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Beijing
Aviation College
Training Manual
Jet
Aircraft
Maintenance
Fundamentals
ATA 21
Air Conditioning
JAR-66
Book No:
Lufthansa
Technical Training GmbH
Lufthansa Base Hamburg
Beijing
Aviation College
ATA 21 AIR CONDITIONING SYSTEM
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ATA 21 Lesson 1
INTRODUCTION
Nowadays, aircraft fly at very high altitudes mainly for economic reasons.
This presents some problems, because humans are not able to live in this
environment without help.
At an altitude of 40.000 ft feet the temperature is about --56E C.
The air pressure is so low that there is not sufficient oxygen for human survival.
Therefore, the crew and passengers must be protected against freezing and
death.
The air conditioning system makes sure there is correct pressure in the cabin
to support life and it also ventilates the cabin to keep the temperature in a
comfortable range.
Now imagine an aircraft standing on the ground on a hot and sunny day with no
air conditioning.This would be uncomfortable and potentially life--threatening for
passengers on board. Also the equipment on the aircraft would be in danger of
overheating.
In summary, we can say the air conditioning system cools and heats the air. It
also ventilates the cabin and pressurizes the aircraft at high flight altitudes.
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Figure 1
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Figure 2
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Figure 3
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AIRCRAFT ZONES
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Freshness
min
0,35 kg/min
Figure 4
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Ozone Converter
Air Filter
Figure 5
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CLEANLINESS
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Correct
Humidity
Grafik fehlt
Figure 6
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HUMIDITY OF AIR
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Pressurization
Figure 7
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PRESSURIZATION
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SYTEM LAYOUT
Here you see the principle layout of the air conditioning system.
The air supply comes from the pneumatic system.
The air conditioning system starts after the pack valve.
The air is cooled by two or more identical packs.Basic temperature and
humidity regulation are carried out in this area of the system.
The air conditioning system then mixes cooled air with hot air to give the desired temperature in the conditioned compartments.
The air conditioning system also supplies the necessary cooling of panels,
batteries and electronic racks by ventilating them with air.
Finally, the conditioned air is distributed to the compartments.
The cabin and flight compartment are pressurized to supply a pressure
corresponding to all flight altitudes. This is regulated by the outflow valve.
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Figure 8
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SYSTEM LAYOUT
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Mixing
Unit
Pack
Valve
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Figure 9
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introduction cont.
The air conditioning controls are located on the overhead panel in the cockpit.
You will also find the indication displays in the cockpit.
The pack and zone controllers are located in the avionics compartment.
The low pressure ground connectors are located on the lower fuselage,
accessible by a door.
The air conditioning packs, the valves and the mixing unit are located in the
center wing box area.
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Figure 10
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introduction cont.
The basic idea of cooling is that because heat is a form of energy it cannot be
made or destroyed, it can only be transformed.
Heat can only flow from an object to a cooler object.
There are three types of cooling device used on aircraft. They are the heat
exchanger, the vapor--cycle machine and the air--cycle machine.
Heat exchangers are very effective, but they do not have sufficient power to
cool all of the cabin air, especially on the ground.
Vapor--cycle machines are used in aircraft when engine bleed air is not
available.
The cooling principle is basically the same as in a refrigerator. An expansion
valve expands a special pressurized cooling fluid by a specific amount.
The special cooling fluid expands which results in the fluid becoming colder.
This cold fluid flows through an evaporator, which is a special heat
exchangerand is heated by the cabin air which flows across the evaporator. So
the result is that the cabin air temperature decreases.
The cooling fluid, which is now heated by the cabin air, changes its state from a
fluid to a gas.
The special cooling fluid, which is now a gas, is compressed in the compressor.
This compression gives the gas a higher temperature. This hot gas flows
through a condensor, which is a special heat exchanger.
In the condenser the special cooling gas is cooled down by ambient air. It
becomes liquid and the cycle starts again.
You can find vapor cycle machines on small aircraft with propellers, on aircraft
without an APU and on older aircraft.
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COMPRESSOR
Figure 11
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introduction cont.
Air--cycle machines use bleed air which comes from the pneumatic system.
The air is under pressure and hot.
The hot, pressurized air flows into a compressor, which increases the pressure
and the temperature.
The heat exchanger receives hot air from the compressor.
The heat exchanger has ambient air flowing across it. Heat decreases but
pressure remains equal.
After the air has been through the heat exchanger, it flows into a turbine. Here,
the air which is now warm, but still highly pressurized, expands and cools.
This cold air then goes to the cabin.
Air--cycle machines are driven by the turbine.
The turbine and the compressor are mounted on one shaft.These machines
are used in most jet aircraft.
In the following lessons there are further details about air--cycle machines.
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Figure 12
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COOLING DESCRIPTION
COOLING PACK
The function of the cooling pack is to cool hot bleed air to a value given by the
pack controller.
The cooling pack has a pack valve, which is the tap of the pack, an ozone
converter which is located upstream of the pack valve and a heat exchanger
which usually has two units, the primary and secondary or main heat
exchanger.
