AEROSPACE

Bombardier Inc.
13100, Henri-Fabre Blvd
Mirabel, Quebec H7N 3C6
thd.crj@aero.bombardier.com
TEL 514-855-8500
FAX 514-855-8501

SERVICE LETTER

In-Service
Engineering
CRJ700/900/1000-SL-27-081 Rev B

ATA: 2780

DATE: June 25, 2015

SUBJECT: Wing Slat System Fault Isolation – SLAT FAIL Events Caused by
BPSU Overspeed States Induced by Drive Line Binding

MODEL: CL-600-2C10 and or CL-600-2D24 and or CL-600-2D15

APPLICABILITY: All

PURPOSE:

This Service Letter is issued to brief operators on a condition where drive line binding,
that is not sufficient to jam the slat system, can cause SLAT FAIL events due to certain
dynamic characteristics of the drive system combined with SFECU overspeed
monitoring. The discussion below explains the origins of the issue, how the fault is
posted depending on the SFECU software version, and recommends interim actions
pending the addition of this information to the Fault Isolation Manual.

DISCUSSION:

A number of SLAT FAIL events have occurred that were caused by the detection, by
both SFECUs, of BPSU resolver overspeed states. Subsequent troubleshooting found
that the overspeed states were induced by temporary binding of the drive line on the
same side that had the BPSU overspeed.

In most cases it was found that the binding was induced by frozen water in a slat
actuator (Refer to Service Letter SL-27-074), but any condition that causes temporary
binding of the drive line, and which breaks out before the system jams, can cause a

CRJ700/705/900/1000 SL-27-081 Rev B Page 1 of 5

SLAT FAIL due to the detection of short-duration overspeed states in the BPSU resolver
signals.

Analysis of the fault mode suggests that the probable cause is related to drive line
backlash and torsional flex. Although the slat drive line uses solid drive shafts, there are
a large number of spline joints, and normal spline tolerances can result in a significant
amount of rotational backlash between the PDU and BPSU. In addition, due to the
overall length, torsional energy can be stored in the torque tubes themselves.

It is suspected therefore, that when the system is moving or starts to move, and
temporary binding or high breakout force in a slat actuator, track, other component
occurs (binding of a telescoping anti-ice duct is suspected in some cases) but is not
enough to jam the system, in certain cases energy is stored in the drive line which is
then suddenly released as the PDU overcomes the binding condition. The sudden
release of torque energy down the drive line can briefly overdrive the BPSU in a
whiplash effect at a higher than normal speed as it “catches up” with the rest of the drive
line.

The minimum duration for an overspeed (more than 48 deg/sec resolver rate of change
for the slat system) to be detected by the SFECU is very short, only 35 milliseconds
(about the length of time of one frame of video playback). It appears that the “catch up”
condition described above can in some cases make both resolver signals overspeed for
more than 35 milliseconds, which is then detected by both SFECUs, causing a SLAT
FAIL.

The MDC fault indications associated with SLAT FAILS caused by slat drive line binding
are different for Pre-Revision 19 (SFECU P/N 766389M/N) or Post-Revision19 (SFECU
P/N 766389P/R) software configurations:

 SFECU 766389M/N shows “ASYMMETRY” for both SFECUs although there is

no driveline disconnect
 SFECU 766389P/R shows “LEFT(RIGHT) SLAT RESOLVER 1” for SFECU 1
and/or “LEFT(RIGHT) SLAT RESOLVER 2” for SFECU 2.

The differences for the SFECU software versions are due to logic changes made for
software Revision 19:

 In SFECU 766389M/N, a resolver overspeed state of between 35 milliseconds

and 1 second generates “ASYMMETRY”, and an overspeed state of more than 1
second generates “SLAT LEFT(RIGHT) RESOLVER 1(2)”. Binding/whiplash
induced overspeed states are less than 1 second, so ASYMMETRY is the fault
that is seen. To determine which BPSU produced the ASYMMETRY fault, it is
necessary to view the SFECU NVM Failure Byte to determine if
CP_SURFACE_LEFT_OVERSPEED or CP_SURFACE_RIGHT_OVERSPEED
was set in each SFECU.
 In SFECU 766389P/R, the above described 35 millisecond to 1 second
asymmetry logic was deleted by software Revision 19 to eliminate the
“ASYMMETRY” message, so that any resolver overspeed state of more than 35
milliseconds generates “SLAT LEFT (RIGHT)RESOLVER 1(2)” in MDC. This

CRJ700/705/900/1000 SL-27-081 Rev B Page 2 of 5

 was done to avoid having to view the SFECU NVM Failure Byte to determine
which BPSU produced the overspeed state.

Note that the troubleshooting procedures based on the above overspeed detection logic
are for SLAT HALFSPEED events, with a single SFECU affected, because the >48
deg/sec overspeed state is assumed to be due to a defect within a resolver or its wiring,
and as such, is likely to occur only in one resolver circuit. With the finding that SLAT
FAIL events are being caused by mechanically induced overspeed in both BPSU
resolvers, it is apparent that technicians can be misled into troubleshooting the BPSU or
wiring when the probable cause is with one or more slat actuators.

