B767 200-300 BOOK 21 101 - Air Conditioning

B767/21/101 Air conditioning

Boeing 767-200/300

Air conditioning Training manual For training purposes only LEVEL 1

ATA 21

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Training manual

This publication was created by Sabena technics training department, Brussels-Belgium, following ATA 104 specifications. The information in this publication is furnished for informational and training use only, and is subject to change without notice. Sabena technics training assumes no responsibility for any errors or inaccuracies that may appear in this publication. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Sabena technics training.

Contact address for course registrations course schedule information Sabena technics training [email protected]

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LIST OF EFFECTIVE PAGES 1................................................ 11 - 04 - 2012 2................................................ 11 - 04 - 2012 3................................................ 11 - 04 - 2012 4................................................ 11 - 04 - 2012 5................................................ 11 - 04 - 2012 6................................................ 11 - 04 - 2012 7................................................ 11 - 04 - 2012 8................................................ 11 - 04 - 2012 9................................................ 11 - 04 - 2012 10.............................................. 11 - 04 - 2012 11.............................................. 11 - 04 - 2012 12.............................................. 11 - 04 - 2012 13.............................................. 11 - 04 - 2012 14.............................................. 11 - 04 - 2012 15.............................................. 11 - 04 - 2012 16.............................................. 11 - 04 - 2012 17.............................................. 11 - 04 - 2012 18.............................................. 11 - 04 - 2012 19.............................................. 11 - 04 - 2012 20.............................................. 11 - 04 - 2012 21.............................................. 11 - 04 - 2012 22.............................................. 11 - 04 - 2012 23.............................................. 11 - 04 - 2012 24.............................................. 11 - 04 - 2012 25.............................................. 11 - 04 - 2012 26.............................................. 11 - 04 - 2012 27.............................................. 11 - 04 - 2012 28.............................................. 11 - 04 - 2012 29.............................................. 11 - 04 - 2012 30.............................................. 11 - 04 - 2012 31.............................................. 11 - 04 - 2012 32.............................................. 11 - 04 - 2012 33.............................................. 11 - 04 - 2012 34.............................................. 11 - 04 - 2012 35.............................................. 11 - 04 - 2012 36.............................................. 11 - 04 - 2012 37.............................................. 11 - 04 - 2012 38.............................................. 11 - 04 - 2012 39.............................................. 11 - 04 - 2012 40.............................................. 11 - 04 - 2012 41.............................................. 11 - 04 - 2012 42.............................................. 11 - 04 - 2012 43.............................................. 11 - 04 - 2012 44.............................................. 11 - 04 - 2012 45.............................................. 11 - 04 - 2012 46.............................................. 11 - 04 - 2012

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TABLE OF CONTENTS 1. ECS - GENERAL. ....................................................................................................................6 1.1. Overview..............................................................................................................................6 1.2. General Description. ............................................................................................................8 1.3. Control & Indication...........................................................................................................12 2. ECS EICAS DISPLAY. ............................................................................................................16 3. COOLING PACK GENERAL. .................................................................................................18 3.1. General Description. ..........................................................................................................18 4. TRIM AIR SYSTEM. .............................................................................................................20 4.1. General..............................................................................................................................20 5. VENTILATION SYSTEM. ......................................................................................................22 5.1. General..............................................................................................................................22 6. SUPPLEMENTAL HEATING SYSTEM. ..................................................................................24 6.1. Description. .......................................................................................................................24 7. EQUIPMENT COOLING - GENERAL. ...................................................................................26 7.1. Control & Indication...........................................................................................................28 7.2. System description. ............................................................................................................30 7.2.1. General. ...................................................................................................................30


LIST OF ILLUSTRATIONS AFT EQUIPMENT COOLING/LAV./GALLEY VENTILATION (GENERAL) ........................................ 23 AUTO CONTROL - SIMPLIFIED ................................................................................................ 37 CABIN PRESSURE MANUAL CONTROL ................................................................................... 39 CABIN PRESSURIZATION CONTROL SYSTEM........................................................................... 33 CONTROL AND INDICATION .................................................................................................. 13 CONTROL & INDICATION ....................................................................................................... 15 CONTROL & INDICATION ....................................................................................................... 35 ECS EICAS DISPLAY ................................................................................................................ 17 ECS GENERAL .......................................................................................................................... 9 ECS OVERVIEW ....................................................................................................................... 7 EQ COOLING - GENERAL ....................................................................................................... 27 EQUIPMENT COOLING CONTROL PANELS .............................................................................. 29 FWD CARGO AIRCO .............................................................................................................. 45 FWD EQUIPMENT COOLING .................................................................................................. 31 PACK GENERAL ..................................................................................................................... 19 POSITIVE & NEGATIVE PRESS. RELIEF VALVE............................................................................ 41 SUPPLEMENTAL HEATING (COCKPIT) ..................................................................................... 25 SYSTEM OPERATION .............................................................................................................. 31 TRIM AIR & ZONE CONTROL SCHEMATIC .............................................................................. 21

8. PRESSURIZATION - GENERAL. ...........................................................................................32 8.1. Control & Indication...........................................................................................................34 8.2. Auto Mode Operation........................................................................................................36 8.2.1. Auto Control - Simplified. ........................................................................................36 8.3. Manual Mode Operation....................................................................................................38 8.4. Pos. & Neg. Press Relief Valve. ............................................................................................40 8.5. Indicating & Warning Systems. ...........................................................................................42 8.5.1. General. ...................................................................................................................42 9. FWD CARGO AIRCO SYSTEM - GENERAL DESCRIPTION. .................................................44