There is also an air--cycle machine and a bypass valve also called temperature
control valve.
The cooling pack also has a ram air system which has ram air ducts with ram
air inlet and exit doors and a fan.
Cooling pack sensors sense the temperature in the pack and these permit the
pack to be controlled and monitored.
There is an anti--ice valve or sometimes an anti--ice function which eliminates
icing conditions in the water separator and so, of course, there is a water
separator.
The cooling pack has a pack check valve which is located downstream of the
water separator.
The pack check valve prevents backflow into the pack. Each pack has a pack
controller which controls pack operation.
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Figure 13
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COOLING PACK
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OZON CONVERTER
The ozone converter is built in upstream of the cooling pack.
Ozone converters are found particularly in aircraft which fly at high altitudes,
because there is a lot of ozone in the atmosphere. Because ozone harms a
persons health, the function of the ozone converter is to minimize the amount
of ozone in the cabin.
The ozone converter minimizes the amount of ozone in the cabin by using a
catalyst which converts the ozone to harmless oxygen.
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Figure 14
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PACK VALVE
The pack valve is a flow control valve, so it is sometimes named the pack flow
control valve or FCV.
It determines the amount of air going to the cabin.
For this reason it is located upstream of the air conditioning packs.
The pack valve is a venturi--type butterfly valve, which is controlled by a
solenoid. It is pneumatically operated and spring--loaded to closed.
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Figure 15
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PACK VALVE
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packvalve cont.
The pack valves have also a shut--off function.
It is controlled to close from the fire handle, during engine start and from the
pack switch.
Each pack has its own pack switch. These switches are located on the air
conditioning panel in the cockpit. Our example shows the air conditioning panel
of an Airbus A320, which has 2 packs.
Please recognize that in the aircraft you must always follow a check list before
you switch on the pack switch. In a later lesson you will learn more about the
necessary precautions.
When a pack switch is operated the pack valve solenoid is de--energized and if
there is bleed air available the pack valve opens. Because of the fail--safe
philosophy, the pack valve also opens when the electrical power supply is
broken. Otherwise, if pneumatic power is not available the pack valve closes.
This is because the actuator spring closes the valve.
There is a microswitch built into the pack valve, it shows whether the pack
valve is fully closed or in the open position.
The pack valve also has a manual override which lets you fix the valve in a
closed position.
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Figure 16
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Figure 17
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REGULATING ASSEMBLY
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Our aircraft, which is an Airbus A 320, supplies 0.9m 3 of fresh air per second to
the cabin .
So first, lets convert the volume flow to minutes by multiplying by 60 s per minute then divide by the assumed maximum number of persons, which is, for this
aircraft type 150, this gives us 0,36 m/3 per minute per person.
So this meets the regulations.
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Figure 18
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AIRFLOW DIAGRAMM
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Figure 19
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HI FLOW SELECTION
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Figure 20
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ATA 21 Lesson 3
HEAT EXCHANGER
Cooling in the cooling packs is a system of heat exchangers and a cooling
machine, the air--cycle machine, which we study in the next segment.
Modern packs have two heat exchangers to improve the cooling effect. So you
can see what the two heat exchangers look like we have separated them for
you.
They are named the primary heat exchanger and the secondary or main
heat exchanger.
Normally, as we have mentioned, the two heat exchangers are mounted
together so they appear to be one component.
The advantage of the two heat exchangers being mounted together is that only
one cooling duct is necessary.
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Figure 21
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HEAT EXCHANGER
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Figure 22
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AIR-CYCLE MASCHINE
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Figure 23
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CONSTRUCTION
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Figure 24
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OPERATION
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BYPASS VALVE
To adjust the temperature in the pack there is a turbine bypass valve built in.
This valve is also called temperature control valve in some aircraft types.This
valve determines the air mass to the turbine.
The more air that flows to the turbine, the higher the turbine speed and the
more the cooling effect.
The location of the bypass valve can change with aircraft type. Sometimes,
only the turbine is bypassed . If this is the case, a bypass check valve is built in
to bypass the compressor, so only part of the air is compressed.
Sometimes, you can find a bypass valve which bypasses the whole air--cycle
machine.
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Figure 25
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BYPASS VALVE
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Position Indicator
Figure 26
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BYPASS VALVE
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RAM AIR
The temperature in the cooling pack can be adjusted by the bypass valve, but
as we mentioned before, adjusting the ram air flow through the heat exchanger
influences the efficiency of the heat exchanger and therefore the temperature
in the cooling pack.
Here you can see a heat exchanger more closely.
The heat exchanger has a cooling air inlet and it has a cooling air outlet.
As ram air is used as cooling air, the air inlet is named the ram air inlet or R.A.I
and the air outlet is named the ram air outlet or exit or R.A.E.
Here you can see a different type of heat exchanger. On this type of heat
exchanger the principle is the same, but the airflow is different from the other
type.
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Figure 27
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HEAT EXCHANGER
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Figure 28
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WATER SEPARATION
INTRODUCTION
In this lesson we examine why and how the cooling packs separate water from
bleed air in the cooling cycle.
