NGS

CH 47

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TABLE OF CONTENTS
GENERAL DESCRIPTION............................................................................... 4
GENERAL DESCRIPTION (CONT)................................................................. 6
THERMAL CONTROL UNIT..............................................................................8
SHUTOFF VALVE............................................................................................10
OZOZNE CONVERTER AND PRESSURE SENSOR..................................... 12
RAM AIR FAN AND PRIMARY HEAT EXCHANGER...................................... 14
TEMPERATURE CONTROL VALVE...............................................................16
TURBOCOMPRESSOR AND TURBOCOMPRESSOR SHUTOFF VALVE....18
REGEN HEAT EXCHANGER..........................................................................20
COMPRESSOR OUTLET TEMPERATURE SENSOR AND THERMAL
SWITCH...........................................................................................................22
AIR FILTER AND DIFFERENTIAL PRESSURE SWITCH............................... 24
AIR SEPERATION UNIT................................................................................ 26
OVERTEMPERATURE SHUTOFF VALVE,THERMAL SWITCH AND INLET
TEMPERATURE SENSOR............................................................................. 28
OVERTEMPERATURE SHUTOFF VALVE......................................................30
AIRSEPERATION MODULE............................................................................ 32
HIGH FLOW VALVE AND OXYGEN SENSOR............................................... 34
DIFFERENTIAL PRESSURE SENSOR AND FLOW ORIFICES...................... 36
DISTRIBUTION SYSYTEM GENERAL DESCRIPTION..................................38
DISTRIBUTION SYSTEM COMPONENTS.....................................................40
NITROGEN GENERATIONSYSTEM CONTROLLER.................................... 42
BITE DISPLAY UNIT........................................................................................44
BITE DISPLAY FUNCTIONS............................................................................46
INDICATIONS.................................................................................................. 48

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NGS - GENERAL DESCRIPTION

General
The Nitrogen Generation System (NGS) makes Nitrogen Enriched Air (NEA).
The NEA goes to the center fuel tank through the Nitrogen Enriched Air
Distribution System (NEADS). The NGS makes NEA at a rate enough to
reduce the oxygen concentration in the center fuel tank below that required to
sustain combustion. The NGS is in the wing to body fairing. The NGS gets
bleed air from the aircraft pneumatic system crossover manifold. The NGS gets
cooling air from the NGS ram air inlet. The NGS thermal control system
conditions the bleed air, and the NGS air separation system separates the bleed
air into two compounds:
NEA
Oxygen Enriched Air (OEA)
OEA is a waste gas that is dumped overboard through a dedicated exhaust line.
The NGS gives the following functions:
Sends NEA to the center fuel tank in order to reduce the risk of fire in the
fuel tank
Supply the required amount of NEA with regulated temperature to the fuel
tank, for different flight profiles
Shut off the air supply flow when the NGS supply temperature gets to the
temperature control limits
Show the NGS parameters for information and maintenance purposes
Give fault reporting and BIT related information through the BITE display
unit (BDU)
The NGS has these major subsystems:

Thermal Control System

Air Separation Unit (ASU)
Nitrogen Enriched Air Distribution System (NEADS)
Control System

Thermal Control Unit

The NGS Shutoff Valve (SOV) gets bleed air from the left side of the pneumatic
manifold. The NGS SOV controls the flow of air to the NGS. The NGS

controller (NGSC) controls the NGS SOV with inputs from the system interface
and airplane systems.
The air goes through the primary heat exchanger and is cooled by the NGS ram
air. The NGSC monitors the temperature sensor and modulates the
temperature control valve (TCV). The TCV modulates to keep the primary heat
exchanger output air temperature within the correct operating limits.
During descent and ground operations, the NGS operates in the boosted mode.
The TCSOV opens and lets bleed air go to the turbo compressor (TC). Air that
goes through the turbine side of the turbo compressor gets cooled through
expansion. This air then precools the air entering the compressor section of the
TC. The boosted air then goes to the primary heat exchanger and TCV.
Air Separation Unit
Air from the TCU goes into the ASU at a regulated temperature of 170F (77C)
through the Over Temperature Shutoff Valve (OTSOV).
There are three Air Separation Modules (ASM) in the ASU. The ASMs separate
the oxygen molecules from the nitrogen molecules in the air supply. This
function leaves NEA that goes to the NEADS. NEADS sends this NEA to the
center fuel tank. The NEA does not have enough oxygen to support an ignition
of the fuel/air mixture. The oxygen in the air goes to a level that is too low to
support combustion. The Oxygen Enriched Air (OEA) is vented overboard.
The NGS operates in both a high and a low flow mode. The NGSC uses the
airplane flight configuration to control for low and high flow modes. When the
NGS operates in the low flow mode the NGSC closes the High Flow Valve
(HFV). NEA goes through the low flow orifice. When the NGSC opens the HFV,
the NEA can go through both the low flow orifice, and the high flow orifice. The
NGSC uses a differential pressure sensor to monitor when the NGS operates in
the low flow or high flow modes. The NGSC uses this information for possible
system fault detection.
The NGSC uses an oxygen sensor to test the NEA for the amount of oxygen
that remains in the NEA. The NGSC uses the oxygen sensor to monitor for
NGS performance degradation.

NGS - GENERAL DESCRIPTION

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NGS - GENERAL DESCRIPTION (CONT)

Distribution System
The NEADS sends the NEA to the center fuel tank. The distribution section has
these parts:

Tubes
Check valves
Float valve
Vent channel
Drain

Built-In Test
The NGSC has Built-In Test (BIT) capability. Faults found with BIT are stored in
the controllers nonvolatile memory. The NGSC also monitors and records the
performance of the NGS.
The controller sends fault information to the BITE Display Unit (BDU).
When the NGS is operating in a degraded mode, an Engine Instrument Crew
Alerting System (EICAS) message shows.
The BDU is used for fault monitoring, system test, and system configuration
data.
A status indicator panel gives a fast way to show the status of the NGS for
airplane dispatch purposes.