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ABBREVIATIONS AND ACRONYMS A/C AC ACM ADC ALT APU AUTO AUX BITE CDU CL CLR CMD Cmptr COMP CONT Cont Desc DIFF DK E&E E/E ECS ECS EEC EICAS EQ EROPS EXCH EXH FCSOV FCV FLT FMC FWD GAL GND HT INB(D) IND

Aircraft Alternating Current Air Cycle Machine Air Data Computer Altitude Auxiliary Power Unit Automatic Auxiliary Built-In Test Equipment Control & Display Unit Close Clear(ance) Command Computer Compass, Compensator Controller Control(ler) Descent Differential Deck Electronic and Equipment Electrical/Electronic Environmental Control System Electronic Cooling System Electronic Engine Control Engine Indicating and Crew Alerting System Equipment Extended Range Operations Exchanger Exhaust Flow Control & Shutoff Valve Flow Control Valve Flight Flight Management Computer Forward Galley Ground Heat Inboard Indication

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INOP LAV LDG LLV LRU MAN MAX MID MIN OP Outbd OVBD OVHT OVRD PCB PFCACC Press PRSOV PSU PWR RECIRC SOL SOV Sq STBY SUP SW T/D TAI TCV TEMP VAL VENT VLV

Inoperative Lavatory Landing Gear Low Limit Valve Line Replaceble Unit Manual Maximum Middle Minimum Open Outboard Overboard Overheat Override Printed Circuit Boards Pack Flow and Cargo Air Conditioning Controller Pressure Pressure Regulating and Shutoff Valve Passenger Service Units Power Recirculation Solenoid Shutoff Valve Square Stanby Supply Switch Time/Delay Thermal Anti Ice Temperature Control Valve Temperature Valve Ventilation Valve

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1. ECS - GENERAL. 1.1. Overview. The environmental control system (ECS) provides a controlled environment for the cabin areas, the E & E equipment, and cargo compartments. System Description. The environmental control system is divided into three major subsystems : - Air conditioning, - Equipment cooling, - And pressurization. Air conditioning is divided into the following subsystems : - Air conditioning packs, - Recirculation, - Cabin (zone) temperature control, - Ventilation, - And supplemental heating.

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ECS OVERVIEW EFFECTIVITY ALL

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1.2. General Description. The air conditioning system provides the means for controlling the temperature and humidity within the airplane and the amount of airflow into the airplane. Air Conditioning Pack & Zone Temperature Control. The two air conditioning packs and a six (6) zone temperature control (trim air) system operate from a source of hot pressurized air, creating a supply of conditioned air, which is controlled to maintain selected temperatures and ventilation rates within the flight compartment zone and passenger compartment zones (FWD AUX, FWD, MID AUX, MID, & AFT). Automatic control functions are accomplished with digital and analog controllers, logic cards, electrical hardware, and electro-pneumatic and/or electric valves. Recirculation. To reduce the amount of bleed air required for ventilation in the compartments, a recirculation system is incorporated. This system recycles filtered cabin air by mixing it with pack discharge air before it is distributed to the flight and passenger compartments. Approximately one-half (50%) of the total airflow to the flight and passenger compartments is composed of recirculated air. This maintains proper ventilation and provides reasonable temperatures in addition to reducing the amount of bleed air required. A set of filters and two fans are used in this system. Distribution. The distribution system connects the air conditioning packs, the recirculation system, and the zone temperature control (trim) systems to the six (6) temperature controlled zones.


Lavatory/Galley ventilation. This system performs three functions. It insures odors are removed from the lavatories and galleys, it draws air across zone temperature sensing devices, and it provides the draw-through air cooling for the aft equipment rack (E6). This system operates automatically and uses one of two vent fans to draw air from the various areas and discharges it near the pressurization outflow valve. Bulk Cargo Ventilation. This system supplies cabin air to the bulk cargo compartment and provides a means to vent it. A fan supplies air to the compartment. The system operates automatically if the compartment temperature is high or may be selected ON for continuous operation. Cargo - Heating. Supplemental heating is provided to the forward, aft, and bulk cargo compartments, flight compartment, and passenger compartment. The cargo systems are controlled independently of each other and operate automatically when selected ON. All three systems use two valves, temperature activated switches and air from the pneumatic distribution system to heat the compartments. Electrical Heating. The flight compartment has electrically operated in-line heaters on the air conditioning ducts that provide air to the rudder pedal area and the side windows. The passenger compartment has the same type of in-line heaters to heat air that is provided near the base of the passenger entry/service doors.

The system uses various types and sizes of ducts. There are two ventilation systems incorporated into the 767.

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L. PACK AUTO

LEFT PACK CONTROLLER

RIGHT PACK CONTROLLER R. PACK AUTO

1

AUT O

F A U L T

INOP

AUTO R. COOLING PACK

PACK OUT TURB IN SEC HX OUT COMPR OUT PRIM HX OUT PRIM HX IN PRECOOL OUT DUCT PRESS PACK FLOW TEMP VALVE RAM IN DOOR RAM OUT DOOR

FWD AUX ZONE

FWD CARGO AC/VENT FAN

OK

ECS/MSG

AUTO L. COOLING PACK

PACK DEMAND TEMP.