Also note that in some cases, even though the SLAT FAIL occurred because both
SFECUs detected a resolver overspeed due to drive line binding, the CURRENT
FAULTS page in MDC may show the RESOLVER fault for only one SFECU. This is due
to the fault priority logic of the DCUs, which assumes that this type of resolver fault only
occurs in a single channel, and therefore may inhibit the second SFECU’s RESOLVER
fault from being posted in CURRENT FAULTS (although both channels should show the
RESOLVER fault on the FAULT HISTORY page on subsequent flight legs). In such
cases, each SFECU’s NVM will confirm that resolver overspeed was detected by both
SFECUs.

OPERATOR ACTION:

To avoid unnecessary BPSU related troubleshooting/removals, operators should brief

technicians on the following points:

 High driveline breakout forces, although not sufficient to cause system jams, can
generate SLAT FAIL events due to the detection by both SFECUs of transient
overspeed states, in the same BPSU, caused by the aforementioned drive line
binding/whiplash effect.
 For SLAT FAIL events, the fault indications from these overspeed states, and
recommended actions, are dependent on the SFECU software version as
follows:

SFECU N/M:

EICAS: SLAT FAIL

MDC MESSAGE: ASYMMETRY
NVM FAULT: ASYMMETRY (In each SFECU)
NVM FAILURE BYTE SET: CP_SURFACE_LEFT (RIGHT)
OVERSPEED (In each SFECU)

Therefore, for SFECU N/M, when a SLAT FAIL event shows ASYMMETRY in
MDC and it is confirmed that there is no drive system disconnect, troubleshoot
for drive line binding (such as a partially frozen slat actuator) before
troubleshooting the BPSU/wiring. To know which side had the binding, it may be
necessary to interrogate each SFECU’s NVM Failure Byte to determine if

CRJ700/705/900/1000 SL-27-081 Rev B Page 3 of 5

 CP_SURFACE_LEFT_ OVERSPEED or CP_SURFACE_RIGHT_OVERSPEED
is set and troubleshoot the indicated side.

SFECU P/R:

EICAS: SLAT FAIL

MDC MESSAGE: SLAT LEFT(RIGHT) BPSU/RESOLVER 1
and/or SLAT LEFT(RIGHT)
BPSU/RESOLVER 2
NVM FAULT: LE(RI)_RESOLVER_WIR (In each SFECU)
NVM FAILURE BYTE SET: CP_SURFACE_LEFT (RIGHT)
OVERSPEED (In each SFECU)

Therefore, for SFECU P/R, when a SLAT FAIL event shows RESOLVER 1
and/or RESOLVER 2 in MDC, troubleshoot for drive line binding before
troubleshooting the BPSU/Wiring. Because the side with the binding is indicated
by the MDC message, interrogation of NVM is not essential to know which side
to troubleshoot.

NOTE

If the MDC CURRENT FAULTS page shows a RESOLVER fault for only
one SFECU, the fact that a SLAT FAIL occurred (assuming no pre-
existing HALFSPEED condition) can be considered an indication that the
resolver fault was detected by both SFECUs (due to drive line
binding/whiplash) but only one was posted in MDC. If desired, a review
of the SFECU NVMs can confirm that overspeed was detected in both
SFECUs, but in any case troubleshooting should proceed based on drive
line binding.

 For SLAT HALFSPEED events, where the above data is shown for only one
SFECU in both MDC and NVM, assume a valid BPSU resolver/wiring defect in all
SFECU versions and troubleshoot accordingly.

In general, when these events occur in cold weather and the SLATS FAIL occurs as
soon as slat extension is selected, suspect moisture in one or more slat actuators.
When these events occur after a successful initial movement, or in above freezing
weather (there have been cases of SLATS FAIL during retraction on the ground), look
for any mechanical condition that could temporarily block the slat, such as binding in the
drive system and actuators, tracks, and the telescoping ducts for wing anti-ice and
wiring.

CRJ700/705/900/1000 SL-27-081 Rev B Page 4 of 5

Operators that suspect chronic water ingress is causing SLAT FAIL events, either due to
jams or whiplash-induced overspeed, are encouraged to incorporate Service Bulletin
670BA-27-060 which adds drainage for the slat actuator bearing housing. In addition,
Service Letter SL-27-080 provides a suggested short term mitigation procedure to
reduce the effects of water ingress.

BOMBARDIER ACTION:

A review of the applicable Fault Isolation procedures is underway to determine what

Fault Isolation Manual changes are appropriate to the conditions described in this
Service Letter.

Please direct responses and inquiries the content of this Service Letter to your
Bombardier Aerospace Regional Aircraft Field Service Representative or the Technical
Help Desk in Montreal at telephone number (514) 855-8500 or facsimile (514) 855-8501
or e-mail thd.crj@aero.bombardier.com

On File On File
John Kahn Herman Bijl
Specialist, Hydro-Mechanical Systems Manager
In-Service Engineering In-Service Engineering, Systems

CRJ700/705/900/1000 SL-27-081 Rev B Page 5 of 5