NGS - GENERAL DESCRIPTION (CONT)

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NITROGEN GENERATION SYSTEM - THERMAL CONTROL

UNIT - GENERAL DESCRIPTION
General Description
The Nitrogen Generation System (NGS) uses hot bleed air to make Nitrogen
Enriched Air (NEA) for the center fuel tank. The Thermal Control Unit (TCU)
controls the bleed air pressure and temperature and delivers the air to
the Air Separation Unit (ASU).
These components are on a frame assembly along with associated tubes and
ducting. The assembly is mounted to the aircraft forward of the left ECS bay.
These are the components of the Thermal Control Unit (TCU):

Ozone converter
Turbocompressor shutoff valve (TCSOV)
Turbocompressor (TC)
Regen heat exchanger
Temperature sensor
Compressor overtemperature thermal switch (COTS)
Pressure sensor
Check valve
Temperature control valve (TCV)
Primary heat exchanger
Filter
Differential pressure switch
Fan
Ram air check valve
Ram air exit

The NGS Shutoff Valve (SOV), filter and differential pressure sensor are not part
of the TCU frame assembly. The NGS SOV valve opens to let bleed air into the
TCU. The NGS SOV also controls the bleed air pressure to the TCU.
The ozone converter uses a catalytic process to convert ozone molecules to
oxygen molecules. This helps to prevent oxidation of the components inside the
three Air Separation Modules (ASM). The ASMs are in the ASU.
The TCSOV controls bleed air flow to the turbine section of the TC. With the
TCSOV open, the TC is on. The NGSC uses the TC for boosted operation of
the NGS.

The regen heat exchanger cools the air that goes to the compressor section of
the TC.
The NGSC monitors the TC compressor outlet temperature with the
temperature sensor. The NGSC will close the TCSOV if TC compressor outlet
temperature becomes too high.
The COTS does a back up to the NGS Controller (NGSC) to close the TCSOV.
The COTS can close the TCSOV if TC compressor outlet temperature becomes
too high.
The NGSC monitors the bleed air pressure in the ASU with the pressure sensor.
The NGSC uses the pressure information for fault monitoring, BITE, and
overpressure protection.
The TC check valve prevents a reverse flow of air out of the TC compressor
back through the ozone converter and pneumatic system. The check valve
prevents this reverse flow with the TC on in the NGS high boost mode.
The NGSC uses the temperature control valve (TCV) to control how much air
goes through the primary heat exchanger. The NGSC uses the TCV and
primary heat exchanger to control the temperature of the air that goes from the
TCU to the ASU.
The primary heat exchanger uses cooler ram air to cool the air supply that goes
from the TCU to the ASU.
The filter removes contaminants and excess water from the TCU air supply that
goes to the ASU. The filter protects the ASMs and other components in the
ASU from contamination damage.
The NGSC uses the differential pressure switch to monitor the condition of the
filter. The NGSC uses the pressure switch information to show the status of the
NGS, and for fault information. The NGSC uses the ground fan to help move air
through the ram air duct. The NGSC turns on the ground fan when the NGS
operates with the airplane on the ground. The ram air duct gives cooling air to
the primary heat exchanger. The ram air check valve prevents air flow from the
ground fan from recirculating back through the ground fan. The check valve
closes with the ground fan on.

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NITROGEN GENERATION SYSTEM - THERMAL CONTROL UNIT - GENERAL DESCRIPTION

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NGS - SHUTOFF VALVE

General
The Nitrogen Generation System (NGS) Shutoff Valve (SOV) is in the bleed air
duct that goes to the Thermal Control Unit (TCU). The valve controls airplane
bleed air flow to the NGS through the TCU.
The NGS SOV regulates the bleed air pressure into the TCU and NGS at 52 +/6 psig.
The SOV is an electrically controlled, pneumatically operated Pressure
Regulating and Shutoff Valve (PRSOV). The butterfly spring loads to the closed
position. The valve has a visual position indicator that you can move and lock in
the closed position.
Normal Operation
During normal operation, a constant reference pressure goes to the base of the
solenoid and the shuttle valve. When the solenoid energizes, the solenoid ball
valve moves off of its seat to seal the ambient vent. Reference pressure goes
to the opening chamber of the actuator. In the shuttle valve, with the reference
pressure more than downstream pressure, the shuttle element holds in the
position shown. Reference pressure goes to the closing chamber of the
actuator. Because the opening chamber area is larger than the closing
chamber area, the valve moves to full open position.
As the butterfly opens, the downstream pressure increases. When the
downstream pressure is more than the reference pressure, the shuttle element
moves to the position opposite of the position shown. Downstream pressure
goes to the closing chamber of the actuator. For normal system operation, the
downstream pressure is less than the regulation set point of the valve.
Pressure Regulating Function
When downstream pressure increases to the regulation set point of the valve,
downstream pressure in the closing chamber and the force of the spring add
together. This balances the force from the reference pressure in the opening
chamber. The butterfly moves as necessary to keep the balance and to control
the downstream pressure.

Shutdown
When the solenoid de-energizes, the ball valve closes. This removes reference
pressure to the opening chamber of the actuator. The opening chamber has an
opening to ambient through the solenoid vent. The spring keeps the butterfly
valve in the closed position. Reference pressure goes through the shuttle valve
to the closing chamber. This helps the spring close the valve.

NGS - SHUTOFF VALVE

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NGS - OZONE CONVERTER AND PRESSURE SENSOR

Ozone Converter Purpose
The ozone converter decreases the ozone content in the bleed air. The
converter converts the ozone to oxygen. This helps to protect the permeable
fiber membrane material inside the three Air Separation Modules (ASM)
from oxidation. The ASMs are in the Air Separation Unit (ASU).
Physical Description
The ozone converter is in the Thermal Control Unit (TCU).
The ozone converter is an aluminum, plate fin, single pass, cross-flow to air
unit. It has an inlet and an outlet at each end. The approximate dimensions
are, length 8.3 inches (21 cm), diameter is 3.9 inches (7.6 cm). The weight is
3.5 lb (1.5 kg).
Operation
The ozone converter removes the ozone from the air by a catalytic process.
The process converts the ozone to oxygen. Hot bleed air enters the catalytic
converter. The bleed air contacts the catalytic reactor core and converts to
oxygen. The bleed air then goes out of the catalytic converter.
Bleed Pressure Sensor Purpose
The NGS controller (NGSC) uses a pressure sensor to monitor the air inlet
pressure to the NGS. The NGSC uses the pressure information for these
functions:
BITE
Fault indication
Overpressure protection
Location
The pressure sensor is in the Thermal Control Unit (TCU), inboard and aft of the
ozone converter.

