B757 Air Systems DO NOT USE FOR FLIGHT Boeing B757 - Systems Summary [Air Systems] 2.20 Air Systems-Air Conditioning System Description Air Conditioning Introduction The air conditioning system supplies conditioned bleed air and recirculated cabin air at a controlled temperature throughout the airplane. The system supplies conditioned air to the flight deck shoulder heaters. The system supplies ventilation for the cabin: • lavatories • galleys • individual passenger seat gaspers. Pack control, zone temperature control, cabin air recirculation, fault detection, and overheat protection are all automatic. The airplane is divided into three temperature zones: the flight deck and two cabin zones. Air Conditioning Packs Two identical air conditioning packs cool bleed air from the engines, APU, or high pressure air from a ground source. Bleed air is precooled before entering the pack. The packs are controlled by two identical pack controllers. Pack output is automatically increased during high pack demand periods (to compensate for a failed pack or recirculation fan), or limited during high bleed air demand periods (such as with an engine inoperative). Air Conditioning Automatic Mode With the pack selector in the AUTO position, pack output temperature is determined by the cabin temperature controller. Zone temperature is then satisfied by the zone temperature controllers using trim air. Air Conditioning Standby Mode With the pack selector in the standby mode, pack output temperature is determined by the position of the pack selector: • N (normal) – constant, moderate temperature • C (cool) – full cold • W (warm) – full warm. Page 2 Boeing B757 - Systems Summary [Air Systems] Ground Conditioned Air Operation When a ground source of conditioned air is available, it may be used to supply conditioned air directly to the cabin distribution system, eliminating the need for pack operation. Pack Non–Normal Operation Pack control, fault detection, and overheat protection are all automatic. The pack INOP light illuminates and the EICAS advisory message L or R PACK TEMP displays for all pack control system faults and overheats. When an automatic control system fault or a pack outlet overheat is detected, the pack continues to operate in an uncontrolled, degraded condition, requiring crew interaction. The pack valve closes and the pack is shut down automatically when an internal pack overheat is detected. The PACK OFF light illuminates and the EICAS advisory message L or R PACK OFF displays in addition to the PACK TEMP indications. If the INOP light remains illuminated after selecting STBY, the fault is a pack overheat. After the pack has cooled, an attempt to restore pack operation may be made by pushing the PACK RESET switch. Air Distribution Conditioned air from the packs flows into a mix manifold where it mixes with air from two recirculation fans. Recirculation fans maintain overall cabin air circulation while allowing a reduction of cabin air ventilation, permitting the packs to be operated at a reduced flow. The mixed air is then ducted into the cabin. The flight deck receives 100% fresh conditioned air from the left pack only and is maintained at a slightly higher pressure than the passenger cabin. This prevents smoke from entering the flight deck. When the left pack is inoperative, the flight deck receives air from the mix manifold. The left recirculation fan draws air through the forward E/E system and returns it to the mix manifold. Air that moves from the cabin to the lower deck either exhausts overboard through the outflow valve or is drawn into the right recirculation fan and returns to the mix manifold. The right recirculation fan can be turned off for several minutes to provide a more rapid exchange of air. The left recirculation fan should not be turned off as this causes the overboard exhaust valve to latch open. Maintenance action is required to reset the OVBD EX VAL OPEN status message. Page 3 Boeing B757 - Systems Summary [Air Systems] The recirculation fan INOP light illuminates and the EICAS advisory message L or R RECIR FAN displays whenever a recirculation fan fails or the switch is off. A slight increase in fuel consumption occurs for each fan that is off. Temperature Control The airplane is divided into three temperature control compartments: • flight deck • forward cabin • aft cabin. The pack controllers regulate the pack output air temperature to satisfy the temperature requirement of the compartment requiring the coolest air. Hot trim air from the bleed air system is added through trim air valves to control the