ISS TCSTrngManualT0012E PDF

01.07.
05(0)T0012
Basic
ERRATA
Thermal Control System Training Manual

January 26, 2004
Errata Dated April 9, 2004
The Section 2 answers in Appendix B were replaced with the correct text.
01.07.05(0)T0012
Basic, CPN-1
(supersedes TD9708)
International Space Station

Thermal Control System
Training Manual
ISS TCS TM 21109
Mission Operations Directorate

Space Flight Training Division
January 26, 2004
National Aeronautics and

Space Administration
Lyndon B. Johnson Space Center
Houston, Texas
01.07.05(0)T0012
Basic, CPN-1
Thermal Control System Training Manual

ISS TCS TM 21109
Prepared by
Original signature obtained

Kathryn R. Bolt
Book Manager
Approved by Approved by
Original signature obtained Original signature obtained

Marc Reagan Ronnie R. Lanier
Group Lead, DT47/Systems Group Branch Chief, DT4/Systems Training Branch
Original Signature Obtained on Basic

Signature not required on this revision per
reason noted in Revision Log.
Wendy B. Lawrence
Station Crew Training Representative
01.07.05(0)T0012
Basic, CPN-1
TECHNICAL SUPPORT
Subject Matter Experts
Internal Thermal Control System
Shawn Harrison (281) 244-7120

Rebecca Juillerat (281) 244-8472
Early External Thermal Control System
External Thermal Control System
Kathryn Bolt (281) 244-9064

01.07.05(0)T0012
Basic, CPN-1
REVISION LOG
Rev. Change
Description Date
letter no.
Basic Hierarchy number assigned; supersedes 11/01/02
TD9708. Edits to all sections
CPN-1 Added Section 3; updated Appendix A 01/26/04
The original Crew Office signature was obtained
on the Basic revision. There have been no
changes to the crew section of this manual
since that revision, including this revision, CPN-
1. As such, Crew Office signature is not
required per Space Flight Training direction.
Errata Replaced Section 2 answers in Appendix B with 04/09/04
correct text
01.07.05(0)T0012
Basic, CPN-1
LIST OF EFFECTIVE PAGES
The current status of all pages in this document is shown below.
Page no. Change no.

Foreword Basic, CPN-1
i – xi Basic, CPN-1
1-1 – 1-38 Basic
2-1 – 2-91 Basic
3-1 – 3-180 Basic, CPN-1
A-1 – A-5 Basic, CPN-1
B-1 – B-3 Basic
C-1 – C-3 Basic
D-1 – D-7 Basic
01.07.05(0)T0012
Basic, CPN-1
FOREWORD
The contents of this document was provided by the International Space Station (ISS)
Electrical Power System (EPS) and Thermal Control System (TCS) Group, Systems
Training Branch, Space Flight Training Division, Mission Operations Directorate
(MOD), Lyndon B. Johnson Space Center (JSC), National Aeronautics and Space
Administration (NASA). Technical documentation support was provided by Integrated
Documentation Services (IDS). Many of the details within Section 3 of this training
manual were taken directly from the THOR Console Handbook, JSC-36432. Many
thanks to the DF84 personnel who provided the details and took the time to review this
training manual for accuracy. Any questions concerning this training manual or any
recommendations should be directed to the training manual book manager, Shawn
Harrison at DT47, (281) 244-7120, Kathryn Bolt at DT47, (281) 244-9064, or Paul
Attaway at DT41, (281) 244-7182.
This material is for training purposes only and should not be used as a source of
operational data. All numerical data, displays, and checklist references are intended as
examples. To determine any prerequisites before using this document, consult the
applicable Certification Plan. For shuttle manuals, consult the Flight Operations
Support Personnel Training Guide (Blue Book) or the Crew Training Catalog. For
Space Station manuals, consult the appropriate Space Station Certification Training
Guide or Training Administration Management System (TAMS). The applicable training
package should be studied before attending any classroom session or lesson for which
this is a prerequisite.
A Training Materials Evaluation form is included at the end of this document. Inputs on
this sheet will be used to evaluate the lesson material. You do not need to sign the
sheet.
01.07.05(0)T0012
Basic, CPN-1
CONTENTS
Section Page
1.0 THERMAL CONTROL SYSTEM OVERVIEW ........................................... 1-1

1.1 INTRODUCTION .......................................................................... 1-1
1.1.1 Objectives ..................................................................................... 1-1
1.2 TCS ARCHITECTURE.................................................................. 1-1
1.3 USOS PASSIVE THERMAL CONTROL SYSTEM ....................... 1-2
1.3.1 Purpose ........................................................................................ 1-2
1.3.2 USOS PTCS Components............................................................ 1-2
1.4 USOS ACTIVE THERMAL CONTROL SYSTEM ......................... 1-5
1.4.1 US Lab Internal Thermal Control System (ITCS).......................... 1-5
1.4.2 USOS Early External Thermal Control System............................. 1-11
1.4.3 USOS External Thermal Control System...................................... 1-17
1.5 USOS TCS SOFTWARE .............................................................. 1-24
1.5.1 Purpose ........................................................................................ 1-24
1.5.2 Architecture................................................................................... 1-24
1.6 ROS THERMAL CONTROL SYSTEM.......................................... 1-27
1.6.1 Purpose ........................................................................................ 1-27
1.7 FLIGHT-BY-FLIGHT OPERATIONS............................................. 1-32
1.8 TCS SUMMARY ........................................................................... 1-34
1.8.1 USOS PTCS Summary................................................................. 1-34
1.8.2 USOS ATCS Summary................................................................. 1-34
1.8.3 USOS TCS Software Summary .................................................... 1-35
1.8.4 ROS TCS Summary ..................................................................... 1-35
2.0 USOS TCS FUNCTIONAL DESCRIPTION ............................................... 2-1