Functional Description
The sensor has pressure sensitive elements hermetically sealed in a shell.
Pressure for the sensor comes from a sense line that connects to the TCU duct.
The electrical connector on the sensor connects to the NGSC. The NGSC
gives electrical excitation power to the sensor. The sensor sends electrical
signals proportional to a sensed pressure to the NGSC. The pressure sensor is
a gauge pressure sensor. The sensor gives an electrical signal proportional to
an increase in pressure at the pressure port. The output range is 4 mA at 0 psig
up to 20 mA at 100 psig.
The NGSC monitors the pressure sensor during NGS operation. An
overpressure fault occurs when the NGSC senses bleed pressure more than 85
psig for more than 3 seconds.
With an overpressure fault the NGSC commands the NGS Shutoff Valve (SOV)
and the Overtemperature Shutoff Valve (OTSOV) to close. The OTSOV is in
the Air Separation Unit (ASU).
If the NGS operates in the boosted mode the NGSC will also command the
Turbocompressor Shutoff Valve (TCSOV) to close.
These closed valves prevent an overpressure condition in the Air Separation
Modules (ASM) and the center fuel tank. THE ASMs are in the ASU.

NGS - OZONE CONVERTER AND PRESSURE SENSOR

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NGS - RAM AIR FAN AND PRIMARY HEAT EXCHANGER

General Description

Ram Air Fan Purpose

The Nitrogen Generation System Controller (NGSC) uses the TCV to control
how much air bypasses the heat exchanger.

The Nitrogen Generation System (NGS) has a dedicated ram air system. A ram
air fan increases cooling ram air flow to the primary heat exchanger with the
airplane on the ground. The fan operates to add ram air cooling flow through
the NGS heat exchanger during ground operation of the NGS.
Physical Description
The ram air fan is a motor-driven, single stage design. The fan operates with a
three-phase, 115 vac motor. The ram air fan, or ground fan is in the ram air
duct. The fan gives an airflow of 267 cubic feet per minute (CFM).
The ram air fan has internal limit switches. These switches open and remove
electrical power from the motor. The switches open at 390F (200C).
Operation
Control for the fan comes from the Nitrogen Generation System Controller
(NGSC). The NGSC uses a control circuit that connects to the fan relay. When
the relay energizes, ac power goes to the fan motor. A ram air check valve
prevents a reverse ram air flow when the ram air fan is on. When the airplane is
in the air the ram air fan is off. Ram air goes through the ram air check valve to
the primary heat exchanger.
Primary Heat Exchanger Purpose
The primary heat exchanger cools the engine bleed air before it enters the air
separation unit (ASU) and goes through the air separation modules (ASM).
Physical Description
The heat exchanger is a single-pass aluminum, plate, cross-flow, air-to-air unit.
It supplies a large surface area for efficient heat transfer from the bleed
air to the air separation module (heat sink). The dimensions are, length 14.8
inches (37.5 cm), width 13.8 inches (35.5 cm), height 8 inches (20.4 cm). The
weight is 12.5 lb (5.7 kg).

As bleed air moves through the heat exchanger, it transfers heat to the walls of
the heat exchanger. The walls are made of plates and fins. Ram air that goes
through the heat exchanger on the other side of the walls removes the heat and
carries it away. Heat transfer goes from the bleed air to the heat exchanger
walls, to the ram air. The heated ram air flow goes overboard.
Training Information Point
The heat exchanger uses narrow passages with thin walls and cooling fins for
efficient heat exchange. Contamination or obstruction of the passages
decreases or prevents airflow and heat transfer. Keep the heat exchanger
clean for maximum performance.

NGS - RAM AIR FAN AND PRIMARY HEAT EXCHANGER

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NGS - TEMPERATURE CONTROL VALVE

Purpose
The Temperature Control Valve (TCV) controls the temperature of the air flow to
the Air Separation Modules (ASM). The ASMs are inside the Air Separation
Unit (ASU). The temperature is kept at an efficient operating level.
The TCV is in the TCU, at the inlet side of the primary heat exchanger.
General Description
The valve is an electrically controlled, pneumatically operated modulating valve.
The valve is spring loaded to the closed position. The butterfly type valve is
modulated by the pneumatic actuator. The pneumatic actuator is controlled by
the torque motor. The torque motor gets electrical commands from the nitrogen
generation system Nitrogen Generating System Controller (NGSC). The torque
motor regulates the amount of air that opens the valve against spring pressure
in the actuator.
The NGSC monitors the air temperature at the inlet of the Air Separation
Modules (ASM). The NGSC uses the air separation module inlet temperature
sensor to monitor the temperature. The ASMs and the sensor are in the air
separation unit (ASU).
The temperature control valve modulates to keep the air temperature to 160180F (71-82C) at the inlet of the ASM. The valve controls the amount of air that
bypasses the primary heat exchanger. Bleed air that does not bypass the
primary heat exchanger, goes through the primary heat exchanger. This bleed
air gets cooled by ram air that comes from ambient air. These are the parts of
the valve:

Electrical connector
Sensing lines
Reference pressure regulator
Actuator
Manual override and position indicator (not shown)
Manual lock mechanism (not shown)
Torque motor
Manual locking hex bolt (not shown)

NGS - TEMPERATURE CONTROL VALVE

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NGS - TURBOCOMPRESSOR AND TURBOCOMPRESSOR

SHUTOFF VALVE
Purpose
The Nitrogen Generation System (NGS) Turbocompressor (TC) increases the
NGS pressure during boosted operation.
Boosted operation occurs when the airplane pneumatic supply pressures are
lower. The NGS controller (NGSC) controls the NGS for boosted and nonboosted operations.
Turbocompresor Operation
When the NGSC commands the Turbocompressor Shutoff Valve open
(TCSOV), engine bleed air goes to the turbine inlet. The bleed air is drawn
through the turbine by the lower absolute pressure at the turbine exit. The
power produced by the turbine turns the compressor. Air in the turbine cools
due to expansion from converting pressurized thermal energy to mechanical
energy.
The air cooled by the turbine goes through the regen heat exchanger to cool the
bleed air before it enters the compressor. Decreasing the bleed air temperature
before it enters the TC helps to limit the temperature of the compressor
discharge air. Engine bleed air from the regen heat exchanger enters the
compressor inlet, where the air goes to a higher pressure and temperature. The
air from the compressor goes to the temperature control valve and primary heat
exchanger. This function increases the airflow through the primary heat
exchanger and bypass.
The Turbocompressor Check Valve (TCCV) operates when the TC operates.
The TCCV prevents a reverse flow of compressor discharge air back through
the ozone converter and the NGS shutoff valve (SOV). Cooling air to the TC
bearing cavity comes from the bleed air exit side of the primary heat exchanger.
Turbocompressor Shutoff Valve Purpose
The Nitrogen Generation System Controller (NGSC) uses the Turbocompressor
(TC) to operate the Nitrogen Generation System (NGS) in the boosted mode.