TEMP SELECTION

C VENT W

AUX ZONE CONTROLLER

FWD CARGO COOLING

FLT DECK COMPT TEMP

FWD ZONE MID ZONE

MID AUX ZONE

ZONE CONTROLLER

L 2 9 1 98 44 171 193 40 120 0,75 0,65 0,61 FLT DK

DUCT TEMP TRIM VALVE

30 0,75

R 3 10 3 96 46 173 196 42 120 0,80 0,71 0,72

ISO VALVE

FROM LEFT PNEUMATIC SYSTEM AUX TEMP BITE ZONE TEMP BITE R PACK BITE L PACK BITE HI FLOW INHIBIT FWD CARGO HEAT AFT CARGO HEAT BULK CARGO HEAT

OZON CONVERTER (OPTIONAL)

FLOW SENSOR

INOP

INOP

FWD CAB

MID CAB

AFT CAB

AUTO

AUTO

AUTO

L STBY. «N» C

OFF W

C

OFF W

Training manual

TRIM AIR

C

OFF W

BULK CARGO TEMP

R FLOW CONT VALVE

AUX FWD

FWD

28 0,80

28 0,80

AUX MID

28 0,80

25

MID

17 0,00

AFT

17 0,00

LEFT COOLING PACK

MAINTENANCE MESSAGES & INFORMATION LOWER EICAS CRT (P2)

FLT DECK

RIGHT COOLING PACK

GND CONNECTION

FWD ZONE TRIM AIR PRESS REG

L. COOLING PACK (4°C) STBY TEMP CONTROLLER

L - RECIRC - R ON

ON

OFF

INOP

INOP

ZONE TRIM AIR MODULATING VALVES

R. COOLING PACK (4°C)

R STBY. «N»

ON

L

L REC FAN

R

R REC FAN MIX MANIFOLD

FLT DK INOP

FLOW SENSOR

L FLOW CONT VALVE

AFT ZONE INOP

FROM RIGHT PNEUMATIC SYSTEM

APU

MID ZONE

AFT ZONE

ISO VALVE

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TO CARGO HEAT

W

C

AUTO

R PACK RESET

L PACK RESET INOP

C

MAN

OFF

PACK OFF N

S

OFF

W

OFF/ON

AUTO N

S

T C

R. PACK

INOP

W

PACK OFF AUTO

OFF/ON

T C

B Y

TEMPERATURE CONTROL PANEL

W

L. PACK FLOW CONTROL CARD

R FCV - OPEN/CLOSED - NORM/ HI FLOW L FCV - OPEN/CLOSED - NORM/ HI FLOW

B Y

R STBY. «C/W»

R. BACK UP

L STBY. «C/W» L. BACK UP CONTROL CARD

COOL MODE WARM MODE DUCT SENSORS - FB SENSOR - OVHT SENSOR (88°C) - BULB

COOL MODE WARM MODE

LAV/ GALLEY VENTILATION

R. ECS C. ECS

1

IF FWD CARGO AIRCO SYSTEM IS INSTALLED

L. ECS FAN CONTROL CARD

FWD ZONE

MID AUX ZONE

MID ZONE

R REC FAN FWD CARGO

LAV/GAL FAN 2

1

L REC FAN

FWD CARGO A/C SOV

CTL VLV

P50 CARD FILE

ECS GENERAL

OUTFLOW VALVE FAN 2 FA N 1

FWD CARGO TRIM AIR MODULATING VALVE

LAV/GAL. FAN 1

BULK CARGO

HEATING

AIRCO

E & E COOLING SYSTEM

AFT CARGO

AFT ZONE

CARGO HEATING

SOV

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FLT DECK

FWD AUX ZONE

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1.3. Control & Indication. Compartment Temperature (COMPT TEMP) Indicators. Displays actual temperature sensed in the compartment. Compartment Temperature Inoperative (INOP) Lights. Illuminated (amber) — • fault in the trim air controller, • the Compartment Temperature Control is OFF, • the trim air switch is OFF. Compartment Temperature Controls. AUTO • provides automatic compartment temperature control, • rotating the control toward C (cool) or W (warm) sets the desired temperature between 18 degrees C and 30 degrees C. OFF • closes the compartment trim air valve • the compartment temperature INOP light illuminates. TRIM AIR Switch. ON — the trim air valve is commanded open. Off (ON not visible) — the trim air valve is commanded closed. Trim Air OFF Light. Illuminated (amber) — the TRIM AIR switch is off.

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Flight Deck (FLT DK) Temperature Inoperative (INOP) Light. Illuminated (amber) — • fault in the trim air controller, • the Compartment Temperature Control is OFF, • the trim air switch is OFF. PACK RESET Switches. Push — resets an overheated pack if the pack has cooled to a temperature below the overheat level. Pack Inoperative (INOP) Light. Illuminated (amber) — • the pack is overheated, • fault in the automatic control system. PACK OFF Lights. Illuminated (amber) — pack valve is closed. Recirculation Fan (RECIRC FAN) Switches. ON — the recirculation fan operates Off (ON not visible) — the recirculation fan does not operate. Recirculation Fan Inoperative (INOP) Lights. Illuminated (amber) — • the recirculation fan is failed or is not operating, • the RECIRC FAN switch is off.

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COMPT TEMP

INOP

INOP

a

FWD CAB

AFT CAB

AUTO

AUTO

OFF W

C

OFF W

TRIM AIR

C

OFF W

L - RECIRC - R

ON

ON w

OFF

a

MID CAB

AUTO

C

INOP

a

INOP

a

ON w

w

a

INOP a

FLT DK INOP

W

C

a

AUTO

R PACK RESET

L PACK RESET INOP PACK OFF OFF

C

a

MAN

INOP

W

a

AUTO N

S

OFF

C

N

S

W

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T C

B Y

a

AUTO

T

CONTROL AND INDICATION

a

PACK OFF

W

B Y

AIR CONDITIONING CONTROL PANEL

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Flight Deck Trim Air Valve Position Indicator. C (cool) — valve closed, W (warm) — valve open. Flight Deck Compartment Temperature Control. AUTO • provides automatic flight deck temperature control • rotating the control toward C (cool) or W (warm) sets the desired temperature between 18°C and 30°C. MAN • provides manual control of compartment trim air valve, • spring loaded to the 6 o’clock position in this sector. PACK Control Selectors. OFF — closes the pack valve. AUTO — the pack is automatically controlled. STBY — • N (normal) • C (cool) • W (warm)

— regulates the pack outlet temperature to a constant, moderate temperature, — sets the pack to full cold operation, — sets the pack to full warm operation.