2.1 INTRODUCTION .......................................................................... 2-1
2.1.1 Objectives ..................................................................................... 2-1
2.2 USOS LAB ITCS FUNCTIONAL DESCRIPTION ......................... 2-1
2.2.1 ITCS Heat Collection .................................................................... 2-5
2.2.2 ITCS Heat Transportation............................................................. 2-8
2.2.3 ITCS Heat Rejection ..................................................................... 2-29
2.3 USOS EETCS FUNCTIONAL DESCRIPTION ............................. 2-32
2.3.1 EETCS Heat Collection ................................................................ 2-35
2.3.2 EETCS Heat Transportation ......................................................... 2-37
2.3.3 EETCS Heat Rejection ................................................................. 2-43
2.4 USOS ETCS FUNCTIONAL DESCRIPTION................................ 2-47
2.4.1 ETCS Heat Collection ................................................................... 2-51
2.4.2 ETCS Heat Transportation ........................................................... 2-55
2.4.3 ETCS Heat Rejection.................................................................... 2-67
2.5 USOS TCS SOFTWARE OVERVIEW ......................................... 2-77
2.5.1 Purpose ........................................................................................ 2-77
2.5.2 TCS Software Architecture ........................................................... 2-77
2.5.3 C&C MDM Software...................................................................... 2-78
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Section Page
2.5.4 US Lab ITCS Software ................................................................. 2-79

2.5.5 EETCS Software........................................................................... 2-81
2.5.6 ETCS Software ............................................................................. 2-82
3.0 TECHNICAL SUPPORT ............................................................................ 3-1

3.1 INTRODUCTION .......................................................................... 3-1
3.2 LAB ITCS COMPONENTS ........................................................... 3-2
3.2.1 ITCS Plumbing.............................................................................. 3-2
3.2.2 ITCS Water................................................................................... 3-4
3.2.3 Coldplates..................................................................................... 3-6
3.2.4 Pump Package Assembly............................................................. 3-7
3.2.5 Pump Bypass Assembly ............................................................... 3-19
3.2.6 Nitrogen Interface Assembly......................................................... 3-20
3.2.7 Rack Flow Control Assembly ........................................................ 3-21
3.2.8 Manual Flow Control Valve ........................................................... 3-24
3.2.9 System Flow Control Assembly .................................................... 3-26
3.2.10 Three-Way Mixing Valve............................................................... 3-27
3.2.11 Loop Crossover Assembly ............................................................ 3-29
3.2.12 Interface Heat Exchanger ............................................................. 3-29
3.2.13 ITCS Contingency Jumpers .......................................................... 3-30
3.2.14 ITCS Overview Display ................................................................. 3-37
3.3 EARLY EXTERNAL THERMAL CONTROL SYSTEM
COMPONENTS ............................................................................ 3-39
3.3.1 Interface Heat Exchanger ............................................................. 3-39
3.3.2 Pump and Flow Control Subassembly.......................................... 3-41
3.3.3 Radiators ...................................................................................... 3-44
3.3.4 EETCS Overview Display ............................................................. 3-46
3.4 EXTERNAL THERMAL CONTROL SYSTEM COMPONENTS .... 3-48
3.4.1 Interface Heat Exchangers ........................................................... 3-48
3.4.2 External DDCU/MBSU Coldplates ................................................ 3-50
3.4.3 Pump Module (PM)....................................................................... 3-50
3.4.4 Ammonia Tank Assembly ............................................................. 3-64
3.4.5 Nitrogen Tank Assembly............................................................... 3-71
3.4.6 Radiators ...................................................................................... 3-79
3.4.7 Radiator Beam Valve Modules (RBVM)........................................ 3-86
3.4.8 Thermal Radiator Rotary Joint ...................................................... 3-90
3.5 USOS PASSIVE TCS HEATERS ................................................. 3-95
3.5.1 Shell Heaters ................................................................................ 3-96
3.5.2 ORU Heaters ................................................................................ 3-103
3.5.3 Line Heaters ................................................................................. 3-104
3.5.4 Truss/Rail Heaters ........................................................................ 3-104
3.5.5 Launch-To-Activation Heaters ...................................................... 3-105
3.6 TCS SOFTWARE DETAILS ......................................................... 3-107
3.6.1 Command and Control MDM Software ......................................... 3-107
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Section Page
3.6.2 INT SYS MDM Software ............................................................... 3-113

3.6.3 LAB SYS MDM Software .............................................................. 3-124
3.6.4 Node 1 MDM Software.................................................................. 3-134
3.6.5 Photovoltaic Controller Unit MDM Software (PVCU MDMs) ......... 3-136
3.6.6 PFCS Firmware Controller (Local Data Interface) ........................ 3-144
3.6.7 External MDM Software (EXT MDM) ............................................ 3-147
3.6.8 Pump and Control Valve Package Firmware (PCVP) ................... 3-160
3.6.9 S1 Truss/P1 Truss MDM Software (S1/P1 MDMs) ....................... 3-162
3.6.10 Starboard (Port) Thermal Radiator MDM Software (STR/PTR
MDMs) .......................................................................................... 3-173
3.6.11 S0 Truss MDM Software (S0 MDMs)............................................ 3-177
3.6.12 Power Management and Control Unit MDM Software .................. 3-179
Appendix
A ACRONYMS AND ABBREVIATIONS........................................................ A-1
B ANSWERS ................................................................................................. B-1
C HEAT TRANSFER FUNDAMENTALS....................................................... C-1
D PUMP/FAN MOTOR CONTROLLER......................................................... D-1
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01.07.05(0)T0012
Basic, CPN-1
TABLES
Table Page
1-1 EETCS/ETCS comparison ......................................................................... 1-17
1-2 TCS comparison......................................................................................... 1-32
1-3 TCS buildup ............................................................................................... 1-33
2-1 ITCS operating modes ............................................................................... 2-29