The NGS Turbocompressor Shutoff valve (TCSOV) controls the bleed air flow to
the turbocompressor turbine. The TC has two functions.
The TC discharge air from the compressor section increases the flow of the
bleed air that goes to the primary heat exchanger and the Air Separation Unit
(ASU). This occurs at lower pneumatic system pressures with the engines at
lower power settings.
Discharge air from the TC goes to the regen heat exchanger. This cooler bleed
air goes through the regen heat exchanger to the compressor section inlet of
the TC.
Turbocompressor Shutoff Valve Operation
The valve works by using the differential pressure between ambient and the inline valve pressure. A 28v dc solenoid valve on the side of the main valve
selects the valve position. The TCSOV is normally spring-loaded closed. It
energizes open by the NGSC. With the TCSOV closed, normally during climb
and cruise, all of the air that goes to the TCU goes through the ozone converter.
The air then goes to the primary heat exchanger inlet, and next to the heat
exchanger bypass. This is the non-boosted mode. When the TCSOV opens,
normally during descent and ground operations, some of the bleed air from the
NGS SOV goes to the turbine inlet port of the TC. Here, the air expands in the
turbine which then turns the compressor in the turbocompressor. The bleed air
that goes into the compressor comes from the regen heat exchanger. The high
pressure air that comes out of the turbocompressor forces the turbocompressor
check valve to close. This prevents a back flow of the boosted air towards the
NGS shutoff valve and into the aircraft bleed air system.
Airflow that comes out of the TC turbine cools through expansion. This cool air
goes through the opposite side of the regen heat exchanger. This air then
precools the air entering the compressor section of the turbocompressor. This
is the boosted mode.
The NGSC will close the TCSOV if the TC compressor outlet temperature
becomes more than 465F (241C). The NGSC also closes the TCSOV when it
shuts down the NGS.

TURBOCOMPRESSOR
COMPRESSOR SECTION

NGS - TURBOCOMPRESSOR AND TURBOCOMPRESSOR SHUTOFF VALVE

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NGS - REGEN HEAT EXCHANGER

Purpose
The Nitrogen Generation System (NGS) regen heat exchanger precools the
bleed air before it goes into the compressor section of the Turbocompressor
(TC). The TC compressor discharge air goes to the primary heat exchanger.
The regen heat exchanger controls the maximum temperature of the airflow
going to the primary heat exchanger.
Operation
The Turbocompressor Shutoff Valve (TCSOV) normally opens during boosted
system operation. Boosted system operation occurs when pneumatic system
bleed pressures are low. The bleed pressure is normally lower at lower
engine power settings.
When the TCSOV opens, part of the bleed air from the NGS Shutoff Valve
(SOV) goes to the inlet port of the TC. The remaining air goes through the
ozone converter and the regen heat exchanger. The air then goes into
the compressor inlet of the TC. The temperature of the airflow through the
turbine decreases through energy conversion and expansion. This cool air
goes through the opposite side of the regen heat exchanger. This air precools
the air that goes into the compressor.
Hot air from the engine bleed system goes into the regen heat exchanger. Cool
turbine exhaust air in the regen heat exchanger core decreases the temperature
of the air before it goes into the compressor inlet. The cool air flow comes from
air that expands in the TC turbine section. This decreases the temperature and
the pressure of the air that goes to the primary heat exchanger. This
temperature controlled air then goes to the Overtemperature Shutoff Valve
(OTSOV) in the Air Separation Unit (ASU).

TURBOCOMPRESSOR
COMPRESSOR SECTION

NGS - REGEN HEAT EXCHANGER

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NGS - COMPRESSOR OUTLET TEMPERATURE SENSOR AND

THERMAL SWITCH
Compressor Outlet Temperature Sensor Purpose
The Compressor Outlet Temperature Sensor (COTS) measures the
temperature of the bleed air that comes out of the Turbocompressor (TC). The
temperature information is used for system fault detection by the Nitrogen
Generation System Controller (NGSC).
Location
The COTS is on the outlet duct of the compressor section of the
turbocompressor. The duct is part of the Thermal Control Unit (TCU).
General Description
The temperature sensor is a dual element probe unit with an electrical
connector. It is sealed in a corrosion resistant stainless steel body. The NGSC
uses the COTS to monitor the air temperature of the turbocompressor outlet.
The COTS is part of a bridge circuit in the NGSC. When the measured
temperature goes more than 465F (241C), the NGSC controller closes the
Turbocompressor Shutoff Valve (TCSOV). The NGSC will also set one or more
fault messages that can show on the BITE Display Unit (BDU) display.
Thermal Switch Purpose
The Thermal Switch (TS) monitors outlet air temperature of the
Turbocompressor (TC) outlet temperature. The thermal switch can close the
Turbocompressor Shutoff Valve (TCSOV). The TCSOV closes for high TC
compressor outlet temperature.
The TS gives a backup to the Nitrogen Generation System Controller (NGSC)
to close the TCSOV. If the NGSC cannot close the TCSOV for high
temperature, the TS will open to cause the TCSOV to close. The NGSC will
also close the TCSOV when the NGS operates in the boosted mode for
overpressure.