Water has to be eliminated because temperatures can reach --50E C in the
cooling packs and any water droplets in lines and valves could freeze. Also,
any water in the cabin could end up as fog or water droplets causing passenger
discomfort and corrosion in the cabin and the distribution lines.
As you can see from the diagram, the amount of water in the air depends
mainly on temperature.
The warmer the air, the more water it can carry. So, as you have probably realized, air near the ground has a large amount of water dissolved in it. This water
condenses in the cooling cycle.
At high flight altitudes the air is very cold and, therefore, very dry so there is no
water which can condense in the cabin. This very dry air is good for the aircraft,
but not so good for the passengers who would prefer more humidity.
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Figure 29
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introduction cont.
Water separation happens in the cooling pack.
There are two ways to separate water. Which system is used depends on the
manufacturer of the cooling pack.
Water can be separated in the high pressure loop, after the air is compressed
by the compressor and before it goes into the turbine. Or water can be
separated in the low pressure loop, which means the water droplets are
separated after leaving the air--cycle machine and before leaving the pack.
In any system the separated water is then collected and sent to the ram air inlet duct to increase the cooling efficiency of the heat exchanger.
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Figure 30
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WATER SEPARATION
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Jet Pump
Figure 31
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Figure 32
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WATER SEPERATOR
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Figure 33
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WATER ASPIRATOR
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Figure 34
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Figure 35
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WATER EXTRACTOR
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Figure 36
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ICE PROTECTION
Here is a pack with a low pressure water separator.
A pressure transmitter sends differential pressure information between the
water separator inlet and outlet to the pack controller.
When the differential pressure increases, the pack controller assumes there is
ice and opens the turbine bypass valve more.
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Pressure
Transmitter
Figure 37
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ICE PROTECTION
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Figure 38
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Water Injector
Figure 39
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PACK CONTROL
INTRODUCTION
Each air conditioning pack has its own pack controller and each pack controller
has a back--up controller.
The pack controller and its back--up can be designed as two separate black
boxes or as one device. Each pack has its own pack switch in the cockpit.
Normally the pack controllers are located in the electric and electronic
compartment.
Each pack controller controls its pack completely and independently including
the pack outlet temperature with all associated operations.
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Figure 40
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PACK CONTROL
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PACK SENSOR
There are several sensors built--in to each pack.
The minimum number of sensors you could have in a pack is 3.
These sensors are, the compressor discharge temperature sensor, the pack
discharge temperature sensor and the compressor overheat switch.
This switch is installed for safety reasons and informs the pack controller of
abnormal conditions. In some aircraft types you can find an overheat sensor
instead of a switch.
The pack controller also receives other signals.
The pack controller monitors the pack flow control valve position and sends it
to the ECAM or EICAS for indication.
The pack controller controls the position of the bypass valve and signals the
valve to open more or less depending on the temperature necessary. The valve
position is measured by limit switches and a position potentiometer.
The pack controller controls the position of the ram air inlet door depending on
the temperature required and the flight mode.
The ram air inlet door position is measured by limit switches and a position potentiometer.
The pack controller controls the position of the ram air exit door, depending on
the temperature required and the flight mode: The ram air exit door position is
measured by limit switches and a position potentiometer.
So, in summary, the pack controller receives signals from the pack flow control
valve, the bypass valve, the ram air inlet door and the ram air exit door.
The cockpit also sends a flow demand signal to the pack controller. So,
together with signals from these sensors, the pack controller receives all this
data about the pack.
Pack regulation starts when the flow control valve opens. When the pack
switch in the cockpit is set to ON, the signal goes directly to the pack valve.
The pack valve opens if bleed air is available.
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Figure 41
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PACK SENSORS
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Figure 42
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BACK-UP CONTROLLER
COMPRESSOR OVERHEAT
BYPASS FAILURE
Figure 43
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FAILURE CONDITIONS
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Figure 44
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PACK FAILURE
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PACK INDICATION
You know that all these signals about components and temperatures are used
for pack control, and you have probably worked out that they are also used for
indication.
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Figure 45
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INDICATION
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Figure 46
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ECS PAGE
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Figure 47
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BLEED PAGE
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Figure 48
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MAINTENANCE PAGE
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DISTRIBUTION
INTRODUCTION
The cold air from the packs goes into the mixing chamber unit also called the
plenum chamber and is then distributed to the different zones in the aircraft.
The mixing unit is a large chamber, like a big duct which has ports for incoming
air and outgoing air.
The mixing unit lets the cold air from the packs mix with discharged cabin air. It
directs the mixed air through the primary supply ducts to the different aircraft
zones.
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Figure 49
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MIXING UNIT
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ATA 21 Lesson 6
AIR FLOW
Mixing unit location and output requirements are different on different aircraft
types.
You can see here the location of the mixing unit on a small aircraft, the Airbus
320. It only has 2 cabin zones to supply the forward zone and the aft zone.
From the mixing unit the air flows along the primary supply ducts that are
located horizontally along the fuselage. Then the air goes through riser ducts
which are located vertically along the fuselage.