CARGO HEAT Switches. ON — provides power for heat valves to cycle open and closed for automatic temperature control, Off (ON not visible) — the heat valves are commanded closed.

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Cargo Heat Overheat (OVHT) Lights. Illuminated (amber) — • cargo compartment temperature above standard control range, • shutoff valve signaled closed. BULK CARGO HEAT Selector. Bulk cargo heat switch must be on NORM — standard cargo heating range. VENT — • requests higher temperature control range than NORM, • turns on ventilating fan for bulk cargo compartment. Equipment (EQUIP) COOLING Selector. AUTO — automatically controls equipment cooling system. STBY — positions equipment cooling system for inboard air flow. FOOT HEATERS Switch. HIGH — the under-floor electric heater operates on high setting. LOW — the under-floor electric heater operates on low setting. OFF — the under-floor electric heater is not operating. SHOULDER HEATERS Switch. HIGH — the electric heater adds heat at high setting to the conditioned air flowing at shoulder level. LOW — the electric heater adds heat at low setting to the conditioned air flowing at shoulder level. OFF — the electric heater is not operating (no heat added to the conditioned air flowing at shoulder level).

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COMPT TEMP

INOP

INOP

a

FWD CAB

AFT CAB

AUTO

AUTO

OFF W

C

OFF W

TRIM AIR

C

OFF W

L - RECIRC - R

ON

ON w

OFF

a

MID CAB

AUTO

C

INOP

a

INOP

a

ON w

w

a

INOP a

FLT DK INOP

W

C

a

AUTO

R PACK RESET

L PACK RESET INOP PACK OFF OFF

C

a

MAN

INOP

W

a

PACK OFF

a

AUTO N

S

OFF

N

S

T C

W

T C

B Y

a

AUTO

W

B Y

AIR CONDITIONING CONTROL PANEL

CONTROL & INDICATION EFFECTIVITY ALL

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2. ECS EICAS DISPLAY. The air conditioning system provides operational information to the EICAS computers for display. Advisories. Advisory messages (level C), are automatically displayed on the upper EICAS CRT. The basic air conditioning system has seventeen (17) messages. If customer options are added, additional messages are displayed when required. Status Messags & Information. Status messages and as options, forward and bulk cargo compartment temperature information,are displayed on the STATUS page of EICAS. The messages shown on the graphic are typical for the air conditioning system. Maintenance Messages & Information. Maintenance messages are provided on the ECS/MSG page of EICAS. This maintenance page may be selected by pushing the EICAS maintenance display select switch (ECS/MSG) located on the P61 panel. Maintenance information for ECS appears on the left of the page. It provides a real time readout of monitored ECS systems. Automatic (AUTO) and manual (MAN) events may be recorded and, recalled for this page.

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ECS EICAS DISPLAY EFFECTIVITY ALL

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3. COOLING PACK GENERAL. 3.1. General Description. Ozone Converter (Optional). The supply air flows through catalytic converters before it enters the flow control and shutoff valves. The catalytic converters reduce the level of ozone in the supply air for the comfort of passengers and crew. Cooling Pack. Supply air enters each cooling pack through the flow control and shutoff valve. The air initially flows through the primary heat exchanger where it is cooled by ram air The air next enters the compressor section of the air cycle machine (ACM). The ACM compresses the air to a higher pressure and temperature. The compressed air then passes through the secondary heat exchanger where it is cooled by ram air. The air then flows through a series of water separation components : - Reheater, - Condenser, and - Water extractor. The air enters the turbine section of the ACM. The air expands in the turbine section and, through expanding, generates power to drive the compressor and fan impellers. The fan impellers drive ram air through its flowpath when the airplane is on the ground. In flight, the fan impellers assist airflow through the ram air path. The energy removed from the supply air during expansion causes a temperature reduction. This results in very low turbine discharge air temperature.

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Water Separator System. High pressure water separation occurs from the following series of airflow through the pack : supply air leaving the secondary heat exchanger passes through the hot side of the reheater; colder air from the water extractor cools the hot air in the reheater. The cooled air then enters the condenser where it is cooled even more by heat exchange with cold turbine discharge air. The air is cooled to a temperature low enough for moisture to condense. Next, the air enters the water extractor. The water extractor removes large droplets of water formed in the condenser. The air then passes a second time through the reheater. The reheater minimizes the temperature difference between the secondary heat exchanger outlet and the turbine inlet. The first pass through the reheater removes heat from the airflow. The second pass returns heat. This reduces the heat added to the turbine discharge air in the condenser and returns the heat to the turbine inlet. Water removed by the extractor is sprayed into the ram inlet and evaporatively cools the ram air providing additional cooling to the ram air system. Temperature Control Valve (TCV). The temperature control valve regulates the flow of hot air through or around the air cycle machine. For maximum cooling, the ram air doors open and the temperature control valve closes. To increase pack discharge temperature, the ram air doors partially close and the temperature control valve opens. Low Limit Control Valve. (LLCV) The low limit control valve provides a deicing function for turbine outlet air. It controls the flow of hot air to the condenser heating muff. The low limit valve also receives signals from the pack controller which opens the valve to limit compressor outlet temperature to 232°C.