General Description
The thermal switch is in the Thermal Control Unit (TCU). The thermal switch is
a bimetallic type of switch. The switch is in the control circuit from the NGSC to
the TCSOV.
Functional Description
The normal position of the thermal switch electrical contacts are closed. The
contacts opens with a sensing element temperature of 465-485F (241-252C).
The thermal switch resets when the temperature goes less than 450F
(232C).
The thermal switch contacts connect in series with the excitation coil of the
TCSOV. The open switch contacts cause the TCSOV excitation power to be
removed. The TCSOV goes to the closed position.

NGS - COMPRESSOR OUTLET TEMPERATURE SENSOR AND THERMAL SWITCH

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NGS - AIR FILTER AND DIFFERENTIAL PRESSURE SWITCH

Air Filter Purpose
The air filter removes the following particulate and aerosol materials that are in
the bleed air:

Dust
Sand
Oil
Hydraulic fluid
Water

The filter helps to prevent contamination of the air separation modules.

Location
The filter is in-line in the pneumatic duct between the Thermal Control Unit
(TCU) and the Air Separation Unit (ASU). The filter is in the right ram air duct
compartment.
Air Filter
The filter assembly is a two stage design. The filter can remove contaminant
particles one micron and higher in size. The filter has an inner coalescer stage
and an outer pleated filter pack. These are the two stages of the filter:
The coalescer stage is made from layers of very high efficiency glass fiber,
polyester and stainless steel, all pleated together into a filter pack.
The outer pleated filter pack is similar in construction. It ensures that the
whole filter element provides high efficiency particulate and periodic fluid
protection to downstream components
The primary and secondary drain poppet valves are at the bottom of the filter.
The primary and secondary drain valves let fluid contaminants leave both
stages of the filter. The valves are normally spring-loaded closed. The drain
poppet lets water and other fluids to go out of the filter housing. Push the valves
to the open position to let contaminants out of the filter housing.

Differential Pressure Switch Purpose

The Nitrogen Generation System Controller (NGSC) uses the differential
pressure switch to monitor the condition of the Nitrogen Generation System
(NGS) air filter.
Filter Differential Pressure Switch
The filter differential pressure switch measures the differential pressure across
the filter. The switch has two sensing ports. The ports are the high pressure
sense port and the low pressure sense port. The high pressure port connects to
duct upstream of the filter. The low pressure port connects to the duct
downstream of the filter. A pressure difference of more than 1.2 psid across the
filter operates the switch. This shows that the filter is clogging. The NGSC
closes the NGS Shutoff Valve (NGS SOV) and the Overtemperature Shutoff
Valve (OTSOV). With these valves closed, the NGS operation stops. The
differential pressure signal goes to the NGSC. The NGSC sends a filter
clogged indication to the BITE Display Unit (BDU).

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NGS - AIR SEPARATION UNIT

General Description
The Air Separation Unit (ASU) frame assembly contains the related ASU
components, related tubes and ducts. The assembly connects to the airplane
forward of the right ECS bay. These are the components of the ASU:

Frame assembly
ASU inlet temperature sensor
Thermal switch
Overtemperature shutoff valve (OTSOV)
Air separation modules (ASM) (3)
Oxygen sensor
High flow valve
Differential pressure sensor
High flow orifice
Low flow orifice

The ASU inlet temperature sensor monitors the bleed air temperature from the
Temperature Control Unit (TCU). The OTSOV closes to protect the ASU
components and center wing fuel tank from damage. The Nitrogen Generation
System Controller (NGSC) or the thermal switch can close the OTSOV.
The ASU has three ASMs. The bleed air oxygen molecules are separated from
the nitrogen molecules as the air goes through the ASMs. The Oxygen
Enriched Air (OEA) goes overboard. The nitrogen enriched air (NEA) goes to
the center fuel tank.
The oxygen sensor measures how much oxygen is in the NEA.
When increased NEA is needed, the high flow valve will open. The differential
pressure sensor monitors the position of the high flow valve.
The high and low flow orifices give measured NEA flow to the distribution
system.

Operation
The key control and monitoring functions of the Air Separation Unit (ASU) are:
Give NEA for distribution to the fuel tanks
Give low or high flow upon command from the NGSC
Give temperature sensing for control of the bleed air that goes into the
ASMs
Give thermal protection from excessive bleed air temperature
Give oxygen concentration data to the NGSC for fault detection
Give flow control monitoring

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NGS - OVERTEMPERATURE SHUTOFF VALVE, THERMAL

SWITCH AND INLET TEMPERATURE SENSOR
Overtemperature Shutoff Valve Purpose
The Overtemperature Shutoff Valve (OTSOV) gives backup protection for the
Air Separation Modules (ASM) if there is a controller failure. It supplies a
secondary means to shut the system down.
General Description
The OTSOV is the same valve as the Turbocompressor Shutoff Valve (TCSOV).
The OTSOV is in the Air Separation Unit (ASU), upstream from the three ASMs.
The valve is electrically controlled and pneumatically operated. It is spring
loaded to the closed position. The Nitrogen Generation System Controller
(NGSC) controls the valve during normal operations. The controller deenergizes the valve when the system is off.
These are the parts of the overtemperature valve:
Electric connector
Solenoid
Valve body

Note:

The NGSC also uses the temperature sensor air temperature for
normal control of the Temperature Control Valve (TCV) in the TCU

The thermal switch gives a back up to the temperature sensor if the NGSC does
not close the OTSOV for high temperature. The thermal switch opens at 275F
(135C). When the thermal switch opens it removes the power that goes to the
solenoid of the OTSOV. The OTSOV solenoid de-energizes and the valve
closes. The thermal switch resets when the temperature at the switch goes to a
temperature of 255F (124C).
Thermal Switch Purpose
The thermal switch works with the Overtemperature Shutoff Valve (OTSOV) to
make sure that the maximum air temperature is less than 280F (138C).
General Description
The thermal switch electrically connects to the OTSOV. The thermal switch
sends a close signal to the OTSOV when an overheat condition is detected.
The normal position of the thermal switch electrical contacts are closed. The
contacts open when temperature at the sensing element goes to between 255
and 275F (124C - 135C). The thermal switch resets when the temperature
goes down to 205F (96C)

If the controller does not close the OTSOV when the temperature is too high,
the thermal switch deenergizes the solenoid. It does this independently from
the controller. This causes the OTSOV to close.