The air finally goes to the zones through the outlets in the cabin.
The air for the cockpit supply goes through seperate ducts that you will look at
more closely later in the lesson.
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Figure 50
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airflow cont.
In this example of an Airbus the passenger cabin air distrbution uses primary
supply ducts that are located on both sides of the cabin under the cabin floor.
From the primary supply ducts, small riser ducts go between the windows to
the outlets above and below the hatracks.
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Figure 51
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airflow cont.
Here you can see a distibution system that uses the same components, but
has a different layout.
In this example the air first goes through big riser ducts to the ceeling and is
then distributed by primary supply ducts.
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Figure 52
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AIR DISTRIBUTION
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airflow cont.
On some aircraft, the passengers have an individual air supply system.
The passengers individual air supply system, also named a gasper system, is
below the hatracks.
In this system you can adjust the outlets to change the quantity and direction of
the air.
The system is supplied by normal cabin air or an individual supply duct.
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Figure 53
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RECIRCULATION SYSTEM
As you have already seeen the mixing unit also gets discharged cabin air to
increase the airflow rate to the cabin.
This system is called recirculation system.
The system supports the airflow from the packs, so that the packs do not have
to run on high airflow each time. This reduces the operational costs of the
aircraft.
When the recirculation system is on there is an airflow through the mixing unit
and through the cabin.
The recirculation fans suck discharged cabin air from the underfloor area, clean
it with filters and feed it back into the mixing unit.
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Figure 54
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RECIRCULATION SYSTEM
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Figure 55
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COCKPIT AIR
Now lets have a look at air distribution in the cockpit.
As the cockpit crew are responsible for the safety they need the very best
working conditions possible.
The cockpit area mainly gets fresh air from the packs. There are 2 different
ways to ensure that the cockpit only receives fresh air.
One way is to take air directly from the pack before it goes into the mixing unit.
The second method is the aerodynamic way. Here the air is taken from the
mixing unit but because of the location of the cockpit supply duct it gets only
fresh air.
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Figure 56
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Figure 57
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Figure 58
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The air source for the trim air system is usually downstream of the pack valves.
Remember that the pack valves are flow control and shut--off valves so the trim
air is usually part of the calculated airflow for the cabin.
When all packs are switched off the supply for the trim air system also stops,
because the trim air valves and the pressure regulating valve close. This
means that the cabin zones only get the recirculated cabin air and there is no
temperature control.
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Figure 59
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Figure 60
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Duct Temperature
Demand
Figure 61
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Figure 62
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PROTECTION CIRCUTS
The protection circuits of the zone temperature control system protect the
system from duct overheat in the event of component malfunctions or
miscontrol in manual mode.
The protection circuits are independent of the temperature control circuits. The
circuits can be either external or internal to the zone temperature controller.
The protection circuits use sensors or overheat switches in the air supply ducts
located downstream of the trim air valves.
When the duct temperature exceeds a critical level, which in this example is
about 90C, then the protection circuit becomes active. It triggers a crew alert
in the cockpit, for example a FAULT light in the control pushbutton.
At the same time the protection circuit automatically closes the trim air
pressure regulating valve. This also closes the trim air valves.
The hot trim air therefore stops independently of the failure source.
In some aircraft types you must indicate to the protection circuit that you have
recognized this failure condition by pressing the pushbutton which displays the
fault light.
When the trim air system is off, then the ducts are only supplied from the
packs and the recirculation system. This cools down all ducts.
When the duct temperature decreases below for example 70C, the FAULT
light extinguishes. This indicates that you can reactivate the zone temperature
control system.
When the trim air system is on again, the trim air pressure regulating valve and
the trim air valves move to the position that is defined by the zone temperature
control circuit.
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Figure 63
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PROTECTION CIRCUTS
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COMPONENTS
The zone controller which is the main component is usually a digital computer.
It is located in the electric and electronic equipment compartment.
The other components are usually located behind the forward cargo
compartment.
All trim air valves in an aircraft are generally of the same valve type. They are
usually operated by an electrical stepper motor.
The valves have potentiometers and limit switches for position feedback and
for control and indication.
Usually, there is also a manual override and visual position indicator on the
valve.
The trim air system switches off completely when a trim air valve is blocked in
the open position or when the zone controller doesnt get a feedback signal
from a valve.
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Figure 64
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components cont.
The trim air pressure regulating valve is a solenoid controlled and pressure
actuated valve.
When the solenoid is de--energized, the valve is closed by a spring.
When you energize the solenoid then the valve is openes by air pressure from
the pneumatic system.
The valve regulates the downstream pressure to ,for example, 4 psi above
cabin pressure.
The exact value depends on the aircraft type.
The valve position is always monitored by the zone controller by means of a
limit switch.
There is also often an pressure switch or sensor downstream of the valve
which monitors the trim air pressure.
Our example shows the trim air pressure regulating valve located inside the
pressurized area of the aircraft. In this case the valve receives cabin pressure
directly.