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RAM AIR INLET

WATER

SECOND. WATER EXTRACTOR TO TRIM AIR BULB OZON CONVERTER (OPTIONAL)

REHEATER

HEAT EXCHANGERS

FCV

BULB

BULB

PNEUMATIC AIR

COMPRES. OUTLET SENSORS PACK FLOW CONTROL & SHUTOFF VALVE AIRFLOW SENSOR

BULB

CONDENSOR

PACK OUT TURB IN SEC HX OUT COMPR OUT PRIM HX OUT PRIM HX IN PRECOOL OUT DUCT PRESS PACK FLOW TEMP VALVE RAM IN DOOR RAM OUT DOOR

R 3 10 3 96 46 173 196 42 120 0,80 0,71 0,72

CABIN SUPPLY AIR CHECK VALVE

T ACM

RAM AIR EXHAUST

PACK PACK OUTLET OVHT TEMP SW. BULB

GROUND CONNECTION

TCV

R PACK BITE L PACK BITE HI FLOW INHIBIT

MAINTENANCE MESSAGES & INFORMATION LOWER EICAS CRT (P2)

EFFECTIVITY ALL

C

FAN

ECS/MSG

L 2 9 1 98 44 171 193 40 120 0,75 0,65 0,61

BULB

COMPRES. OUTLET OVHT SW.

AUTO STBY PACK TEMP SENSORS LOW LIMIT CONTROL VALVE

PRIMARY WATER EXTRACTOR

' P

PACK GENERAL page 19 11 - 04 - 2012 rev : 1

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4. TRIM AIR SYSTEM. 4.1. General. The trim air system for the flight deck, forward auxiliary, forward, mid auxiliary, mid and aft zones is enabled when either or both packs are operating. The packs provide hot air to the trim air pressure regulating valve. The zone control system for the above zones is enabled when the trim air switch is selected to ON. The zone controller monitors the temperature sensors in the cabin zones, distribution ducting and mix manifold. The controller compares the actual temperatures to the position of the rotary temperature selectors on the temperature control panel. The zone controller sends a demand signal to the (auto) pack temperature controllers to provide the coldest temperature required by the four primary cabin zones. The zone controller regulates the trim air system in order to inject hot air to trim up each individual zone, as required. The auxiliary zone controller monitors the temperature sensors in the two auxiliary zones and associated distribution ducting. By comparing these actual temperatures to those selected by the FWD and MID zone rotary temperature selectors on the temperature control panel, the auxiliary controller controls the position of the forward auxiliary and mid auxiliary trim air modulating valves in order to supply hot trim air to these areas, when required.

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TRIM AIR & ZONE CONTROL SCHEMATIC EFFECTIVITY ALL

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5. VENTILATION SYSTEM. 5.1. General. The 767 ventilation systems are designed to provide the following : - Draw through cooling for the aft equipment rack (E6), - Smoke & odor removal from the galleys, - Odor removal from the lavatories, - Induce airflow through the cabin zone temperature assemblies, - Induce airflow through the bulk cargo temperature sensing assembly, - Ventilation of the bulk cargo compartment (animal carrying option). • The AFT Equipment. COOLING / LAVATORY / GALLEY VENTILATION system provides the first five items listed above. It has two fans, one operating at all times, except during aft cargo fire, & the other is a backup. Control cards provide automatic control. If one fan fails, the backup fan is selected automatically. • The BULK CARGO VENTILATION system provides the sixth item listed above. It has one fan, controlled through relays. The fan may operate automatically as a function of overheat or may be selected ON or OFF.

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EQ COOLING CTL (P5)

115V AC R BUS

28V DC R BUS

AUTO STBY

BULK CARGO HEAT CTL C689 (P11)

BULK CARGO VENT FAN C344(P33)

OVRD

VALVE

28V DC GND HLDG BUS

OVHT

28V DC R BUS

P34

115V AC GND SVC BUS EQUIP COOL AFT FAN 1 (P33)

P11

SMOKE NO COOLING

(P5)

AFT CARGO FIRE ARMED AFT/BULK CARGO FIRE NORM

FUEL JTS ON & L &R BTB CLOSED

BULK CARGO OVHT

PWR

AUTO/OVRD STBY FAN 2 FAIL

OVHT NORM VENT

K346 (P37)

FAN OVHT

K504 (P37)

CURRENT SENSOR (P37)

R ECS FAN CTL CARD (P50)

EICAS

135°C

OVHT

OVHT

BULK VENT FAN (B123)

AFT EQ EXH FAN 1 ,,M,,

R. AC BUS ON

FAN 2 COPYRIGHT SABENA TECHNICAL TRAINING

CHECK VALVE FILTER

TYP ZONE TEMP SENSORS

MUFFLER

AFT EQ EXH FAN 2 ,,M,,

FWD

MID AUX

MID

AFT BULK CARGO VENT FAN

AFT CARGO

AFT EQUIPMENT RACK

AFT GALLEY

FWD AUX

MID GALLEY

EICAS

FLT DECK MID LAV

AFT EQ CLG FAN ,,S,,

FWD GALLEY

2 sec

L. AC BUS ON

L ECS FAN CTL CARD (P50)

OVHT

FAN 1

FWD LAV

CURRENT SENSOR

FAN OVHT

ON

FUEL JTSN ON L & R BTB CLOSED

2 sec

STBY AUTO/OVRD FAN 1 FAIL

K347 (P37)

CURRENT SENSOR

CURRENT SENSOR

P11

P36

PWR

ON VENT

BULK CARGO HEAT

28V DC L BUS

AFT LAV

ON

115V AC L BUS

1

OUTFLOW VALVE

AFT EQUIPMENT COOLING/LAV./GALLEY VENTILATION (GENERAL) EFFECTIVITY ALL

2

BULK VENTILATION FANS

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6. SUPPLEMENTAL HEATING SYSTEM. 6.1. Description. The air supply heating is an electrical in-line airflow heater. It is installed in the conditioned air distribution foot and shoulder air supply ducting for the captain and first officer. The shoulder heater operates at a different wattage than the foot heater. The heaters are located in the forward equipment center on both sides of the nose wheel well box. The shoulder heaters are accessed from the main equipment center entry to each side of the forward equipment center. The foot heaters are accessed from the forward equipment center access door. The heater contains a control thermal switch and a safety thermostat. An airflow direction indicator plate is provided on the heater body.