temperature in each of the other compartments. Each temperature control compartment has an associated temperature control. A compartment INOP light illuminates and the EICAS advisory message FLT DECK TEMP, FWD CABIN TEMP, or AFT CABIN TEMP displays to indicate: • zone temperature controller failure • zone selector is in the OFF position • trim air switch is OFF Temperature Control With Loss of Trim Air System During operation with the trim air system off, the packs attempt to maintain all compartments at an average temperature. The trim air OFF light illuminates and the EICAS advisory message TRIM AIR displays when a TRIM AIR switch is off. Shoulder and Foot Heaters Flight crew shoulder heat is provided by electric heaters in the ducts that supply conditioned air to the side windows. Foot heat is provided by electric heating elements only, with no airflow. The high setting for both shoulder and foot heat is available in flight only. Forward Equipment Cooling System Forward equipment cooling supplies cooling air to the equipment in the forward equipment racks and the flight deck avionics. The system has a supply fan that draws cooling air from the cabin and forces it through the equipment racks and avionics. The air is then exhausted into the air conditioning mix manifold by the left recirculation fan. If the differential pressure is low, the overboard exhaust valve automatically opens and most of the air is exhausted overboard. Page 4 Boeing B757 - Systems Summary [Air Systems] An auxiliary fan automatically operates to provide cooling for essential avionics and electrical equipment if the alternate supply fan has been selected but both supply fans are inoperative. However, non–essential avionics and electrical equipment are subject to imminent failure. The auxiliary fan can be powered by the hydraulic driven generator. On the ground, the OVHT light illuminates, the EQPT OVHT message displays and the ground crew call horn sounds if insufficient cooling airflow is detected. Equipment Smoke The equipment cooling SMOKE light illuminates and the EICAS advisory message FWD EQPT SMOKE displays when smoke is detected in the equipment cooling system. The following items, which may be observed in the flight deck, occur automatically to help evacuate the smoke: • one or both recirculation fans turn off • one or both air conditioning packs switch to high flow • the overboard exhaust valve is latched open. When smoke is no longer detected, the recirculation fans and air conditioning packs automatically return to normal operation. Cargo Heat System Cargo compartment heating and ventilation is completely automatic. There are no controls or indicators in the cockpit. Page 5 Boeing B757 - Systems Summary [Air Systems] Air Conditioning System Schematic COMPT TEMP C INOP INOP INOP FLT DK AUTO FWD CAB AUTO AFT CAB AUTO OFF W C OFF W C W OFF MIX MANIFOLD TRIM AIR RECIRC FAN L ON ON OFF INOP INOP L PACK R PACK RESET RESET INOP INOP PACK OFF PACK OFF AUTO OFF AUTO N OFF N S CT B Y PACK AIR EXHAUST AIR MIX MANIFOLD AIR R ON W S CT B Y W TRIM AIR PNEUMATIC SUPPLY PNEUMATIC SUPPLY Page 6 Boeing B757 - Systems Summary [Air Systems] 2.30 Air Systems-Pressurization System Description Pressurization Introduction Cabin pressurization is controlled by adjusting the discharge of conditioned cabin air through the outflow valve. Positive pressure relief valves and negative pressure relief doors protect the fuselage against excessive pressure differential. The pressurization system has automatic and manual operating modes. Pressurization System Automatic Operation The pressurization system is in the automatic mode when the cabin altitude mode selector is set to AUTO 1 or AUTO 2. If the selected auto mode fails, control is automatically switched to the other auto mode. In the automatic mode, the pressurization system uses ambient pressure data from the air data system in conjunction with the selected cabin auto rate, the takeoff altitude and the indicated landing altitude to calculate the cabin pressurization schedule. Takeoff For takeoff, the system supplies a small positive pressurization to cause a smooth cabin altitude transition. Climb During climb, cabin altitude increases on a schedule related to the takeoff field elevation, airplane altitude, and the selected auto climb rate limit. If the maximum cabin pressure differential is reached, cabin climb rate becomes a function of airplane climb rate, while maintaining the maximum differential pressure. Cruise Shortly after the airplane levels off, the system enters the cruise mode. The landing altitude