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Pneumatic
Pressure
Cabin
Pressure
Figure 65
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components cont.
In this example which shows another aircraft type, there are 2 valves in the
unpressurized area near the packs.
In this case cabin pressure is supplied via pressure reference tubes.
Some valves have a second solenoid. It is energized when the duct
temperature increases to an overheat condition. This reduces the trim air pressure and also the hot airflow.
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Pneumatic
Pressure
To Zone Controller
Figure 66
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components cont.
Finally, we will have a look at the temperature sensors in the zone temperature
control system.
We can differentiate between 2 types of temperature sensor installation. The
duct temperature sensors and the zone temperature sensors. All sensors are
of the thermistor type.
The duct sensors measure the temperature of the airflow directly and send the
signal to the zone controller. If a sensor fails the zone controller usually closes
the corresponding trim air valve.
To prevent this some aircraft types have 2 sensors in one housing.
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Figure 67
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components cont.
The zone temperature sensors are installed in the cabin ceiling area.
There is 1 or more in each zone, depending on the size of the zone.
The sensors must be ventilated to measure the real temperature. In some
aircraft types this is done by an electrical fan.
Another way is for the sensors to be connected to the lavatory ventilation or the
equipment cooling system which draws air through the sensors.
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Sensor Housing
Cabin Air
Inlet
Sensor
Housing
Figure 68
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Figure 69
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Figure 70
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ATA 21 Lesson 8
VENTILATION
INRODUCTION
You can find several different types of ventilation systems on an aircraft.
There is a ventilation system for the galleys and lavatories which removes hot,
humid and stale air.
Another type of ventilation system in the cargo compartments can change the
air when necessary, for example, when carrying live cargo.
There is also a separate system for equipment cooling, we learn about this in
the next lesson.
The first system we are going to study is the cargo ventilation.
The various cargo compartments can be sub--divided into 4 different ventilation
types, the non--ventilated cargo compartment, the ventilated cargo
compartment,.which can be heated or unheated and the air--conditioned cargo
compartment.
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Figure 71
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VENTILATION SYSTEMS
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In a ventilated cargo compartment system, cabin air goes through exit grill and
enters the cargo hold.
The air is extracted from the compartment by differential pressure or by fans
and it then goes overboard through the outflow valves.
Another way to ventilate the forward cargo compartment is to supply it with
discharge air from the equipment cooling system via a duct.
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Figure 72
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CARGO COMPARTMENTS
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Figure 73
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Figure 74
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CARGO VENTILATION
CONTROLLER
Figure 75
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Figure 76
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Hot Air
from Pneumatic
System
Figure 77
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Hot Air
from
Figure 78
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CARGO OVERHEAT
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Figure 79
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Figure 80
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Figure 81
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FAULT CONDITION
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Figure 82
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EXTRACTION FAN
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ATA 21 Lesson 9
SYSTEM COMPONENTS
The equipment cooling system uses electrically operated valves to control the
air flow for the different modes of operation. These valves work as shut--off
valves, but in some aircraft they can also be moved to a partially open position.
There are two similar fans in this cooling system which transports the air. They
guarantee system operation even if one fan is not operating.
Sometimes there is a skin heat exchanger installed which increases the cooling
efficiency. The skin heat exchanger is a duct or duct system directly under the
aircraft skin. It works as an air -- to -- air heat exchanger. Warm air flows
through this duct and is cooled by the cold skin when the aircraft is flying at
high altitudes.
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Figure 83
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Figure 84
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ABNORMAL SITUATIONS
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AUTOMATIC OPERATION
Usually the equipment cooling system works automatically in two different
modes.
These modes depend mainly on the ambient temperature and whether the aircraft is on the ground or in flight.
In automatic operation there are 2 normal modes.
One is called inboard, which means that the exhaust air goes to the underfloor
area or to the forward cargo compartment.
The second mode is called outboard, which means that the air goes out of the
aircraft.
The outboard mode is normally used on ground.
The electric equipment is cooled by air from outside the aircraft which enters
through the skin air inlet valve.
The 2 fans transport the air, which exits the aircraft via the extractor valve. All
other valves are closed.
When the outside temperature is so cold that the equipment could be damaged
by ice or humidity, cabin air is used instead of ambient air.
The inboard mode is normally used during flight, take off and landing. In this
mode the skin inlet and extractor valves are closed and discharged cabin air is
used.
In this inboard mode, as you can see, the air flows through the electric equipment and then goes to the underfloor area or to the forward cargo compartment.
During automatic operation, the equipment cooling system computer receives
all the data necessary to ensure that the equipment cooling system operates in
the best and safest way for the equipment.
In addition to the two modes shown, in some aircraft types there are several
other submodes available.
These Modes are defined by the manufacturer for each aircraft type.
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Figure 85
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OVERRIDE OPERATION
The override operation occurs for example when the equipment cooling system
has a component failure or if smoke is detected.
In these abnormal situations the cockpit crew gets an indication from the
controller. When this happens they must manually operate the cooling system.