EFFECTIVITY ALL

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SUPPLEMENTAL HEATING (COCKPIT) EFFECTIVITY ALL

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7. EQUIPMENT COOLING - GENERAL. Purpose. The electrical/electronic (E/E) equipment cooling system provides a supply of cooling air and/or evacuates the hot exhaust air from the electrical and electronic equipment. System Description. The equipment cooling system is divided into a forward and an aft system. The forward system has blow through (forced air) and draw through (suction) cooling. The aft system has draw through cooling only. Both systems are controlled automatically. MODE SELECTION for the desired mode of operation is the only input that is required by the operator. System Interface. Fwd system : Equipment cooling system faults will be annunciated on EICAS, on the equipment cooling control panel, and through the ground crew call horn. Aft system : Aft equipment cooling is provided by the LAV/GALLEY ventilation system. The fan faults will be annunciated on EICAS.

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EQ COOLING - GENERAL EFFECTIVITY ALL

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7.1. Control & Indication. AUTO position provides optimum cooling dependent on system inputs of air/ground relays, skin sensed temperature and engine operation. STBY position puts the equipment cooling system in the standby mode. This is a back-up mode for system failures. OVRD position puts the equipment cooling system in the override mode. This mode is used for system failures and/or smoke clearance. Annunciator Lights. VALVE light indicates a valve malfunction. OVHT light indicates a high temperature or low flow condition. SMOKE light indicates smoke sensed in the equipment cooling ducting. NO COOLING light indicates no airflow through the equipment racks. Miscellaneous Test (P61). Equipment cooling test provides a ground test of the low flow detectors and the smoke detector. Proper operation will illuminate the discrete lights on the equipment cooling control panel.

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EQUIPMENT COOLING CONTROL PANELS EFFECTIVITY ALL

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7.2. System description. 7.2.1. General. Air for system cooling is provided either through an intake (inboard supply valve) behind the cargo compartment sidewall (inboard loop configuration), or by closing the intake and circulating the air already inside the E/E cooling system ducting (closed loop configuration). The air can be cooled by ducting it through the skin heat exchangers. The air is circulated through the system by a supply fan and/or an exhaust fan. A smoke detector, two low flow detectors, and one overheat switch monitor the air as it is being circulated. AUTO select : When the AUTO position is selected on the mode selector switch it will command fan operation and the heat exchanger shutoff valve POSITION. The system logic will determine the status of air/ground, engine operation and skin sensed temperature and position the inboard supply valve and the overboard exhaust valve accordingly.


OVRD select : Selection of OVRD causes the smoke clearance valve and the manifold interconnect valve to open and all other valves to close. It commands both fans OFF. This configuration reduces the possibility of smoke entering the flight compartment and creates and overboard flow to exhaust smoke from the system and provide cooling flow without the fans. INDICATION : EICAS and annunciator lights provide indication for system faults. The fan logic cards provide fan failure signals. The smoke detector provides a smoke detection signal. The indication logic card provides valve and overheat faults. The differential pressure switch provides a no cooling signal during OVRD selection. A test switch provides a system test of the smoke detector and low flow detectors. The ground crew call horn will be activated by a signal from the indication logic card (OVHT on ground or IRS on DC power on ground) or selecting OVRD on the ground which energizes the differential pressure relay.

STBY select : Selection of STBY configures the system valves to a fixed position and commands the supply fan ON. The system logic senses air/ground condition and switches the exhaust fan ON on the ground or OFF in flight.

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FWD EQUIPMENT COOLING SYSTEM OPERATION

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8. PRESSURIZATION - GENERAL. The pressurization system schedules cabin altitude to airplane altitude during a variety of flight modes to minimize passenger discomfort caused by rapid changes in air pressure. System control is maintained in either of two independent automatic modes or by a manual mode. Pressure relief - so that airplane structural limitations are not exceeded is provided two ways. Positive pressure relief is provided by two positive pressure relief valves. Negative pressure relief is provided by four springloaded vent doors which are integral components of the cargo doors. On the -300/-300ER airplanes an additional negative pressure relief door is located forward of the two positive pressure relief valves. Altitude warning is provided by an EICAS level A warning for excessive cabin altitude.

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The cabin pressure control system consists of : - A selector panel, two automatic controllers, an outflow valve, pressure relief valves, and a cabin altitude warning switch. - The components function to permit aircraft flight altitudes up to nominal 43,000 feet with cabin pressure controlled to equivalent altitudes between minus 1,000 feet and 14,000 feet. The nominal maximum pressure differential is 8.6 psi. The selector panel provides control-display interface between the flight crew and the system. The two controllers provide redundant automatic control of the outflow valve actuator. The outflow valve regulates air outflow from the cabin. Two identical pressure relief valves are provided for overpressure protection of the pressurized cabin. Five negative pressure vent doors are provided for negative pressure protection. A cabin altitude warning switch provides indication of excessive cabin altitude.

