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Jun 30/01
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SD3-60 AIRCRAFT MAINTENANCE MANUAL
AMM21-00-00 1.0.0.0AIR CONDITIONING - DESCRIPTION AND OPERATION
1. General
Refer to Figure 1.
A single air conditioning system supplies conditioned air to the flight and passenger
compartments with separate temperature control for each.
The system derives its hot air from bleeds on both engines but will continue to work, with reduced
performance on a supply from one engine only.
2. Bleed air conditioning
Refer to Figure 1. Refer to Figure 2 (Sheet 1).
Bleed air is taken via fixed orifices from the P2.5 and P3 bleed connections on each engine. At
low power settings, when the P3 bleed pressure is below 35 p.s.i.g., the temperature control
valve (TCV) is fully open admitting P3 bleed air only, to operate the system. At high power
settings, when pressure in the P3 bleed line exceeds 35 p.s.i.g. a pressure switch operates to
initiate modulation control via the solenoid selector valve and temperature sensor (TS), initially
closing the TCV. Due to the absence of P3 pressure, the check valve in the P2.5 bleed line
opens, maintaining system requirements on P2.5 bleed air only. Should the temperature in the
common bleed line fall to below 300° F whilst operating on P2.5 bleed air, a temperature sensor
(TS) will modulate the TCV to open, allowing P3 bleed air to mix with P2.5 thus maintaining the
bleed air temperature above 250° F. To prevent spurious over-pressure warning being caused by
a cold TS, a time delay is included to postpone the opening of the TCV until 10 seconds after the
HA/SOV is selected open.
Downstream of the TS air passes through a hot air shut-off valve (HA/SOV), a venturi and a
check valve to a common line. The check valves in each half system prevent cross-flow between
engines and the dumping of all bleed air, should either duct fracture.
Air in the common line passes to a refrigeration unit consisting of a dual heat exchanger and a
three-wheel air cycle machine (ACM). In the heat exchanger the bleed air is cooled in the primary
section, compressed and then intercooled in the secondary section. The cooling medium in the
heat exchanger is ambient air driven through the heat exchanger by the fan of the ACM. The
NACA inlet for ambient air is located in the fuselage roof fairing. A flap at the top rear is spring-
loaded closed and will open inwards to supplement the supply during static running should the
demands of the ACM cause a partial depression within the fairing. A lip at the rear of the flap (aft
hinge point) provides for aerodynamic assistance of flap closure during flight (in addition to spring
action).
From the secondary section of the heat exchanger, the bleed air is ducted to the turbine inlet and
to one half of a dual bypass valve; the outlets from both units combine and deliver the air to a
water separator. The cooled air from the secondary section expands in the turbine and produces
a low temperature and condensed mixture (fog); it also provides the power to drive the
compressor and the fan. The water separator coalesces the fog into drops which, when
Jun 30/01
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collected, are delivered as water to an aspirator which sprays into the cooling air stream of the
heat exchanger.
Beyond the water separator, the ducting divides to provide for the various services detailed in
para 4.
3. Bleed air control, indication and warning
A. HA/SOV control and indication
The left and right motorised HA/SOVs are each controlled by ON/OFF switch modules having
integral line indication of valves open/shut condition on the AIR CONDITIONING panel 9P.
Line indication, which is controlled by 'travel limit' switches within each HA/SOV is provided
by coloured strip lights in the cap of each module. On post-mod A8033 aircraft, indication of
engine bleed point is given by P2.5 (Green letters)/P3 (yellow letters) indicators, one for each
engine.
Power supplies for the left and right control switches are respectively taken from the 28V dc
left shedding busbar and the 28V dc ground services busbar (via 5 amp circuit breakers Nos
90 and 211 on distribution panels 1D and 2D). The power supply for indication is taken from
the 28V dc right essential services busbar via 5 amp circuit breaker No. 196 on distribution
panel 2D.
The HA/SOVs will close automatically in the following contingencies:-
(1) When the Reserve Power System is activated for either engine a supply will be made
available from the relevant reserve power relay to the 'close' field of the HA/SOV on that
side.
(2) Each HA/SOV will close under the influence of its control relay (located on control panel
1C-left, 2C right) should the centre duct temperature exceed 525° F or the centre duct
pressure exceed 35 p.s.i.g.
The initiating circuitry for the control relays is taken from a temperature sensor and an
over-pressure switch situated upstream of the primary heat exchanger in the centre duct.
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SD3-60 AIRCRAFT MAINTENANCE MANUAL
Air Conditioning Schematic
Figure 1
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When either the temperature or pressure switch settings are exceeded the respective
switch contacts make to:-
(a) illuminate the BLEED air caption on the centralised warning panel and the duct
OVERHEAT or OVER PRESSURE light on panel 9P as appropriate.
(b) energise the control relays which 'lock on' providing a supply to the 'close' field of the
HA/SOV.