The thermal switch contacts are in series between the power supply and the
excitation coil of the OTSOV. The NGSC has the ground for the excitation coil.
When the contacts open the OTSOV excitation power is removed and the
OTSOV goes to the closed position.

Operation

Function

At the start of NGS operation the NGSC energizes the OTSOV solenoid and the
valve opens. Air from the Temperature Control Unit (TCU) goes through the
valve to the ASMs. The air that leaves the OTSOV first goes past a thermal
switch and the air separation module inlet temperature sensor.

The switch is a backup to the Air Separation Module (ASM) inlet temperature
sensor. When the temperature measured by the sensor is more than 235F
(113C), the NGSC will open the 28v dc return power or ground to the OTSOV.
The solenoid coil de-energizes causing the OTSOV to close. The ASM inlet
temperature sensor and ASM inlet thermal switch are both located in the same
duct in between the OTSOV and the ASM inlet ports. If the temperature is more
than 235F (113C) and the OTSOV remains closed because of a NGSC control.
control.lt, the thermal switch will open.

The NGSC monitors the air temperature going to the ASMs using the
temperature sensor. If the air temperature at the ASU inlet temperature sensor
goes to 255F (107C) the NGSC will de-energize the OTSOV solenoid. The
OTSOV will close. The NGSC will also close the NGS shutoff valve (SOV).

NGS - OVERTEMPERATURE SHUTOFF VALVE, THERMAL SWITCH AND INLET TEMPERATURE SENSOR
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NGS - OVERTEMPERATURE SHUTOFF VALVE, THERMAL

SWITCH AND INLET TEMPERATURE SENSOR (CONT)
Purpose
The air separation unit inlet temperature sensor measures the temperature of
the bleed air that goes into the ASM.
Description
The temperature sensor is a dual-element, platinumtype, nominal at 32F (0C)
RTD sensor. The sensor can measure temperatures from -67F to 500F
(-55C to 260C). The temperature sensor is part of a bridge circuit in the
Nitrogen Generating System Controller (NGSC).
Location
The temperature sensor is in the duct between the Overtemperature Shutoff
Valve (OTSOV) and the Air Separation Modules (ASM) inlet. The sensor is in
the Air Separation Unit (ASU).
General Description
Each element of the dual-element sensor is a thermal resistive device. The
resistance changes in proportion to the temperature of the element. The NGSC
measures the resistance of the element and converts this resistance to degrees
celsius or degrees fahrenheit. The NGSC uses the temperature sensor for
control of the Temperature Control Valve (TCV). The NGSC also uses the
sensor for system fault detection and overtemperature control.

NGS - OVERTEMPERATURE SHUTOFF VALVE, THERMAL SWITCH AND INLET TEMPERATURE SENSOR (CONT)
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NGS - AIR SEPARATION MODULE

Purpose
The Air Separation Modules (ASM) take oxygen from the bleed air in the
Nitrogen Generation System (NGS).
Location
The ASMs are in the right ram air duct compartment, forward of the ECS bay.
They are in the Air Separation Unit (ASU).
General Description
The ASMs use bleed air to make Nitrogen Enriched Air (NEA) for the center fuel
tank. The ASMs remove the oxygen from the bleed air. The oxygen removed
from the bleed air is Oxygen Enriched Air (OEA). The OEA goes overboard
through a port on the ASM. The remaining air is Nitrogen Enriched Air (NEA).
NEA goes from the outlet port through the distribution system to the center fuel
tank.
The ASMs are made of porous fiber membrane bundles in an aluminum
housing. The inlet and outlet fittings are flexible couplings that connect to bleed
air supply and NEA outlet ducts. The OEA port is also a flexible coupling.
Both the inlet and outlet surfaces of the fiber bundle are sealed against the
housing to prevent air bypassing the bundle. Bleed air enters the bundle
through the inlet manifold. As the air goes through the bundle, oxygen is
separated through the fiber walls. The OEA goes overboard through the OEA
port. Carbon dioxide and water molecules separate with the oxygen molecules.
The remaining NEA goes through the outlet port towards the NEA distribution
system.
The major driver of nitrogen enriched air quality is the pressure difference
between inlet bleed air pressure and oxygen enriched air pressure.
Operation
The ASMs enable the generation of NEA that goes to the center fuel tank. The
units operate normally at an ambient temperature of 170F (77C). The main
factor of NEA quality is the pressure difference between inlet bleed air pressure

and OEA pressure. The hollow fiber membrane ASM makes better NEA with
the same inlet pressure (psia) at high altitude compared to sea level
conditions.
The system includes three ASM units in parallel with each other. The ASMs are
in the ASU frame assembly. The ASMs are connected to each other through
the bleed air, NEA and OEA ducting.

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NGS - HIGH FLOW VALVE AND OXYGEN SENSOR

High Flow Valve Purpose
The high flow valve causes the increase of the amount of Nitrogen Enriched Air
(NEA) flow to the center fuel tank.
Location
The high flow valve is in the right ram air duct compartment, forward of the ECS
bay. It is part of the Air Separation Unit (ASU).
General Description
The high flow valve is solenoid controlled and pneumatically operated. It is a
sliding gate valve. The valve spring loads to the closed position.
With the solenoid de-energized, the valve vents pressure behind the piston
through the solenoid to ambient. Spring pressure moves the valve gate to the
closed position. The NEA is in low flow.
With the solenoid energized, inlet air pressure goes to the actuator piston
through the solenoid valve. Air pressure on the piston overcomes spring
pressure. This opens the gate to the open position.
Note:

The valve visual position indicator retracts with the valve closed.
The indicator extends with the valve open.

Operation
The Nitrogen Generation System Controller (NGSC) sends a discrete voltage
signal to open the high flow valve. The NGSC uses the high-flow valve select
high-flow operation.
During normal operation, high flow happens during descent, and also during
maintenance operation. High flow also happens during ground operations
following a system restart. With the high-flow valve open, a parallel flow path to
the fuel tank activates. This allows increased NEA flow for descent operation.
With the high-flow valve closed, this additional path is not used.