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PRESSURE CONTROL SELECTOR AND INDICATION PANEL

P 0.5 psi

P +8.9 psi +9.4 psi

P 0.5 psi

DC MOTOR AC MOTORS

P -0.5 psi

CABIN PRESSURE AUTO CONTROLLERS (2) NORM. P 8.6 psi MAX. P +8.8 psi

OUTFLOW VALVE

CABIN PRESSURIZATION CONTROL SYSTEM EFFECTIVITY ALL

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8.1. Control & Indication. Outflow VALVE Position Indicator. OP : Open. CL : Closed Cabin Altitude MANUAL Control. Spring : loaded to center. Controls cabin outflow valve position with the Cabin Altitude Mode Selector in manual (MAN) mode. CLIMB : moves outflow valve toward open. DESCEND : moves outflow valve toward closed. Cabin Altitude MODE SELECTOR. AUTO 1 : - Activates Auto 1 cabin altitude control for automatic operation, - Outflow valve positioned automatically. AUTO 2 : - Activates Auto 2 cabin altitude control for automatic operation, - Outflow valve positioned automatically. MAN (Manual) : - Outflow valve position is controlled by the cabin altitude MANUAL control, - AUTO INOP light illuminates. Landing Altitude (LDG ALT) Indicator. Feet. Displays selected landing altitude. Range is from -1,000 ft to +14,000 ft

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Landing Altitude (LDG ALT) Selector. Rotate - sets landing altitude indicator. Cabin Altitude AUTO RATE Control. Rotate : - Sets limit for cabin altitude rate of climb or descent during auto control - Index mark establishes approximately 500 ft/min climb and 300 ft/min descent. AUTO Inoperative (INOP) Light. Illuminated (amber) : - AUTO 1 and AUTO 2 cabin altitude control functions are inoperative - MAN mode is selected. Cabin Differential Pressure Indicator. Pounds per square inch (psi). Cabin Altitude. Feet x 1,000. Cabin Altitude Rate. Feet per minute (ft/min x 1,000) :- MIN : Climb 50 ft/min. Descent : 30 ft/min. - INDEX : Cl. 500 ft/min. Desc. : 300 ft/min. - MAX : Cl. 2000 ft/min. Desc. : 1200 ft/min. Cabin Altitude Light. Illuminated (red) : - Cabin altitude exceeds 10,000 feet - Extinguishes when cabin altitude descends below 8,500 feet. Pressure Differential (PRESS DIFF) Limit Placard. Specifies differential pressure limitation for takeoff and landing.

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CABIN PRESSURE SELECTOR PANEL

CONTROL & INDICATION EFFECTIVITY ALL

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8.2. Auto Mode Operation. 8.2.1. Auto Control - Simplified. The pressure controller modulates the outflow valve to maintain the desired cabin pressure. Opening the valve allows more air to exhaust from the airplane. This reduces cabin pressure. Closing the valve increases cabin pressure. Modulating the valve between the full open and full close extremes, allows the desired cabin pressure to be maintained.


The selected auto rate limits the rate of change. In cruise, the cabin pressure follows the cabin pressure command. The controller positions the outflow valve to maintain the correct cabin pressure and rate of cabin pressure change. A tachometer on the outflow valve ac motor provides a feedback signal to the controller. If the cabin altitude reaches 11,000 ft (low cabin pressure) the controller automatically closes the outflow valve.

Before takeoff the crew selects the desired auto mode, landing (field) altitude and the auto rate limit. Placing the mode selector to AUTO 1 or AUTO 2 releases control of the pressurization system to the cabin pressurization performance. The other controller goes into a standby mode and monitors the cabin pressurization performance. The airplane’s two air data computers (ADC) supply ambient pressure signals and barometric corrections to each pressure controller. The controller’s integral pressure sensor measures cabin pressure. A throttle advance signal from the throttle microswitch pack assembly greater than 10.5°, puts the controller in the takeoff mode. At lift-off the controller receives a signal from the air/ground relay, and enters the flight mode. Once in the flight mode, the controller references a cabin pressure autoschedule. The autoschedule is the ideal cabin altitude for various airplane altitudes. The selected landing altitude and the maximum cabin—to—ambient pressure ratio (P = 8.6 psi) limit the autoschedule. The error between the cabin pressure and the cabin pressure command determines the cabin pressure change command. EFFECTIVITY ALL

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AUTO CONTROL - SIMPLIFIED EFFECTIVITY ALL

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8.3. Manual Mode Operation. Powered by 28V DC standby bus. A toggle switch controls dc motor movement when the manual mode is selected. Manual CLIMB selection drives the valve open; thus, decreasing cabin pressure and raising the cabin altitude. Manual DESCEND selection drives the valve close; thus, increasing cabin pressure and lowering the cabin altitude. A position potentiometer provides a signal to the cabin pressure selector panel to provide valve indication. Cam operated limit switches located within the DC motor housing cut power to the motor at the full open and full closed limits of travel.

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CABIN PRESSURE MANUAL CONTROL EFFECTIVITY ALL

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8.4. Pos. & Neg. Press Relief Valve. Positive Pressure Relief. Positive pressure relief valves prevent differential pressure from exceeding structural limits in the event of a pressurization system malfunction. The valve is spring-loaded closed. When activated, the respective metering section unseats its ball and allows the cabin pressure inside the valve to vent to ambient. An indicator flag is included in the valve to visually indicate the valve has opened. The rim of the flapper is painted red. The flag will prevent the flapper from completely closing and thus make the red rim of the flapper visible to ground personnel. The indication is reset by manually opening the flapper and pushing the flag in.

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Negative Pressure Relief. Negative pressure relief doors prevent cabin pressure from becoming less than ambient pressure in the event of an emergency descent. Negative pressure of -0.3 to -0.5 psi air load on the negative relief door on the left side of the airplane and the two (negative relief) vent doors in each of the forward/aft cargo doors will cause the doors to open inboard against the spring load. The opening of the cargo door mounted vent doors, due to a negative pressure load, will not operate the cargo door latch mechanism.