2-2 Coldplate ORU Electrical Power Interfaces................................................ 2-55
2-3 RBVM limit switch position vs. valve configuration ..................................... 2-72
2-4 TRRJ EPS/CDH connectivity...................................................................... 2-76
2-5 ITCS operational modes............................................................................. 2-79
2-6 TRRJ string definitions ............................................................................... 2-84
3-1 PPA components ....................................................................................... 3-7

3-2 Fine filter characteristics............................................................................. 3-9
3-3 Gas trap characteristics.............................................................................. 3-12
3-4 Accumulator physical characteristics.......................................................... 3-14
3-5 Pump characteristics .................................................................................. 3-17
3-6 PPA flowmeter physical characteristics...................................................... 3-19
3-7 NIA components......................................................................................... 3-20
3-8 RFCA components ..................................................................................... 3-21
3-9 MFCV service............................................................................................. 3-25
3-10 SFCA components ..................................................................................... 3-26
3-11 TWMV components.................................................................................... 3-27
3-12 LCA components........................................................................................ 3-29
3-13 IFHX ITCS components ............................................................................. 3-30
3-14 ITCS contingency jumpers ......................................................................... 3-30
3-15 Forward endcone equipment overheat times ............................................. 3-31
3-16 LAB1D1 equipment overheat times............................................................ 3-32
3-17 IFHX EETCS components.......................................................................... 3-39
3-18 IFHX freezing/leakage risks and preventative measures ........................... 3-39
3-19 EETCS IFHX physical characteristics ........................................................ 3-40
3-20 Pump and flow control subassembly components summary...................... 3-41
3-21 Radiator component summary ................................................................... 3-45
3-22 Comparison of low-load and high-load IFHX characteristics ...................... 3-48
3-23 ETCS coldplate temperature sensor and heater connectivity .................... 3-50
3-24 Pump module components summary......................................................... 3-51
3-25 PM physical characteristics ........................................................................ 3-52
3-26 PM PCVP pump flow/dP design characteristics ......................................... 3-53
3-27 Radiator leg flow resistance with reduced active flow paths....................... 3-53
3-28 PM accumulator characteristics ................................................................. 3-54
3-29 Accumulator heater characteristics ............................................................ 3-54
3-30 PM accumulator heaters ............................................................................ 3-55
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Table Page
3-31 PM isolation valve design characteristics ................................................... 3-55
3-32 Inlet isolation relief valve characteristics .................................................... 3-56
3-33 PM temperature sensor characteristics ...................................................... 3-57
3-34 PM flowmeter characteristics ..................................................................... 3-59
3-35 PCVP out line temperature characteristics................................................. 3-61
3-36 Absolute pressure transducer characteristics............................................. 3-62
3-37 PM ORU power summary........................................................................... 3-63
3-38 ATA components summary ........................................................................ 3-64
3-39 ATA physical characteristics ...................................................................... 3-65
3-40 ATA isolation valve physical characteristics ............................................... 3-68
3-41 Tank heaters characteristics ...................................................................... 3-68
3-42 ATA accumulator heaters........................................................................... 3-69
3-43 Differential pressure sensor physical characteristics.................................. 3-70
3-44 ATA ORU power summary......................................................................... 3-71
3-45 NTA components summary........................................................................ 3-72
3-46 NTA physical characteristics ...................................................................... 3-72
3-47 Nitrogen tank physical characteristics ........................................................ 3-72
3-48 NTA GPRV relief valve properties .............................................................. 3-74
3-49 NTA base (MMOD) heater characteristics.................................................. 3-74
3-50 NTA GPRV survival heater characteristics................................................. 3-74
3-51 NTA heaters ............................................................................................... 3-75
3-52 Nitrogen outlet pressure sensor characteristics ......................................... 3-77
3-53 Nitrogen tank ORU power summary........................................................... 3-78
3-54 Radiator components summary ................................................................. 3-79
3-55 Radiator performance characteristics......................................................... 3-80
3-56 Radiator deploy phases.............................................................................. 3-83
3-57 Radiator deployment conditions ................................................................. 3-83
3-58 Radiator retract phases .............................................................................. 3-83
3-59 S1 radiator heaters..................................................................................... 3-84
3-60 P1 radiator heaters..................................................................................... 3-85
3-61 RBVM components summary..................................................................... 3-86
3-62 RBVM physical characteristics ................................................................... 3-87
3-63 RBVM relief valve characteristics ............................................................... 3-88
3-64 RBVM thermostat setpoints........................................................................ 3-89
3-65 RBVM ORU power summary (8A-12A) ...................................................... 3-90
3-66 TRRJ components...................................................................................... 3-91
3-67 TRRJ characteristics .................................................................................. 3-92
3-68 S1 TRRJ heaters........................................................................................ 3-94
3-69 P1 TRRJ heaters........................................................................................ 3-94
3-70 Airlock shell heater patches per zone ........................................................ 3-102
3-71 Airlock shell temperature limits................................................................... 3-103
3-72 Thermal safing failure indications............................................................... 3-108
3-73 Thermal safing load shed response ........................................................... 3-109
3-74 Survival mode trigger conditions ................................................................ 3-111
3-75 ITCS status ................................................................................................ 3-113
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Table Page
3-76 ITCS modes ............................................................................................... 3-114
3-77 Leak limit initialization values ..................................................................... 3-117
3-78 IFHX heaters .............................................................................................. 3-119
3-79 PUMP PPA C&W limits .............................................................................. 3-119
3-80 PUMP NIA C&W limits ............................................................................... 3-121
3-92 S1 MDM pair nominal configuration ........................................................... 3-151
3-93 P1 MDM pair nominal configuration ........................................................... 3-151
3-97 FCV temp control methods......................................................................... 3-161
3-98 PCVP commands ....................................................................................... 3-167
3-99 Commanded absolute angular position...................................................... 3-172
3-100 TRRJ control FDIR ..................................................................................... 3-173
3-101 RDR initialization values............................................................................. 3-174
3-102 RDR commands ......................................................................................... 3-175
3-103 RC initialization values ............................................................................... 3-176
3-104 RC commands............................................................................................ 3-176
vi
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Basic, CPN-1
FIGURES
Figure Page
1-1 ISS TCS architecture.................................................................................. 1-1
1-2 Typical USOS PTCS .................................................................................. 1-3
1-3 USOS ATCS architecture........................................................................... 1-5
1-4 US Lab Internal Thermal Control System TCS1B-US-I-8A ........................ 1-7
1-5 USOS Early External Thermal Control System TCS1B-US-EE-8A ............ 1-13
1-6 EETCS radiators ........................................................................................ 1-16
1-7 USOS External Thermal Control System TCS1B-US-ETCS-AC................ 1-19
1-8 ETCS radiators........................................................................................... 1-23
1-9 USOS TCS software architecture (Flights 12A.1+) .................................... 1-25
1-10 USOS TCS software architecture (Flight 12A.1+) ...................................... 1-26
1-11 FGB Internal and External Thermal Control Systems TCS1B-RS-FGB-
8A-US......................................................................................................... 1-29
2-1 US Lab Internal Thermal Control System................................................... 2-3