With the valve closed, NEA is in low flow. The NGS low flow mode occurs in the
climb and cruise segments of flight. Low flow also occurs during ground
operation of the NGS. The NGSC sends a command to operate the turbo
compressor for NGS ground operations. NGS operates in low flow, boosted
mode on the ground.
The NGSC uses a differential pressure sensor to measure the NEA flow across
the high flow orifice. The NGSC uses differential pressure data for high flow
valve fault detection.
Oxygen Sensor Purpose
The oxygen sensor measures the oxygen content and absolute pressure of the
Nitrogen Enriched Air (NEA). This information is sent to the Nitrogen
Generation System Controller (NGSC). The oxygen sensor monitors the
performance of the Air Separation Modules (ASM). The ASMs are in the Air
Separation Unit (ASU).
Location
The oxygen sensor is in the right ram air duct compartment, forward of the ECS
bay. It is part of the ASU.
General Description
The oxygen sensor measures the oxygen content and absolute pressure of the
NEA supply gas. The sensor sends the data to the NGSC, which uses the data
for system status. The sensor normally operates once per flight leg with
command from the NGSC. The NGSC normally sends the command at the first
part of cruise flight.
Operation
The NGSC starts a timer at takeoff, when the airplane goes into the air. After
thirty minutes the NGSC sends the command for the sensor to start to operate.
The oxygen sensor starts a five minute warm up period. After five minutes the
oxygen sensor gets NEA samples from the common manifold downstream from
the three ASMs. The NGSC compares the oxygen sensor output to an
expected value of oxygen concentration. Airplane pressure and altitude
determines this expected value. The NGSC uses this data for system status
monitoring. If the first reading was unsuccessful one more attempt will be made
at top of descent.

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NGS - DIFFERENTIAL PRESSURE SENSOR AND FLOW

ORIFICES
Purpose
The Nitrogen Generation System Controller (NGSC) uses the differential
pressure sensor to test the high flow valve. The sensor detects the pressure
change when the valve is open or closed.
General Description
The pressure sensor measures differential pressure across the high flow orifice
before the nitrogen enriched air is sent to the center fuel tank. The NGS
controller provides electrical excitation for the sensor. The sensor sends a
voltage output to the NGS controller relative to the pressure being sensed.
The sensor is connected between the upstream and downstream sides of the
high flow orifice.
The high and low flow orifices ensure that a specific NEA flow rate is maintained
for the different NGS flow modes.
Operation
The sensor contains a silicone strain gauge for pressure sensing. The sensing
elements and the electronics are protected inside a stainless steel housing.
The NGSC sends a nominal 28v dc excitation signal to the sensor. The sensor
sends a voltage output between 0.5v dc and 10.5v dc back to the NGSC. This
variable voltage is proportional to a differential pressure of 0 to 45 psid. The
NGSC reads the variable voltage return and converts it to engineering units of
psid.

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NGS - DISTRIBUTION SYSTEM GENERAL DESCRIPTION

Purpose
The Nitrogen Enriched Air Distribution System (NEADS) sends the Nitrogen
Enriched Air (NEA) to the center fuel tank. The system also makes sure that
outside air does not cross flow into the center tank.
Location
The distribution system components are in these areas:

Forward right hand wing to body fairing

Right hand leading edge
Center wing fuel tank
Left hand surge tank

Physical description
The NEA distribution system has these components:

Cross vent check valve

Backflow prevention check valve (2)
Float valve
Distribution manifold
Insulator tube
Sump drain valve
NEA ejector tube

Operation
The NEADS has a distribution manifold, which sends the NEA from the Air
Separation Unit (ASU) into the center wing fuel tank. There are two backflow
check valves. The check valves keep fuel from going into the distribution
manifold and ASU.
Use the sump drain valve to remove fuel from distribution manifold. The valve
is at the low point in the system. Push the valve in to remove the fuel. The
insulator tube is a 1 inch (2.5 cm) non-conductive tube. The tube prevents
lightning current from entering the fuel tank. The flame arrestor prevents too

much heat from going through the center tank front spar. This helps to prevent
an auto ignition of the fuel vapor and air mixture in the center tank.
The NEA ejector tube connects the distribution manifold to the vent system in
the center fuel tank. The ejector sends NEA forward to the right climb vent
portion of the tube.
The float valve connects to the left hat-section vent channel on the right side of
the center tank. The float valve opens when the center fuel tank is not full. The
open valve gives even NEA distribution to the center tank. With the valve open,
NEA will go from the left center tank area into the hat-section vent channel, then
to the right vent tube. The NEA will then go back into the right center tank area.
The cross vent check valve does not let outside air dilute the NEA in the center
fuel tank. The check valve will not let air go between the left and right surge tanks.
Note:

The GSE O2 PORT lets test equipment connect to the NGS. This
allows testing of the O2 content of the NEA

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NGS - DISTRIBUTION SYSTEM COMPONENTS

Float Valve
The float valve helps the supply of Nitrogen Enriched Air (NEA) go through the
center fuel tank at low fuel levels. This lets the vent system continue to operate.
When the tank is almost full, the float valve closes. This does not let fuel go into
the vent system. While the fuel level decreases during flight, the float valve
opens. This lets the distribution system supply full circulation of the NEA.
Cross-Flow Vent Check Valve
The cross-flow vent check valve is a flapper type. The check valve prevents
cross flow ventilation of the fuel tank. It is in the left surge tank. The valve is
spring-loaded closed, and goes to open at 0.2 to 0.5 psi. This lets the unwanted
fuel fumes flow from the vent channel to go to the surge tank. This prevents the
dilution of the nitrogen enriched air (NEA) in the center tank with fresh air.
Ventilation cross flow usually occurs during refueling operations.
Back flow Prevention Check Valves
The back flow prevention check valves give backflow protection from the center
fuel tank. This keeps the center fuel tank fuel out of the air separation unit
(ASU).
Drain Valve
You use the drain valve to do a check for fuel or other fluid in the nitrogen
generation system (NGS) distribution system tube.
Drain Valve Location
The drain valve is in the distribution system downstream of the Air Separation
Modules (ASM) and forward of the air separation unit (ASU). You can get
access to the drain through the right side air conditioning bay access door.
General Description
The drain valve has a spring-loaded poppet that you can open with a small hex
driver. Make sure you have an approved container to catch fluid from the valve.

Refer to the Airplane Maintenance Manual (AMM) when you do maintenance on

the airplane.