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POSITIVE & NEGATIVE PRESS. RELIEF VALVE EFFECTIVITY ALL

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8.5. Indicating & Warning Systems. 8.5.1. General. The pressurization indicating and warning systems provide indication in the flight compartment for : - Cabin pressure differential, - Cabin altitude, - Cabin altitude rate of change, and - High cabin altitude warning (10,000 feet or greater). The pressurization indicating system consists of a differential pressure sensor and a pressurization indication module. The sensor provides a variable resistive signal to the module. The module contains three electrically operated gauges. The gauges are cabin to ambient differential (DIFF), cabin altitude (ALT), and cabin altitude rate of change (RATE).


Cabin Altitude Warning System. An aneroid switch sensing cabin altitude will activate and provide a warning if the cabin pressure decreases to an equivalent altitude of 10,000 feet. The switch resets when the cabin altitude decreases to ± 8,500 ft. Altitude Switch. The switch is located in the main equipment center on the outboard side of the E2 equipment rack. Pressure Indication. Pressure instruments provide an indication of cabin to ambient pressure (differential pressure gage), cabin altitude (cabin altitude gage) and cabin rate of change of altitude (cabin rate gage). Altitude Warning System. When cabin altitude exceeds 10,000 feet the altitude switch actuates, the CABIN ALTITUDE warning lights on the PS and P1-3 panels illuminate, and EICAS will display a level A warning CABIN ALTITUDE.

The warning system consists of a cabin altitude warning switch, two cabin altitude warning lights, an EICAS level A message, two warning lights and an aural warning. The switch provides a signal to activate the warning indications in the flight compartment when cabin altitude equals 10,000 feet or greater.

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THIS PAGE IS INTENTIONALLY LEFT BLANK

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9. FWD CARGO AIRCO SYSTEM - GENERAL DESCRIPTION. The forward cargo air conditioning distribution system supplies conditioned air to the forward cargo compartment. The purpose of the system is to maintain the forward cargo compartment at any temperature between 6°C & 25°C. This allows for any temperature sensitive cargo to be transported in a controlled environment. The forward cargo air conditioning distribution system has a shutoff valve, ducts, restrictors, and outlets. Conditioned air is supplied to the forward cargo compartment from the left air conditioning pack. The forward cargo compartment ducting attaches to the left air conditioning pack outlet duct before the outlet duct reaches the mix manifold. If the air conditioning shutoff valve is open, about 16 percent of the air from the left air conditioning pack flows into the forward cargo compartment ducting, while the rest of the air flows into the mix manifold. If the air conditioning shutoff valve is closed, all of the air from the left air conditioning pack flows into the mix manifold. The shutoff valve controls the supply of air to the forward cargo compartment. The valve is installed in the forward cargo A/C distribution duct just after the duct leaves the mix manifold. When the shutoff valve is open, conditioned air can flow through the dusting, through the outlets, and into the forward cargo compartment. When the shutoff valve is closed, conditioned air cannot enter the dusting and is not supplied to the forward cargo compartment. The shutoff valve is controlled by the pack flow controller. Air leaves the forward cargo compartment via the forward cargo compartment exhaust system.

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When the forward cargo compartment air conditioning system is on, the forward cargo compartment temperature is controlled by the temperature control system. Also, the temperature control system operates in coordination with the forward cargo compartment heating system. It is suggested that the forward cargo heat system be on whenever the forward cargo A/C system is on. This will prevent a large temperature gradient condition occurring in the forward cargo compartment. However, the forward cargo heat system should be selected off when the temperature in the forward cargo compartment is to be maintained below 7°C by the forward cargo A/C system. This will prevent the forward cargo heat system from interfering with the operation of the forward cargo A/C system since both systems are controlled by the pack flow and cargo air conditioning controller (PFCACC). The forward cargo zone temperature selector, located on the pilots’ overhead panel P5, allows selection of automatic control of the zone temperature control system or cargo compartment ventilation. FWD CARGO A/C ON & AUTO. The forward cargo air conditioning shutoff valve opens. The forward cargo heating shutoff valve opens. The forward cargo exhaust valve or the forward cargo ground exhaust valves will open. The left air conditioning pack goes into the high flow mode. FWD CARGO A/C ON & VENT. The forward cargo air conditioning shutoff valve closes. The forward cargo heating shutoff valve closes. The forward cargo exhaust valve or the forward cargo ground exhaust valves stay open. The left air conditioning pack goes into the normal flow mode.

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FWD CARGO AIRCO FORWARD CARGO A/C PANEL

FLIGHT COMPARTMENT

P5 PANEL APU/CARGO FIRE CONTROL PANEL

P8 PANEL

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If the left air cooling pack is inhibited from the high flow mode, the forward cargo air conditioning shutoff valve will remain open. However, because of the reduced air flow, the passenger cabin may not receive the amount of air needed to keep its selected temperature. If the passenger cabin environment is more important than the forward cargo compartment environment, then the FWD CARGO A/C temperature selector should be turned to VENT. If the forward cargo air conditioning shutoff valve fails, the COND CARGO VALVE message will also be shown on the EICAS display. The pack flow controller monitors the shutoff valve and, if a failure occurs, sends a signal to the EICAS computer. A failure occurs when the shutoff valve is not in the position it has been commanded to be in. FWD CARGO A/C INOP/FAULT. Two indications show that a CARGO A/C INOP fault condition has occurred. The INOP light on the FWD CARGO AC module will come on and an EICAS advisory message FWD CARGO A/C” will be displayed. Any of these failures wilt cause the CARGO A/C INOP condition to occur : - The FWD CARGO AC temperature selector potentiometer fails. The auxiliary zone temperature controller fails. Power is not supplied through the auxiliary controller. The forward cargo air conditioning shutoff valve fails.

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B767 200-300 BOOK 21 101 - Air Conditioning

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