2-2 Typical coldplate design ............................................................................. 2-5
2-3 Coldplate functional schematic................................................................... 2-6
2-4 Heat exchanger functional schematic ........................................................ 2-7
2-5 Pump Package Assembly .......................................................................... 2-8
2-6 PPA cross-sectional view ........................................................................... 2-9
2-7 PPA functional schematic........................................................................... 2-9
2-8 Venturi flowmeter ....................................................................................... 2-12
2-9 PPA interfaces ........................................................................................... 2-13
2-10 Nitrogen Interface Assembly ...................................................................... 2-14
2-11 Nitrogen Interface Assembly functional schematic..................................... 2-15
2-12 Nitrogen Interface Assembly interfaces...................................................... 2-16
2-13 Rack Flow Control Assembly...................................................................... 2-17
2-14 Rack Flow Control Assembly functional schematic .................................... 2-18
2-15 Rack Flow Control Assembly interfaces ..................................................... 2-18
2-16 RFCA connections ..................................................................................... 2-19
2-17 Manual Flow Control Valve......................................................................... 2-20
2-18 System Flow Control Assembly.................................................................. 2-21
2-19 System Flow Control Assembly functional schematic ................................ 2-22
2-20 System Flow Control Assembly interfaces ................................................. 2-22
2-21 Three-Way Mixing Valve ............................................................................ 2-23
2-22 LTL and MTL TWMV functional schematic ................................................ 2-24
2-23 RHX TWMV functional schematic .............................................................. 2-24
2-24 Three-Way Mixing Valve interfaces............................................................ 2-25
2-25 Loop Crossover Assembly ......................................................................... 2-25
2-26 Loop Crossover Assembly functional schematic ........................................ 2-26
2-27 LCA valve configurations showing vacuum system interference................ 2-27
2-28 Loop Crossover Assembly interfaces ......................................................... 2-27
2-29 Interface heat exchanger ORU................................................................... 2-29
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Basic, CPN-1
Figure Page
2-30 IFHX functional schematic.......................................................................... 2-30
2-31 IFHX interfaces........................................................................................... 2-31
2-32 USOS Early External Thermal Control System schematic
TCS2B-US-EE-8A ...................................................................................... 2-33
2-33 EETCS components on the P6 long spacer............................................... 2-35
2-34 IFHX functional schematic.......................................................................... 2-36
2-35 PFCS functional schematic ........................................................................ 2-38
2-36 PFCS accumulator ..................................................................................... 2-39
2-37 Pump and flow control subassembly interfaces ......................................... 2-41
2-38 Early External Thermal Control System radiator ........................................ 2-43
2-39 EETCS Radiator functional schematic ....................................................... 2-44
2-40 EETCS radiator (stowed) ........................................................................... 2-45
2-41 Radiator interfaces ..................................................................................... 2-46
2-42 USOS External thermal control system (TCS2B-US-ETCS-AC) ................ 2-49
2-43 ETCS components ..................................................................................... 2-51
2-44 Typical IFHX functional schematic ............................................................. 2-52
2-45 DDCU coldplate ORU installation............................................................... 2-54
2-46 Pump Module ............................................................................................. 2-56
2-47 ETCS PM functional schematic.................................................................. 2-57
2-48 PM interfaces ............................................................................................. 2-59
2-49 Ammonia Tank Assembly........................................................................... 2-60
2-50 Ammonia Tank Assembly functional schematic ......................................... 2-61
2-51 ATA Heaters............................................................................................... 2-62
2-52 ATA interfaces............................................................................................ 2-63
2-53 Nitrogen Tank Assembly ............................................................................ 2-64
2-54 NTA functional schematic........................................................................... 2-65
2-55 NTA Gas Pressure Regulator Valve Assembly .......................................... 2-66
2-56 NTA Heater Patches .................................................................................. 2-66
2-57 NTA interfaces ........................................................................................... 2-67
2-58 ETCS radiator wing assembly .................................................................... 2-68
2-59 Radiator ORU functional schematic ........................................................... 2-69
2-60 Radiator ORU interfaces ............................................................................ 2-70
2-61 Radiator Beam Valve Modules................................................................... 2-70
2-62 RBVM functional schematic ....................................................................... 2-71
2-63 RBVM interfaces ........................................................................................ 2-73
2-64 Thermal Radiator Rotary Joint (TRRJ) ....................................................... 2-73
2-65 TRRJ Functional Schematic....................................................................... 2-74
2-66 TRRJ interfaces.......................................................................................... 2-76
2-67 USOS TCS software architecture (Flights 5A through 12A.1).................... 2-77
2-68 USOS TCS Software Architecture (Flight 12A.1+) ..................................... 2-78
3-1 LTL plumbing isometric .............................................................................. 3-2