NOTE: The system is reset by tripping and resetting circuit breakers Nos 90 and 211 on
respective distribution panels 1D and 2D when warning lights are extinguished i.e.
bleed air temperature or pressure has returned to normal.
B. Spar box overheat warning
A thermostat is located in the centre-wing spar box bay left and right at station 68.80. Should
the ambient temperature at either position rise to 110°C, possibly as a result of a leak in
either the air-conditioning or aerofoil bleed air piping, the contact of the thermostat will close
to illuminate:-
(1) The BLEED caption on the centralised warning panel 1P.
(2) The SPAR BOX OVERHEAT lights on panel 9P and the Anti-icing Services Panel 4P.
Power supplies for operation are taken from the 28V d.c. right essential services busbar,
via C/B No. 196 on distribution panel 2D.
NOTE: Upon receipt of a warning, the crew adopt a drill to determine and isolate the source of
seepage.
C. Duct low pressure warning
Warning of duct low pressure is afforded by three LP switches, two of which sense the
pressure of the bleed air ducting immediately downstream of the venturi in each half system
and the other sensing the pressure in the common (centre) duct upstream of the primary heat
exchanger.
Each switch 'breaks' on a rising pressure not greater than 6 p.s.i.g. and 'makes on' a falling
pressure less than the break pressure but not less than 5 ± 0.25 p.s.i.g.
Power supplies for signalling operation are taken from the 28V d.c. right essential services
busbar via C/B No. 196 on distribution panel 2D.
The LP switch in each half system is wired in parallel with the LP switch in the centre duct
and becomes operational only when the HA/SOV is fully open ie. the valve's limit switch has
tripped (open) providing power to operate the LP circuit control relay.
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SD3-60 AIRCRAFT MAINTENANCE MANUAL
With flow in both half systems, should the pressure at any of the three LP switches fall below
the make pressure, a supply will be completed to illuminate the BLEED caption on the
centralised warning panel and the DUCT LOW PRESSURE warning light on panel 9P.
When there is flow in one half system only, the warning lights will illuminate should either the
LP switch in that half system or in the common duct fall below the make setting.
D. Duct overpressure warning
A high pressure switch is tapped into the centre duct upstream of the primary heat
exchanger. The HP switch makes on a rising pressure of 35 ± 1 p.s.i.g. and breaks on a
falling pressure less than the make pressure but not less than 29 p.s.i.g.
NOTE: To avoid initial surge activation of overpressure warning, a 3 second interval should be
observed between ON selection of both engine bleeds.
Should the make pressure be operationally exceeded as a result of a system malfunction a
supply will be completed to illuminate the BLEED caption on the centralised warning panel
and the duct OVER PRESSure light on panel 9P. Power supplies for operation are taken from
the 28V dc right essential services busbar via C/B no. 196 on distribution panel 2D.
Upon a receipt of a warning, the crew adopt a drill to identify and isolate the faulty HA/SOV.
4. Air conditioning services
NOTE: On 300F series aircraft (post-mod A8593), all reference to passenger compartment
services are to be ignored.
- Pre Mod A8593 Air Conditioning Control Panel 9P - Refer to Figure 2 (Sheet 1).
- Post Mod A8593 Air Conditioning Control Panel 9P - Refer to Figure 2 (Sheet 2)).
The deleted services on Figure 2 (Sheet 2) are inhibited.
A. Flight compartment conditioned air
A cold air tapping is taken from downstream of the water separator and is connected to a hot
bleed air junction controlled by an electrically operated, single/dual (-300F series aircraft
bypass valve. The junction forms an ejector type mixer and is connected to a distribution duct
which supplies two floor level distributors located on the left and right of the flight
compartment. The conditioned air enters the flight compartment through a series of holes in
the forward faces of each floor level distributor. The air flow is controlled by manually
operated butterfly valves located at the aft end of each distributor. The valves are identified
CABIN HEAT - ON/OFF.
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A temperature sensor and a duct overheat switch are located in the common duct to the flight
compartment. The temperature control is described in para 6.
NOTE: Except for -300F series aircraft, conditioned air from the passenger compartment
system is available through two gaspers located on the flight compartment aft
bulkhead. See para 4.C.
B. Windshield and side window demisting
Two tappings are taken from the flight compartment conditioned air duct and routed to a
manually controlled butterfly valve located at either side of the flight compartment on the
forward face of station 74 at rear window height. The valves are identified DEMIST - ON/OFF
and control the demist air flow to the flight compartment side windows and windshields.
C. Passenger compartment conditioned air
A cold tapping is taken from downstream of the water separator and is connected to a mixing
box. Hot bleed air is also connected to the mixing box through one half of an electrically
controlled dual bypass valve.
The mixing box forms an ejector type mixer and supplies conditioned air to a distribution duct.