If there is a component failure, for example if 1 fan is damaged then a low flow
situation is detected by a low flow detector. This low flow detector sends a
signal to the equipment cooling system computer. In this case, the cockpit crew
gets a caution message on the ECAM/EICAS display.
On some aircraft types a fault light is also displayed.
In our example the blower push button switch has to be pushed to close the
valves.
The equipment continues to be cooled by the one operational fan which moves
the air in a closed circuit around the equipment and by the surrounding air from
the cockpit.
On some aircraft this configuration is selected automatically.
The cooling efficiency can be increased by supplying conditioned pack air or by
using a skin heat exchanger.
If a smoke detector detects smoke you get a smoke warning in the cokpit, a
caution message appears on the ECAM/EICAS displays and on some aircraft a
fault light also illuminates.
When this happens the equipment cooling system must be set to the override
mode and the air sent out of the aircraft for safety.
There is further information in lesson 26--3 about smoke detection in the
equipment cooling system.
The switch or switches for putting the system in override operation are on the
ventilation panel.
You must press the blower and extract pushbutton switches to put the system
in override operation.
The override operation turns off the 2 fans opens the extractor valve and on
some aircraft also the air conditioning inlet valve. All other valves are closed.
The cabin differential pressure gives an air flow through the equipment and
causes the air to flow out of the aircraft.
The system operates in the same way if the two fans are damaged.
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A ground crew call horn alerts the ground crew when the cooling air gets too
hot or a blower is not working correctly.
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Figure 86
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OVERRIDE OPERATION
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3
8,000
Figure 87
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definitions cont.
When the aircraft is on ground with open doors the ambient pressure and the
cabin pressure are the same.
Now the aircraft climbs to 40000 ft in 20 minutes. This means that the aircraft
has a positive rate of climb of 2000 ft /min, this is also called vertical speed.
In the same time the cabin has to climb only to 8000 ft. This is called the cabin
rate or cabin vertical speed. In our example the cabin climbs, with a positive
climb rate of 400 ft/min. This means that the pressure in the cabin decreases
at the same time
When there is a negative cabin rate, like during a descent, then the pressure
increases. This means that an increase of cabin altitude is always a decrease
of the cabin pressure and a decrease of cabin altitude is an increase of cabin
pressure.
The pressure changes and therefore the cabin rates must not exceed a certain
value for a longer period of time. This is because the human ear needs some
time to compensate for the pressure inside the inner ear. Therefore the positive
cabin rate should not exceed 500 ft /min and the negative cabin rate should
not exceed 300 ft/min per minute.
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Figure 88
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CABIN RATE
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SYSTEM LAYOUT
As you have learned already the pressurized cabin gets a constant airflow from
the air conditioning system.
The pressure in the cabin is regulated by one or more outflow valves, which
limit the amount of air leaving the cabin. You can find the valves on the aft
fuselage or on some aircraft there is one aft valve and one forward valve.
Air also leaves the cabin via leakages and overboard vents for example from
the lavatories. This is taken into account by the control circuits.
The cabin pressure and therefore the cabin altitude is stable when the amount
of air which enters the cabin and the amount of air which leaves the cabin are
the same.
When pack number 2 is switched off the cabin air supply is decreased.
Without any reaction the cabin altitude increases.
To stabilize the cabin altitude you must also decrease the amount of air that
leaves the cabin.
When the outflow valves are driven to a more closed position the airflow that
leaves the cabin is decreased. This stabilizes the cabin altitude again at for example 6000 ft.
Another parameter that influences the cabin pressure is the flight altitude,
because it determines the differential pressure at the outflow valves.
When the aircraft flies higher, for example at 40000 ft, the differential pressure
increases. This also increases the airflow through the outflow valves if they
stay in the same position. Therefore to hold the cabin altitude at the same level
you must drive the outflow valves toward closed.
Note that some aircraft types have a reduced maximum flight altitude when
only one pack is operating. This is for when you cannot hold the cabin altitude
even with fully closed outflow valves.
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Figure 89
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CABIN PRESSURIZATION
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definitions cont.
Some aircraft types have an overboard shutoff valve instead of a forward
outflow--valve.
Usually the valve is closed and the recirculation fans suck the air from the forward cabin underfloor area back into the distribution.
When the recirculation fans are switched off the valve opens to extract the air
from the forward area to overboard.
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Figure 90
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PROTECTION FUNCTIONS
The aviation regulations require that pressurization systems have protection
functions.
They must prevent damage to the aircraft and injury to the people on board,
when the system has a failure or when extreme environmental conditions appear.
The protection functions must become active when there is an excessive cabin
altitude, or excessive differential pressure, or negative differential pressure.
When the cabin altitude increases above normal values -- 3 things must
happen at different altitudes.
Before reaching 10000 ft the flight crew gets a warning to put on the oxygen
masks.
At 14000 ft the oxygen masks are automatically released from the passenger
cabin ceiling.
At 15000 ft the outflow valves must close automatically and independently of
the normal control signal.
When the differential pressure increases the stress on the aircraft structure
also increases.