and the scheduled cabin altitude are compared and the higher of these two is selected for the cruise cabin altitude. If necessary, the cabin climbs to the cruise cabin altitude at one–half the auto rate or descends to the cruise cabin altitude at the auto rate. The cruise cabin altitude does not change for minor altitude variations. A significant altitude change causes the system to re–enter the climb mode or to enter the descent mode. Page 7 Boeing B757 - Systems Summary [Air Systems] Descent and Landing During descent, cabin altitude decreases to slightly below the selected landing altitude. This ensures that the airplane lands pressurized. Landing altitude barometric pressure correction comes from the captain’s altimeter. At touchdown, the outflow valve opens to depressurize the airplane. Non–Normal Indications If the cabin altitude climbs above 10,000 feet, the CABIN ALT and CABIN ALTITUDE lights illuminate and the EICAS warning message CABIN ALTITUDE displays. The lights extinguish and the EICAS message blanks when the cabin altitude descends below 8,500 feet. The AUTO INOP light illuminates and the EICAS caution message CABIN AUTO INOP displays when automatic pressurization control fails or when cabin altitude MODE SELECT is MAN. Manual operation is required if the automatic system fails. Only the automatic mode is equipped with an aneroid switch that automatically closes the outflow valve when the cabin altitude exceeds 11,000 feet. The manual mode has no auto closure feature. To operate the pressurization system manually: • set the cabin altitude MODE SELECT to MAN • hold the cabin altitude MANUAL control to CLIMB to move the outflow valve toward open and cause the cabin altitude to climb • hold the cabin altitude MANUAL control to DESCEND to move the outflow valve toward closed and cause the cabin altitude to descend. Page 8 Boeing B757 - Systems Summary [Air Systems] 2.40 Air Systems-Bleed Air System Description Bleed Air Introduction Bleed air can be supplied by the engines, APU, or a ground air source. Bleed air is used for: • air conditioning • pressurization • engine start • wing and engine anti–ice • hydraulic reservoir pressurization. Engine Bleed Air Supply Engine bleed air comes from either the high pressure (HP) or the low pressure (LP) engine compressor sections. LP air is used during high power setting operations. HP air is used during descent and other low power setting operations. The engine bleed air valves are armed when the engine bleed air switches are selected ON. The valves are pressure actuated and remain closed until engine bleed air pressure is sufficient to cause forward flow. The valves may close when the APU is starting either engine. The valves may close when ground pneumatic air is connected or during periods of low engine bleed air demand, such as when the air conditioning packs are OFF. The engine bleed air OFF light illuminates and the EICAS advisory message L or R ENG BLEED OFF displays when the engine bleed air valve is closed. The HI STAGE light illuminates and the EICAS advisory message L or R ENG HI STAGE displays when engine bleed air pressure is excessive and the high pressure bleed air valve automatically locks closed. The engine BLEED light illuminates and the EICAS Caution message L or R ENG BLEED VAL displays if the engine bleed air temperature is excessive. APU Bleed Air Supply APU bleed air is used primarily during ground operations for air conditioning pack operation and engine starting. In flight, APU bleed air is available up to approximately 17,000 feet. The check valve in the APU supply line prevents reverse flow of bleed air from the duct into the APU. The APU bleed air VALVE light illuminates and the EICAS advisory message APU BLEED VAL displays when the APU Bleed Valve position disagrees with the commanded position. Page 9 Boeing B757 - Systems Summary [Air Systems] Ground Pneumatic Air Supply External connectors are provided to connect a ground source of high pressure air directly to the bleed air duct. Check valves prevent reverse flow of bleed air from the bleed air duct to the connectors. Bleed Air Duct System The duct pressure indicator displays the pressure in the left and right bleed air ducts. The isolation valve separates the bleed air ducts into isolated segments. The isolation valve is normally closed except for engine start or single bleed source operation. The isolation VALVE light illuminates and the EICAS advisory message BLEED ISLN VAL displays when the isolation valve position disagrees with the commanded position. The DUCT LEAK light illuminates