3-2 MTL plumbing............................................................................................. 3-3
3-3 ITCS sampling tool ..................................................................................... 3-4
3-4 LTL sampling tool installation in AR rack (LAB1D6)................................... 3-5
viii
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Figure Page
3-5 MTL sampling tool installation in AV-1 rack (LAB1D5)............................... 3-5
3-6 Coldplate characteristics ............................................................................ 3-6
3-7 Fine filter .................................................................................................... 3-7
3-8 Fine filter cross section............................................................................... 3-8
3-9 Fine filter details ......................................................................................... 3-8
3-10 Two-membrane gas trap design................................................................. 3-10
3-11 Gas trap cross section................................................................................ 3-11
3-12 Accumulator bellows functional schematic ................................................. 3-12
3-13 Accumulator quantity sensor ...................................................................... 3-13
3-14 Impeller ...................................................................................................... 3-14
3-15 PPA impeller............................................................................................... 3-15
3-16 Pump cross section .................................................................................... 3-15
3-17 Impeller/motor diagram .............................................................................. 3-16
3-18 PPA flowmeter cross section...................................................................... 3-18
3-19 Pump bypass assembly ............................................................................. 3-19
3-20 NIV/AVV cross section ............................................................................... 3-20
3-21 RFCA FCV manual override knob .............................................................. 3-22
3-22 Lab RFCA locations ................................................................................... 3-23
3-23 Manual flow control valve ........................................................................... 3-24
3-24 Rack standalone temperature sensor ........................................................ 3-25
3-25 LTL and MTL TWMV.................................................................................. 3-28
3-26 Regen HX TWMV....................................................................................... 3-28
3-27 LCA valve schematics (dual vs. single) ...................................................... 3-29
3-28 Forward endcone jumpers.......................................................................... 3-31
3-29 Functional schematic showing airlock jumper installation .......................... 3-35
3-30 Rack/Airlock jumper assembly ................................................................... 3-36
3-31 LCA jumper reconfiguration........................................................................ 3-37
3-32 *ITCS Lab overview PCS display ............................................................... 3-38
3-33 IFHX control (Flights 5A through 12A.1)..................................................... 3-40
3-34 Pump and flow control subassembly.......................................................... 3-42
3-35 PFCS manifold assembly ........................................................................... 3-43
3-36 PFCS control (Flights 5A through 12A.1) ................................................... 3-44
3-37 EETCS radiator loop flow schematic.......................................................... 3-45
3-38 EETCS overview PCS display.................................................................... 3-47
3-39 Loop A IFHX control (at assembly complete) ............................................. 3-49
3-40 Loop B IFHX control (at assembly complete) ............................................. 3-49
3-41 Pump module ............................................................................................. 3-51
3-42 PCVP components ..................................................................................... 3-52
3-43 PM vent (and relief) valve........................................................................... 3-56
3-44 PM N2 inlet temperature sensor location ................................................... 3-57
3-45 PM out and radiator return temperature sensor locations .......................... 3-58
3-46 Bypass temperature sensor location .......................................................... 3-59
3-47 PCVP outlet line temperature sensor location............................................ 3-60
3-48 PM ORU fluid interfaces............................................................................. 3-62
3-49 PM line heaters .......................................................................................... 3-63
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Figure Page
3-50 Ammonia tank assembly ............................................................................ 3-64
3-51 Ammonia tank cross section ...................................................................... 3-66
3-52 ATA fluid interfaces .................................................................................... 3-67
3-53 ATA heaters ............................................................................................... 3-69
3-54 ATA pressure sensor locations .................................................................. 3-69
3-55 Nitrogen tank assembly.............................................................................. 3-71
3-56 NTA base (MMOD) survival heater (HR1) .................................................. 3-75
3-57 NTA GPRV survival heater (HR2) .............................................................. 3-75
3-58 NTA ORU fluid interfaces ........................................................................... 3-76
3-59 NTA nitrogen supply temp RTD mounting.................................................. 3-77
3-60 Radiator wing assembly ............................................................................. 3-79
3-61 ETCS radiator ORU, deployed ................................................................... 3-80
3-62 Radiator IMCA data/power interfaces ........................................................ 3-82
3-63 RBVM ORU components ........................................................................... 3-87
3-64 TRRJ components...................................................................................... 3-91
3-65 TRRJ strings............................................................................................... 3-93
3-66 Node 1 shell heater zones.......................................................................... 3-96
3-67 Typical Node 1 shell heater control ............................................................ 3-97
3-68 PMA 1 shell heater zones .......................................................................... 3-97
3-69 Typical PMA 1 shell heater control............................................................. 3-98
3-70 Node 1, PMA 1, and PMA 2 heater PCS displays...................................... 3-98
3-71 PMA 2 shell heater control display ............................................................. 3-99