The temperature of the conditioned air is determined by the amount of bleed air allowed to
enter the mixing box via the dual bypass valve.
The distribution duct delivers warm conditioned air to the left and right floor level distributors
or cold conditioned air to the left and right ceiling level distributors. The conditioned air enters
the passenger compartment through a series of holes in the face of each distributor.
The distribution of conditioned air to either the floor level distributors or the ceiling level
distributors is controlled by two manually operated valves located on the left and right of the
flight compartment aft bulkhead. Each valve has two positions:-
(1) SUMMER - with the control lever in this position the duct to the floor level distributors is
blocked off and cold conditioned air is delivered to the ceiling level distributors.
(2) WINTER - with the control lever in this position the duct to the ceiling level distributors is
blocked off and warm conditioned air is supplied to the floor level distributors.
Two tappings are taken from the common duct to the passenger compartment and are
connected to two gaspers, one located on the right and one on the left of the flight
compartment aft bulkhead. The gaspers provide a secondary source of air conditioning
for the flight compartment.
D. Compartment Anti-Fog System
NOTE: On 300F series aircraft (post mod A8593) subsequent reference to passenger
compartment in the following text is to be read as flight compartment.
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In hot, humid conditions, with the air conditioning system operating in the full cooling mode
fogging may appear in the passenger compartment.
This condition ensues when the passenger compartment duct sensor detects an actual
temperature several degrees higher than that at the water separator inlet, modulating both
portions of the dual by-pass valve to close. This may cause the water separator to freeze,
thus activating its integral by-pass and permitting turbine delivered fog from the ACM to enter
the compartment.
In this contingency the ANTI-FOG ON/OFF switch (panel 9P) which series-links a 33K.ohm
resistor with the duct sensor and passenger compartment controller is selected ON.
This will bring the duct sensed temperature, in the full cooling mode to approximate more
closely to that of the water separator.
The sensor will then signal the low temperature limiting circuitry of the controller to modulate
the dual by-pass valve such that the water separator inlet temperature remains above 35° F.
The ANTI-FOG ON/OFF switch should not be switched ON in normal conditions, so that, in
the heating mode, the passenger compartment duct temperature upper limit of 160° F (71°)
remains effective and full advantage of the cooling mode is available when fog would not
ensue.
E. Individual ventilation
(1) Passenger compartment
Individual ventilation is provided by air outlets (gaspers) located on the passenger
service units (PSUs). The PSUs are located above the seats on each side of the
passenger compartment. The right hand side PSUs have double gasper installations.
Each gasper comprises a manually operated butterfly valve which is opened and closed
by a knurled ring located on the bottom of each gasper.
Two cold air tappings are taken from downstream of the water separator. One tapping is
connected, via a flap valve, to the right gasper system and the other is connected, via a
second flap valve, to the left gasper system. The flap valves prevent feed back from the
gasper fans.
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Control Panel 9P (Pre-mod A8593)
Figure 2 (Sheet 1)
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SD3-60 AIRCRAFT MAINTENANCE MANUAL
Control Panel 9P (Post-Mod A8593)
Figure 2 (Sheet 2)
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(2) Flight compartment
Two gaspers, one for the left side and one for the right side, are located on the main
instrument panel 1P and provide cool, conditioned air for the flight compartment.
Pre Mod A8593
The cool air for the flight compartment gaspers is tapped from the left and right supply to
the passenger compartment. The tappings are taken downstream of each flap valve and
are connected to the associated gasper via a collector box. The collector box prevents
ingress of water and/or condensation when the gasper boost system is in operation. See
para 4.F.(2).
Post Mod A8593
From the two tappings in the water separator outlet duct, cold air is ducted to either side
of the aircraft to individual gaspers positioned in the flight deck. There is no gasper ram/
fan system.
F. On-ground ventilation
On-ground ventilation, with engines shut down, may be taken from any of the following
independent sources.
(1) Main Fan
The fan, situated within the fuselage roof between stations 74 and 137 supplies ambient
air via a tapping in the main ducting immediately downstream of the water separator. A
shut-off valve in the fan duct prevents back flow through the fan when the normal air
conditioning is operating.
(a) Shut-off valve
The shut-off valve idented HR6, is actuated by a split field (open-shut) series wound
motor, incorporating limit switches which prevent overtravel and control an indicator
module displaying line indication of valve open/shut condition.
(b) Power supplies and control
Electrical power is derived from the 28V dc ground services busbar (right) via a 5
amp circuit breaker No. 211 (for shut-off valve operation) and a 25 amp circuit
breaker No. 212 (for fan operation) on distribution panel 2D.
Control is by a three position switch ON-RAM-OFF on AIR CONDITIONING panel
9P.
The control circuitry is such that, following an ON selection at the control switch,
power will not be available to drive the fan until the control valve is fully opened (limit