To prevent structural damage the aircraft must have at least 2 safety valves
also called positive pressure relief valves. You can find the valves for example
in the area of the aft pressure bulkhead.
The valves open against a spring when the differential pressure exceeds a
maximum allowed value. This value depends on the aircraft type and starts at
about 8.5 psi.
Below this value the valve closes again so that the differential pressure is
limited to this value.
A negative differential pressure means that the pressure in the cabin is lower
than the ambient pressure. This is very dangerous because the fuselage is only
constructed for a positive differential pressure.
A negative pressure relief valve prevents this, because it opens when the
ambient pressure is higher than the cabin pressure.
In some aircraft types you do not find a separate negative pressure relief valve,
because this is also a function of the safety valve. You will see this in more
detail later in this lesson.
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Cockpit Warning
Figure 91
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Negative
Pressure
Relief
Valve
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Figure 92
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EQUALIZATION VALVES
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Figure 93
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June 1998
INDICATION
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FUNDAMENTALS
ATA 21 Lesson 10
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June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
Figure 94
HAM US jk
June 1998
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Aviation College
FUNDAMENTALS
ATA 21 Lesson 10
DITCHING MODE
In some aircraft types you can find a ditching pushbutton on the control panel.
You can use this button to isolate the cabin from entering water during an
emergency landing on sea
When you press the ditching pushbutton you close all valves below the flotation
line of the aircraft, and also the pack valves, so water cant enter the aircraft via
these valves.
When the negative pressure relief valve is located below the flotation line, as in
our example, a standpipe prevents water entering the cabin.
When you press the ditching pushbutton with the aircraft on the ground you
must be very careful, because the closing valves can injure personnel that are
near the valves.
You must also ensure that the cabin is not pressurized by an external air
conditioning unit, because an uncontrolled cabin pressure can build up .
Note that the equipment cooling is also effected when their valves are closed.
During the aircraft normal ground time the outflow valves are fully open to
prevent unintended cabin pressurization.
You can see on the indication that the valves for the equipment cooling system
are also open.
HAM US jk
June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
Figure 95
HAM US jk
June 1998
DITCHING MODE
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FUNDAMENTALS
ATA 21 Lesson 10
AUTOMATIC MODE
As you already know a cabin pressure controller automatically controls the
normal pressurization.
To do this the controller uses the atmospheric ambient pressure. It receives the
pressure from the air data system or from a static port. It also uses the cabin
pressure from a direct pressure port on the controller.
The controller converts pressure signals into altitudes.
For an average value it uses the references of the international standard atmosphere which you know from other units such as aerodynamics and oxygen.
To get exact values you must take into account the actual weather conditions
which influence the pressure. This is acheived by a reference pressure signal
called the barometric correction.
In modern aircraft either the flight management or the air data system delivers
this signal automatically.
On other aircraft you must select this barometric correction value on the
pressurization panel.
HAM US jk
June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
BAROMETRIC
CORRECTION
Figure 96
HAM US jk
June 1998
AUTOMATIC MODE
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FUNDAMENTALS
ATA 21 Lesson 10
HAM US jk
June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
1000 ft
Sea
Level
Figure 97
HAM US jk
June 1998
GROUND MODE
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ATA 21 Lesson 10
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June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
T/O
Sea
Level
HAM US jk
-Throttles
-Engine
Parameters
-Aircraft
Speed
Pre-Pressurization
Figure 98
June 1998
PRE-RESSURIZATION MODE
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FUNDAMENTALS
ATA 21 Lesson 10
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June 1998
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Sea
Level
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June 1998
FUNDAMENTALS
ATA 21 Lesson 10
Climb
Figure 99
HAM US jk
Beijing
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FUNDAMENTALS
ATA 21 Lesson 10
HAM US jk
June 1998
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Aviation College
ATA 21 Lesson 10
Time to
TOC
Sea
Level
Time to Reach
Figure 100
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June 1998
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Beijing
Aviation College
FUNDAMENTALS
ATA 21 Lesson 10
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June 1998
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ATA 21 Lesson 10
Sea
Level
Figure 101
HAM US jk
June 1998
ABORT MODE
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FUNDAMENTALS
ATA 21 Lesson 10
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June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
Top of Climb
Sea
Level
Figure 102
HAM US jk
June 1998
CRUISE PHASE
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FUNDAMENTALS
ATA 21 Lesson 10
HAM US jk
June 1998
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Max
FUNDAMENTALS
ATA 21 Lesson 10
SAFETY
MARGIN
Sea
Level
Sea
Level
Figure 103
HAM US jk
June 1998
CRUISE MODE
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FUNDAMENTALS
ATA 21 Lesson 10
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June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
Sea
Level
Figure 104
HAM US jk
June 1998
DESCENT MODE
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FUNDAMENTALS
ATA 21 Lesson 10
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June 1998
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ATA 21 Lesson 10
Figure 105
HAM US jk
June 1998
OUTFLOW VALVES
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FUNDAMENTALS
ATA 21 Lesson 10
HAM US jk
June 1998
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ATA 21 Lesson 10
Figure 106
HAM US jk
June 1998
SAFETY VALVE
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FUNDAMENTALS
ATA 21 Lesson 10
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June 1998
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ATA 21 Lesson 10
Figure 107
HAM US jk
June 1998
DIFFERENTIAL PRESSURE
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FUNDAMENTALS
ATA 21 Lesson 10
HAM US jk
June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
Figure 108
HAM US jk
June 1998
LEAKAGE TEST
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FUNDAMENTALS
ATA 21 Lesson 10
HAM US jk
June 1998
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FUNDAMENTALS
ATA 21 Lesson 10
Figure 109
HAM US jk
June 1998
SAFETY BARRIERS
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FUNDAMENTALS
ATA 21 Lesson 10
HAM US jk
June 1998
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Ameco
TABLE OF CONTENTS
Beijing
Aviation College
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURIZATION AND ZONES . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING FUNCTION . . . . . . . . . . . . . . . . . . . .