and the EICAS caution message L or R BLD DUCT LEAK displays when a high temperature bleed air leak is detected. Page 10 Boeing B757 - Systems Summary [Air Systems] Bleed Air System Schematic R PACK L PACK GROUND PNEUMATIC GROUND PNEUMATIC BLEED AIR 60 80 20 0 DUCT PRESS PSI 40 DUCT LEAK DUCT LEAK ISOLATION BLEED HI STAGE BLEED HI STAGE VALVE L WING ANTI-ICE HYDRAULIC RESERVOIRS R WING ANTI-ICE HYDRAULIC RESERVOIRS L ENG APU V A L V E O F F ENGINE ANTI-ICE STARTER R ENG O F F ENGINE ANTI-ICE APU LP LP HP HP PANEL FLOW LINES FLOW LINES NOT ON PANEL Page 11 STARTER Boeing B757 - Systems Summary [Air Systems] L PACK R PACK GROUND PNEUMATIC BLEED AIR GROUND PNEUMATIC 60 40 20 80 DUCT PRESS PSI 0 DUCT LEAK DUCT LEAK ISOLATION BLEED HI STAGE BLEED HI STAGE VALVE L WING ANTI-ICE HYDRAULIC RESERVOIRS R WING ANTI-ICE HYDRAULIC RESERVOIRS L ENG O F F ENGINE ANTI-ICE STARTER APU R ENG V A L V E O F F APU ENGINE ANTI-ICE LP LP HP HP STARTER PANEL FLOW LINES FLOW LINES NOT ON PANEL Page 12 Boeing B757 - Systems Summary [Air Systems] 2.50 Air Systems-EICAS Messages Air Systems EICAS Messages The following EICAS messages can be displayed. Message Level Light Aural Condition APU BLEED VAL Advisory VALVE L BLD DUCT LEAK Caution DUCT LEAK BLEED ISLN VAL Advisory VALVE Bleed isolation valve position disagrees with the commanded position. CABIN ALTITUDE Warning CABIN Siren ALTITUDE, CABIN ALT Cabin altitude excessive. CABIN AUTO INOP Caution AUTO INOP Automatic pressurization control has failed or the cabin altitude mode selector is in manual. AFT CABIN TEMP Advisory INOP A fault in the zone temperature controller or trim air switch OFF. Advisory OFF Engine bleed air valve is closed for a system fault. Caution BLEED Advisory HI STAGE Engine bleed system pressure is excessive and the high pressure bleed air valve has automatically locked closed. Advisory OVHT Forward equipment cooling system inoperative. R BLD DUCT LEAK APU bleed valve position disagrees with the commanded position. Beeper Beeper FWD CABIN TEMP L ENG BLEED OFF R ENG BLEED OFF L ENG BLEED VAL R ENG BLEED VAL L ENG HI STAGE R ENG HI STAGE EQPT OVHT Page 13 Beeper A high temperature bleed air leak is detected. Engine bleed air temperature excessive. Boeing B757 - Systems Summary [Air Systems] Message Level Light Aural Condition FWD EQPT SMOKE Advisory SMOKE Smoke detected in the forward equipment cooling ducts. FLT DECK TEMP Advisory INOP Duct overheat, fault in the zone temperature controller, or trim air switch off. L PACK OFF Advisory PACK OFF Pack valve is closed. Advisory INOP Automatic control system fault or overheat. Advisory INOP Fan is failed or not operating. Advisory OFF Trim air switch off. R PACK OFF L PACK TEMP R PACK TEMP L RECIR FAN R RECIR FAN TRIM AIR Page 14 2.10Boeing Air Systems-Controls andSummary Indicators [Air Systems] B757 - Systems Air Conditioning System Air Conditioning Control Panel COMPT TEMP 1 2 INOP INOP INOP FLT DK AUTO FWD CAB AUTO AFT CAB AUTO 3 C OFF C W OFF 4 6 OFF ON ON ON OFF INOP INOP L PACK RESET INOP INOP 8 PACK OFF PACK OFF AUTO 10 R PACK RESET 7 OFF W RECIRC FAN R L TRIM AIR 5 C W N 9 W S CT B Y OFF AUTO N W S CT B Y OVERHEAD PANEL 1 Compartment Temperature (COMPT TEMP) Indicators Displays actual temperature sensed in the compartment. 2 Compartment Temperature Inoperative (INOP) Lights Illuminated (amber) – • fault in the zone temperature controller • the Compartment Temperature Control is OFF • the trim air switch is OFF. Page 15 11 Boeing B757 - Systems Summary [Air Systems] 3 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. 4 TRIM AIR Switch ON – the trim air valve is commanded open. Off (ON not visible) – the trim air valve is commanded closed. 5 Trim Air OFF Light Illuminated (amber) – the TRIM AIR switch is off. 6 PACK RESET Switches Push – resets an overheated pack if the pack has cooled to a temperature below the overheat level. 7 Pack Inoperative (INOP) Lights Illuminated (amber) – • the pack is overheated • fault in the automatic control system. 8 PACK OFF Lights Illuminated (amber) – the pack valve is closed. 9 PACK Control Selectors OFF – closes the pack valve. AUTO – the pack is automatically controlled. STBY– • N (normal) – regulates the pack outlet temperature to a constant, moderate temperature • C (cool) – sets the pack to full cold operation • W (warm) – sets the pack to full warm operation. Page 16 Boeing B757 - Systems Summary [Air Systems] Recirculation Fan (RECIRC FAN) Switches • ON – the recirculation fan operates • Off (ON not visible) – the recirculation fan does not operate. 