NGS - DISTRIBUTION SYSTEM COMPONENTS

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NGS - NITROGEN GENERATION SYSTEM CONTROLLER

Purpose
The Nitrogen Generation System Controller (NGSC) controls and monitors the
Nitrogen Generation System (NGS). The NGSC also gives an interface to other
airplane systems.
Location
The NGSC is behind the sidewall liner, on the right side of the forward cargo
compartment. The NGSC is near the aft bulkhead. The three-point location of
the NGSC is STA 984, WL 180 and RBL 87.
Physical Description
The NGSC is inside a compact lightweight chassis. The chassis attaches to the
airplane with four shock resistant mounting flanges. The chassis contains one
circuit card assembly, with an integrated power supply.
Functions
Airplane air/ground mode causes the NGSC to operate in different modes. The
NGS mode will determine how the NGSC uses these are the functions:
Regulation of bleed air temperature entering the ASM by modulation of the
temperature control valve (TCV)
Open/closed control of the NGS SOV
Open/closed control of the OTSOV
Open/closed control of the TCSOV
Open/closed control of the HFV
Ground fan control via command of the associated airplane electrical
power relay
Detection of overpressure conditions
Detection of over temperature conditions (time filtered) Backup over
temperature protection also comes from thermal switches
Detection of loss of flow
Oxygen (O2) sensor interface, for air separation module (ASM)
performance degradation detection
BITE of all line replaceable units (LRU)s and interfaces

ARINC 429 data communication. RS422 communication for software

download and controller monitor data
BITE display unit (BDU) interface
System status display on the operability indicator
Recording of specified data in the non-volatile memory (NVM) at the time of
any failure detection for later review
BITE
The NGSC has different Built-In-Test (BITE) functions. The BITE functions set
faults, and isolates LRUs for fault isolation. BITE also records faults for service
history records. The NGSC BITE includes these tests:
Power-up self-test for the central processing unit (CPU) and power supply
test
Start BIT
Continuous BIT
Initiated BIT
Fault recording
Start BIT does a test at the start of flight. This test starts at takeoff by an input
from air/ground logic. The test finds failures of the open NGS shutoff valve
(NGSOV), over temperature shutoff valve (OTSOV), high flow valve, and
monitoring system sensors. The test operates for two minutes.
Continuous BIT occurs at set intervals when the NGSC is in control mode.
Continuous BIT starts after the powerup self test bit completes.
Initiated BIT is the test you start from the BITE display unit (BDU).
The NGSC sends recorded fault information detected by BITE to the BDU. The
NGSC sends NGS status information to the status indication panel (SIP).

NGS - NITROGEN GENERATION SYSTEM CONTROLLER

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NGS - BITE DISPLAY UNIT

Purpose
The BDU is the maintenance connection to the Nitrogen Generation System
Controller (NGSC). You use the BITE Display Unit (BDU) to troubleshoot the
Nitrogen Generation System (NGS) faults. The BDU also lets you initiate BITE
tests in the NGSC. The BDU has no processing capability. The BDU connects
with the Nitrogen Generation System Controller (NGSC) over the RS232 digital
interface.
Location
The BDU is in the R/H wing to body fairing. The BDU is aft of the R/H wing front
spar, at STA 782. You get access through the R/H pressure relief panel near
the NGS filter.
Physical Description
The BDU unit has these items:
BITE instruction plate
The two-line Vacuum Fluorescent Display (VFD)
Membrane type BITE control buttons (6)
BITE
The BDU unit has these selections on the main menu:

EXISTING FAULTS
FAULT HISTORY
GROUND TESTS
OTHER FUNCTIONS

These are the functions of the BITE control buttons:

ON/OFF button - turns on and turns off BITE functions
MENU button - used to show the main menu or to move up one level in the
BITE selections
YES button - used to select a main menu item
NO button - used to not select a main menu item

Up arrow button - use to scroll up through the menu or the results of the
BITE test
Down arrow button - use to scroll down through the menu or the results of
a BITE test.

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NGS - BITE DISPLAY FUNCTIONS

EXISTING FAULTS

If there are no faults during the test, the display shows SYSTEM OK. If there is
a fault during TESTING, the display shows EXIST FAULTS for 2 seconds. Then
the display shows the existing faults menu.

The EXISTING FAULTS menu shows faults that are currently present. You can
see faults and fault details from the main menu EXISTING FAULTS. Faults are
maintenance messages of the primary problem. For more information on a
fault, there are fault details available.

OTHER FUNCTIONS

If there is a fault or faults, the most recent fault shows on the display. To see the
next fault, push the NO or DOWN arrow button. If there are no more faults,
the display shows BOTTOM OF LIST for 2 seconds.

From the OTHER FUNCTIONS menu push the NO or DOWN arrow button.
The display shows the following:

FAULT HISTORY
The FAULT HISTORY menu shows previous faults that are in Non-Volatile
Memory (NVM) that have not been cleared. From the FAULT HISTORY menu,
push the YES button. If there are no faults, the display shows NO FAULT
HISTORY. To go back to the main menu, push the MENU button.

The OTHER FUNCTIONS menu shows the specifics of the nitrogen generation
system.

SYSTEM CONFIGURATION
I/O MONITOR
SYSTEM CONFIGURATION
The SYSTEM CONFIGURATION page gives this information:

Hardware part number

Software part number
Configuration part number
Aircraft ID 767

If there are faults, the display shows FLIGHT 00. To show the next flight leg,
push the NO or DOWN arrow button. Then the display shows the next flight leg.
If there are no more flight legs in memory, the display shows BOTTOM OF LIST
for 2 seconds. The highest number flight leg that can show is FLIGHT 09. The
controller can hold up to 10 flight legs in NVM.

I/O MONITOR

GROUND TEST

The I/O MONITOR page gives this information:

The GROUND TEST menu lets you do a series of tests of the nitrogen
generation system (NGS). From the GROUND TEST menu you push the NO or
DOWN arrow button. The display shows the following tests:

ELECTRICAL TEST
SYSTEM TEST
GSE PERF NON-BOOSTED (low flow mode)
GSE PERF BOOSTED (high flow mode)
DISPLAY TEST

When you select a particular test, the message TEST IN PROGRESS shows.

Analog inputs
Discrete inputs
Valve drivers

NGS - BITE DISPLAY FUNCTIONS

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