SYTEM LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
4
8
16
18
18
COOLING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OZON CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PACK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PACK VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CYCLE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAM AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
26
28
30
34
42
44
50
54
WATER SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOW PRESSURE WATER SEPARATION . . . . . . . . . . . . .
HIGH PRESSURE WATER SEPARATOR . . . . . . . . . . . . .
ICE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
58
62
68
74
PACK CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PACK SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PACK TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . .
PACK INDICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
80
82
84
90
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECIRCULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
COCKPIT AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAM AIR AND GROUND SUPPLY . . . . . . . . . . . . . . . . . . .
98
98
100
108
112
116
118
118
118
120
122
126
128
138
VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NON VENTILATED CARGO COMPARTMENT . . . . . . . .
VENTILATED CARGO COMPARTMENT . . . . . . . . . . . . .
CARGO COMPARTMENT HEATING . . . . . . . . . . . . . . . . .
AIR CONDITIONED CARGO COMPARTMENT . . . . . . . .
LAVATORY AND GALLEY VENTILATION . . . . . . . . . . . . .
142
142
144
144
152
158
164
166
166
166
170
172
174
174
178
182
186
190
192
210
216
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TABLE OF FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
61
63
65
67
69
71
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 48
Figure 49
Figure 50
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
Figure 63
Figure 64
Figure 65
Figure 66
Figure 67
Figure 68
Figure 69
Figure 70
73
75
77
79
81
83
85
87
89
91
93
95
97
99
101
103
105
107
109
111
113
115
117
119
121
123
125
127
129
131
133
135
137
139
141
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TABLE OF FIGURES
Figure 71
Figure 72
Figure 73
Figure 74
Figure 75
Figure 76
Figure 77
Figure 78
Figure 79
Figure 80
Figure 81
Figure 82
Figure 83
Figure 84
Figure 85
Figure 86
Figure 87
Figure 88
Figure 89
Figure 90
Figure 91
Figure 92
Figure 93
Figure 94
Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Figure 101
Figure 102
Figure 103
Figure 104
Figure 105
VENTILATION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . .
CARGO COMPARTMENTS . . . . . . . . . . . . . . . . . . . . . . .
VENTILATED CARGO COMPARTMENT . . . . . . . . . . . .
VENTILATED CARGO COMPARTMENT . . . . . . . . . . . .
CARGO VENTILATION CONTROLLER . . . . . . . . . . . . .
ELECTRICAL HEATING SYSTEM . . . . . . . . . . . . . . . . .
CARGO HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
CARGO OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONED CARGO COMPARTMENT . . . . . .
AIR CONDITIONED CARGO COMPARTMENT . . . . . .
FAULT CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXTRACTION FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIPMENT COOLING SYSTEM . . . . . . . . . . . . . . . . .
ABNORMAL SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . .
MODES OF EQUIPMENT COOLING . . . . . . . . . . . . . . .
OVERRIDE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .
CABIN ALTITUDE DIFFERENTIAL PRESSURE . . . . .
CABIN RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABIN PRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . .
OVERBOARD SHUTOFF VALVE . . . . . . . . . . . . . . . . . .
EXCESSIVE CABIN ALTITUDE OR PRESSURE . . . . .
EQUALIZATION VALVES . . . . . . . . . . . . . . . . . . . . . . . . .
INDICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABIN PRESSURE CONTROLLER . . . . . . . . . . . . . . . .
DITCHING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROUND MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRE-RESSURIZATION MODE . . . . . . . . . . . . . . . . . . . .
INTERNAL CLIMB MODE . . . . . . . . . . . . . . . . . . . . . . . . .
EXTERNAL CLIMB MODE . . . . . . . . . . . . . . . . . . . . . . .
ABORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCENT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTFLOW VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
145
147
149
151
153
155
157
159
161
163
165
167
169
171
173
175
177
179
181
183
185
187
189
191
193
195
197
199
201
203
205
207
209
211
Figure 106
Figure 107
Figure 108
Figure 109
SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . .
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY BARRIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
213
215
217
219
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