3-72 Lab shell heater zones ............................................................................... 3-100
3-73 Typical lab shell heater control................................................................... 3-100
3-74 Lab shell heater control display.................................................................. 3-101
3-75 Airlock shell heater zones .......................................................................... 3-102
3-76 Airlock TCS overview ................................................................................. 3-103
3-77 Sample utility rail (power bus) heater display ............................................. 3-104
3-78 Load shed timeline ..................................................................................... 3-110
3-79 Thermal load reduction PCS display .......................................................... 3-112
3-80 IFHX safing PCS display (15A+) ................................................................ 3-112
3-81 FRITCS failure conditions and software response ..................................... 3-115
3-82 IFHX heaters .............................................................................................. 3-118
3-83 ITCS software commands PCS display ..................................................... 3-121
3-84 ITCS software additional commands PCS display ..................................... 3-122
3-85 PPA commands PCS display ..................................................................... 3-123
3-86 NIA commands PCS display ...................................................................... 3-123
3-87 IFHX heater commands display ................................................................. 3-124
3-81 TWMV initialization values ......................................................................... 3-125
3-88 MTL TWMV commands PCS display......................................................... 3-126
3-89 LCA commands PCS display ..................................................................... 3-127
3-82 SFCA initialization values ........................................................................... 3-127
3-90 MTL SFCA commands display................................................................... 3-128
3-83 RFCA MDM connectivity ............................................................................ 3-129
3-84 RFCA initialization values........................................................................... 3-129
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3-91 RFCA PCS display ..................................................................................... 3-131
3-85 RSTS racks and MDM interfaces ............................................................... 3-132
3-92 Lab rack details PCS display...................................................................... 3-132
3-86 PTCS heaters MDM connectivity................................................................ 3-133
3-87 IFHX sensor initialization values................................................................. 3-135
3-93 IFHX commands PCS display .................................................................... 3-136
3-94 IFHX additional commands PCS display.................................................... 3-136
3-88 EETCS control algorithms .......................................................................... 3-139
3-89 EETCS Control algorithms initialization parameters................................... 3-139
3-90 EETCS FDIR algorithms ............................................................................ 3-141
3-91 EETCS FDIR initialization parameters ....................................................... 3-142
3-95 PFCS nominal commands PCS display ..................................................... 3-144
3-96 EETCS PFCS FDIR PCS commands displays........................................... 3-144
3-97 STCR commands PCS display .................................................................. 3-147
3-98 Loop A PFCS nominal additional commands PCS display ........................ 3-147
3-94 RGAC initialization values .......................................................................... 3-152
3-99 Loop A RGAC PCS display ........................................................................ 3-154
3-95 TRRJ manager initialization values ............................................................ 3-155
3-100 Relationship between the TRRJ Manager modes ...................................... 3-157
3-96 TRRJ Manager FDIR.................................................................................. 3-158
3-101 Loop A TRRJ mode commands PCS display............................................. 3-159
3-102 Loop A DLA commands PCS display......................................................... 3-159
3-103 Loop A TRRJ PCS display ......................................................................... 3-159
3-104 Relationship between the PTC modes ....................................................... 3-163
3-105 PCVP Commands PCS display.................................................................. 3-166
3-106 Manual Startup PCS display ...................................................................... 3-168
3-107 PM PCS display ......................................................................................... 3-168
3-108 ATA valves PCS display............................................................................. 3-169
3-109 ATA overview PCS display......................................................................... 3-169
3-110 NTA valves PCS display............................................................................. 3-170
3-111 NTA overview PCS display......................................................................... 3-170
3-112 DLA state change parameters.................................................................... 3-171
3-113 Radiator IMCA PCS display ....................................................................... 3-175
3-114 S1-1 radiator PCS display .......................................................................... 3-175
3-115 Radiator RBVM IMCA PCS display ............................................................ 3-176
3-116 S0 TCS and heater commands PCS displays............................................ 3-177
3-117 ETCS IFHX Commands display ................................................................. 3-179
3-118 MBSU coldplate heaters PCS display ........................................................ 3-180
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1.0 THERMAL CONTROL SYSTEM OVERVIEW
1.1 INTRODUCTION
Throughout the life of the International Space Station (ISS), experiments, equipment,
and crewmembers inside the modules are generating heat that must be removed.
Outside the modules, experiments and equipment must be protected from the
environment in low Earth orbit. The purpose of the Thermal Control System (TCS)
is to maintain ISS equipment and payloads within their required temperature
ranges.
This section provides an overview of the ISS TCS. The components and general
operational capabilities of the TCS are presented as well as the various interfaces with
other ISS systems.
1.1.1 Objectives
After completing this section, you should be able to
• Compare and contrast the major capabilities performed by the United States Orbital
Segment (USOS) and Russian Orbital Segment (ROS) TCS
• Identify the functions of each of the TCS subsystems
• Explain the redundancy scheme for Internal and External TCS loops and the
operational consequences of a loss of those major functions
1.2 TCS ARCHITECTURE