10 11 Recirculation Fan Inoperative (INOP) Lights Illuminated (amber) – • the recirculation fan is failed or not operating • the RECIRC FAN switch is off. Shoulder and Foot Heaters HEATERS FOOT HI LOW OFF 1 SHOULDER HI LOW OFF 2 LEFT AND RIGHT SIDEWALL 1 FOOT HEATERS Switch • HIGH – the under–floor electric heater operates on high setting (in flight only). • 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 (in flight only). • 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.). 2 Page 17 Boeing B757 - Systems Summary [Air Systems] Equipment Cooling Panel EQUIP COOLING 1 ALTN SMOKE OVHT 2 3 OVERHEAD PANEL 1 Equipment Cooling SMOKE Light Illuminated (amber) – smoke is detected in the forward equipment cooling ducts. 2 Alternate (ALTN) Equipment Cooling Switch ALTN – • activates the alternate supply fan • activates the auxiliary fan, if the alternate supply fan fails. 3 Equipment Cooling Overheat (OVHT) Light Illuminated (amber) – • insufficient airflow (on the ground) • the supply fan is inoperative • the alternate supply fan is inoperative. Page 18 Boeing B757 - Systems Summary [Air Systems] Pressurization System Cabin Altitude Controls 1 CABIN ALTITUDE CONTROL VALVE OP CLIMB MANUAL AUTO RATE 5 2 MIN CL MAX DESCEND LDG ALT 3 6 AUTO INOP 00340 MODE SELECT AUTO 2 AUTO 1 4 MAN 7 OVERHEAD PANEL 1 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. 2 Outflow VALVE Position Indicator OP – Open. CL – Closed 3 Landing Altitude (LDG ALT) Indicator Feet. Displays selected landing altitude. 4 Landing Altitude (LDG ALT) Selector Rotate – sets landing altitude indicator. Page 19 Boeing B757 - Systems Summary [Air Systems] Cabin Altitude AUTO RATE Control 5 Rotate – • sets limit for cabin altitude rate of climb or descent during auto control • index mark establishes approximately 500 fpm climb and 300 fpm descent. AUTO Inoperative (INOP) Light 6 Illuminated (amber) – • AUTO 1 and AUTO 2 cabin altitude control functions are inoperative • MAN mode is selected. Cabin Altitude MODE SELECTOR 7 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. Cabin Altitude Indicators CABIN 1 10 8 0 6 2 4 DIFF PSI 0 2 25 4 20 15 6 10 8 ALT 1 2 1 2 FT X 1000 2 OVERHEAD PANEL Page 20 3 0 FPM X RATE 1000 CABIN ALTITUDE 4 PRESS DIFF LIMIT: TO/LDG .125 PSI 5 Boeing B757 - Systems Summary [Air Systems] 1 Cabin Differential Pressure Indicator Pounds per square inch (psi). 2 Cabin Altitude Feet x 1,000. 3 Cabin Altitude Rate Feet per minute (fpm x 1,000). 4 Cabin Altitude Light Illuminated (red) – • cabin altitude exceeds 10,000 feet • extinguishes when cabin altitude descends below 8,500 feet. 5 Pressure Differential (PRESS DIFF) Limit Placard Specifies differential pressure limitation for takeoff and landing. Cabin Altitude (CABIN ALT) Light CABIN ALT 1 CENTER FORWARD PANEL 1 Cabin Altitude Light Illuminated (red) – • cabin altitude exceeds 10,000 feet • extinguishes when cabin altitude descends below 8,500 feet. Page 21 Boeing B757 - Systems Summary [Air Systems] Bleed Air System Bleed Air Control Panel BLEED AIR 60 1 80 40 0 20 2 DUCT PRESS PSI DUCT LEAK DUCT LEAK ISOLATION BLEED HI STAGE BLEED HI STAGE 3 VALVE L ENG O F F 4 APU V A L V E R ENG O F F 5 OVERHEAD PANEL 1 Duct Pressure (DUCT PRESS) Indicators Pounds per square inch (psi). 2 ISOLATION Switch On (bar in view) – commands isolation valve to open. Off (bar not visible) – commands isolation valve to close. 3 Isolation VALVE Light Illuminated (amber) – isolation valve position disagrees with commanded position. 4 Engine (ENG) Bleed Air Switches On (bar in view) – the engine bleed air valve opens when engine bleed air is available. Off (bar not visible) – valve is manually commanded closed. 2.10.8 Copyright © The Boeing Company. Page See 22title page for details. D632N001-200 Boeing B757 - Systems Summary [Air Systems] 5 Engine Bleed Air OFF Lights Illuminated (amber) – engine bleed air valve is closed: • automatically due to a system fault • the switch is OFF • the engine is not running. 6 DUCT LEAK Lights Illuminated (amber) – a high temperature bleed air leak is detected. 7 Engine BLEED Lights Illuminated (amber) – the engine bleed air temperature is excessive. 8 Engine High Stage (HI STAGE) Lights Illuminated (amber) – • the engine bleed system pressure is excessive • the engine high pressure bleed air valve is automatically locked closed. 9 APU Bleed Air Switch On (bar in view) – the APU bleed air valve is automatically controlled Off (bar not visible) – commands APU bleed air valve to close. 10 APU Bleed Air VALVE Light Illuminated (amber) – APU bleed air valve position disagrees with commanded position. Page 23