red CABIN PRESSURE light flashes when there is a residual pressure in
the cabin with the slide disarmed.

Warning: Do not open a door when the aircraft is pressurized. This will cause
explosive decompression, and kill or cause injury to persons and material.

Note: The A321 emergency exit doors have the same control indicating as the
passenger doors.

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Figure 22. CONTROL AND INDICATING - PASSENGER DOORS

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CONTROL AND INDICATING (continued)

EMERGENCY EXITS

Accidental opening of the cover flap for access to the inner control handle will
automatically activate the white indication light beside the exit.

The ARMED/DISARMED condition of the exit is indicated on the ECAM

DOOR/OXY Page (DISARMED position only for maintenance work).

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Figure 23. CONTROL AND INDICATING - EMERGENCY EXITS

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CONTROL AND INDICATING (continued)

CARGO DOORS

Two different indicating systems are installed on the cargo door:

- a mechanical indicating system,
- an electrical indicating system.

In the access panel at the bottom of the door, there are indication windows to
check if the door is correctly locked.
- red marks: door not correctly locked,
- green marks: door correctly locked.

When the door is fully open and locked, a green indicator light comes on, on
the cargo door control panel. The cargo door control panel is installed on the
centre line of the aircraft near each door.

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Figure 24. CONTROL AND INDICATING - CARGO DOORS

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CONTROL AND INDICATING (continued)

ECAM DOOR/OXY PAGE

The ECAM page - DOOR/OXY monitors the status of all the doors and the
escape slide/slide raft.

The indications on the ECAM page are:

- green when the door is closed and locked,
- amber when the door is unlocked.

The white SLIDE indications on the ECAM DOOR page means that the slides
are armed.

When the slide is disarmed on any door no indication is displayed.

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Figure 25. CONTROL AND INDICATING - ECAM DOOR/OXY PAGE

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Airbus A318/A319/A320/A321 ATA 51-57
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MAINTENANCE/TEST FACILITIES

The MCDU is used to trouble shoot the monitored components through the
INST and L/G keys. The proximity sensors, which monitor the status of the
doors, are connected to the ECAM system or Landing Gear Control Interface
Units (LGCIUs).

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Airbus A318/A319/A320/A321 ATA 51-57
(CFM 56 and IAE V2500) cat. C AIRFRAME STRUCTURES

Figure 26. MAINTENANCE/TEST FACILITIES

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Airbus A318/A319/A320/A321 ATA 51-57
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SAFETY PRECAUTIONS

When you work on the aircraft, make sure that you obey all the AMM safety
procedures. This will prevent injury to personnel and/or damage to the aircraft.
Here is an overview of main safety precautions about the door system.

Be careful before opening a cabin door. Make sure that the red warning light
does not flash. If it flashes, it means a residual pressure remains in the cabin.
When you open in this configuration a door it could kill or cause serious injury
to persons and cause damage to the aircraft.

Make sure that when you work on a cabin door the emergency control handle
is in the disarmed position with the safety pin installed. Check that the
percussion lever of the door damper and emergency operation cylinder is in
disarmed position with the safety pin installed.

Install a safety barrier or an access platform before opening any cabin door.
When opening or closing a cargo door, make sure that the access platform is
at the correct height.
When the wind speed is expected to exceed 40 knots do not open the forward
or aft cargo door and if open close the doors immediately. Stay beside the
cargo door during opening or closing. Use protective
clothes Use solvents/cleaning agents, sealants and other special materials only
with a good flow of air through the work area. Put on protective clothing,
rubber gloves, goggles and mask. Obey the manufacture's instructions when
you use these materials.

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Airbus A318/A319/A320/A321 ATA 51-57
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Figure 27. SAFETY PRECAUTIONS

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