In order to understand how the thermal control process takes place, a look at the
overall ISS TCS architecture is necessary. As shown in Figure 1-1, the ISS TCS is
composed of Passive and Active TCSs.
Figure 1-1. ISS TCS architecture
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The Passive Thermal Control System (PTCS) consists of insulation, coatings, heaters,
and heat pipes. Its components generally have few operational requirements and
require low maintenance. PTCS components are also less complex and easier to
implement.
The Active Thermal Control System (ATCS) uses a mechanically pumped fluid to
perform heat transfer. Although this approach is more complex, the ATCS handles
much greater heat loads and provides a higher degree of control over how the heat
loads are managed.
The USOS and ROS use this same architecture, modified to meet the needs of
individual elements. ROS TCS is very similar in design to the Mir Space Station and
functionally similar to USOS TCS (i.e., the modules do not share internal and external
systems as in the USOS).
The following sections address the USOS architecture first, followed by a discussion of
ROS TCS.
1.3 USOS PASSIVE THERMAL CONTROL SYSTEM

Since temperatures vary drastically across the ISS, thermal control requirements are
different and unique to each location. Temperatures along the truss decrease as the
distance from the modules increases because most of the heat is generated around the
module area. Temperatures around the modules can vary from -126° to 149° Celsius
(C) (-195° to 300° Fahrenheit (F)), and temperatures at the outer limits of the truss can
vary from -184° to 149° C (±300° F). Passive thermal control is the first method
evaluated when equipment or payloads need to be protected because it is less
expensive and simpler than active thermal control.
1.3.1 Purpose
The PTCS is responsible for maintaining USOS structures and external equipment
within an allowable temperature range. With no fluid interface, it isolates USOS
elements from the external environment. PTCS components are designed to minimize
maintenance and refurbishment.
1.3.2 USOS PTCS Components

The four components used in the PTCS are insulation, surface coatings, heaters,
and heat pipes. These components are used to maintain temperatures within
acceptable ranges based on the local thermal environment. Examples are shown in
Figure 1-2.
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Figure 1-2. Typical USOS PTCS

Multilayer Insulation: Multilayer Insulation (MLI) is used to control heat transfer rates
and minimize temperature gradients. Just as home insulation prevents heat from
entering or escaping, an MLI blanket performs the same function for the ISS. The MLI
consists of several layers. Overall thickness varies from 3.2 to 6.4 millimeter (mm)
(0.125 to 0.25 inch). A single aluminized outer cloth layer provides protection for the
intermediate layers from atomic oxygen, Micro-Meteoroid/Orbital Debris (MMOD). The
intermediate layers provide very efficient thermal radiation shielding. An aluminized
inner layer provides flammability protection and also helps to protect the intermediate
layers from damage during handling and installation. MLI blankets are also designed to
allow trapped gases to escape during launch. Improper venting could result in inflation
of the blankets, causing them to come loose, damage themselves, or damage the
surrounding structure.
MLI is used both inside and outside the modules, on truss segments, and on Orbital
Replacement Units (ORUs). It is also used as a safety device to prevent crew contact
with extreme temperatures.
Surface Coatings and Paints: Since thermal requirements vary from location to
location, surface finishes vary throughout the ISS. Thermal coatings and paints must
be compatible with the environment and must be resistant to atomic oxygen and
radiation.
The concepts of emissivity and absorptivity are critical to understanding surface

finishes. All matter continuously emits electromagnetic radiation. Emissivity deals with
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the ability of an object to emit radiant energy (to radiate), while absorptivity describes
the ability of an object to absorb radiant energy falling upon it. (Reflectivity is the
opposite of absorptivity and should not be confused with emissivity.)
Emissivity and absorptivity values are defined in relation to a theoretical ideal called a
“blackbody.” If such a surface existed, it would emit the theoretical maximum amount of
energy per unit area at each wavelength for any given temperature. It would also
absorb all radiant energy incident upon it. Such a surface would have emissivity and
absorptivity values of 1.0, while a surface that did not emit or absorb any energy
(a theoretically perfect reflector) would have values of 0.0. All real surfaces fall
somewhere between these two ideals and are sometimes referred to as “gray bodies.”
Their emissivity and absorptivity values can be determined empirically and must be
between 0.0 and 1.0.
The color of a surface may not indicate its overall capacity to absorb or reflect since
radiant energy may be outside the visible spectrum. For example, snow is highly
reflective of visible radiation but strongly absorbs infrared. Likewise, black objects
absorb most visible light but may reflect other wavelengths.
Different types of finishes are used to provide various degrees of thermal control for
equipment. The two types of finishes on the USOS are anodized coatings (which
change the physical characteristics of the surface) and paints (which add a layer of
material on top of the surface). By using coatings or paints with different emissivity or
absorptivity characteristics, an ORU can either be “warmed” or “cooled” as required.
For example, TCS radiators use high emissivity and low absorptivity coatings to help
radiate excess heat to space.
Heaters: Electrically powered heaters are used in locations where it is impossible or

impractical to satisfy both high and low temperature requirements through the use of
other PTCS or ATCS implementations. For example, heaters are used to prevent
external TCS fluid lines from freezing in extremely cold environments and/or “no flow”
conditions. There are over 300 heaters throughout the USOS on fluid lines, ORUs, and
modules.
Three types of heaters, operational heaters, survival heaters, and shell heaters, are
used on the USOS. Operational heaters keep a component at or above a minimum
temperature while it is operating. Survival heaters prevent a component from damage
by low temperatures while it is not powered. Shell heaters prevent condensation on the
interior walls of pressurized modules.
Redundancy is achieved by grouping heaters into zones that are controlled by separate
Multiplexer/Demultiplexers (MDMs) and powered by separate Remote Power Controller
Modules (RPCMs).
Heat Pipes: An additional form of passive thermal control is the heat pipe. Heat pipes
provide a near-isothermal method for transporting heat over short distances and have
no moving parts.
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A heat pipe operates by using the latent heat of vaporization of a working fluid (ISS
applications use ammonia) to absorb heat at one end of a pipe and reject the heat into
space at the other end. The working fluid is evaporated at the warm end of the pipe
(where heat-generating equipment is located) and travels as vapor to the cool end
(which is exposed to space). The fluid condenses and gives up its latent heat and
returns as a liquid by capillary action. Several pipes are usually arranged side by side
with a protective covering and structural attachments.
Heat pipes are used on the USOS to provide additional heat rejection for various types
of equipment mounted on the Z1 Truss Segment, Pressurized Mating Adapter 1
(PMA-1) and the S0 Truss Segment. Heat pipes are also used on the ROS (see
Section 1.6).
1.4 USOS ACTIVE THERMAL CONTROL SYSTEM

An ATCS is required when the environment or the heat loads exceeds the
capabilities of the PTCS. As shown in Figure 1-3, an ATCS uses a mechanically
pumped fluid in closed-loop circuits to perform three functions: heat collection, heat
transportation, and heat rejection.
Figure 1-3. USOS ATCS architecture

All USOS pressurized elements are outfitted with ATCS. The ATCS is composed of
internal systems that collect heat from equipment within elements and an external
system that rejects the heat to space. Some elements, such as Node 1 and the Airlock,
only contain heat collection devices and fluid lines, while other elements have complete
thermal loops. The following sections will discuss the purpose and components of the
US internal and external thermal control systems.
1.4.1 US Lab Internal Thermal Control System (ITCS)

The ITCS described in this training manual is based on the US Laboratory Module (US
Lab). The ITCS for the Node 2, Columbus Module (COL), Node 3, and Japanese
Experiment Module (JEM) are similar.
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1.4.1.1 US Lab ITCS Purpose
The purpose of the US Lab ITCS is to maintain equipment within an allowable
temperature range by collecting, transporting, and rejecting waste heat. The ITCS uses
water because it is an efficient thermal transport fluid and is safe inside a habitable
module.
The US Lab contains two independent loops, a Low Temperature Loop (LTL) and a
Moderate Temperature Loop (MTL). This approach allows for segregation of the heat
loads, simplifies heat load management, and provides redundancy in case of
equipment failure (see Figure 1-4). The LTL is designed to operate at 4° C (40° F) and
service systems equipment requiring low temperatures, such as the Environmental
Control and Life Support System (ECLSS) Common Cabin Air Assembly (CCAA) and
some payload experiments. The MTL nominally operates at 17° C (63° F) and provides
most of the cooling for systems equipment (i.e., avionics) and payload experiments.
Normally, both ITCS loops operate independently in what is known as dual-loop

mode. Under certain conditions (for example, a pump failure in one of the loops),
the two loops can be connected. This configuration is known as single-loop
mode and is used to prevent a loss of cooling to critical systems.
1-6
Figure 1-4. US Lab Internal Thermal Control System
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1.4.1.2 US Lab ITCS Components
The components that make up the ITCS can be categorized by function into three major
groups: heat collection ORUs, heat transportation ORUs, and heat rejection ORUs.
Heat Collection ORUs

In order to collect heat, the ITCS uses coldplates and heat exchangers. Most heat
collection devices are located in the racks; others are located in the endcones.
Coldplates: Coldplates acquire heat from systems, avionics, and payload equipment.
Heat-generating equipment is mounted to the surface of the coldplate where the heat is
transferred by conduction to the coldplate surface. The heat is then transferred by
convection to water flowing through the internally finned structure of the coldplate.
There are no EPS or CDH interfaces with coldplates.
Heat Exchangers: Heat exchangers are similar in function to coldplates, but provide a
fluid-to-fluid transfer of heat. Heat exchangers are composed of alternating layers of
finned passages that allow heat collected by another fluid to be transferred to the ITCS
water. Heat exchangers may also be used to condense moisture from the air, as is the
case with the CCAA. There are no EPS or CDH interfaces with heat exchangers.
Another important ITCS ORU is the Regenerative Heat Exchanger (Regen HX). When
the ITCS is in single-loop mode, the Regen HX warms LTL water before it flows through
MTL lines to prevent condensation from forming on the uninsulated fluid lines.
Heat Transportation ORUs
Heat transportation components include pumps, accumulators, filters, fluid lines, Quick
Disconnects (QDs), and valves. These components move and direct the flow of water
around the loops.
Pump Package Assembly: In order for coldplates and heat exchangers to transfer
heat to the water, the water must be circulating. A centrifugal pump, which is part of the
Pump Package Assembly (PPA), provides this circulation. There is one PPA for each
complete loop.
Another important component of the PPA is the accumulator. It maintains inlet

pressure to the pump and accommodates volumetric changes in a loop because of
temperature variations. If a leak occurs, the accumulator can replenish lost water.
Other PPA items include filters, a gas trap, a flowmeter, and temperature and pressure
sensors. Control of the PPA is accomplished by software in the MDMs.
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Lines: ITCS lines consist of rigid titanium and flexible Teflon tubing throughout the
standoffs and endcones. Supply lines carry cool water to the heat loads and the return
lines carry warm water from the heat loads to the Interface Heat Exchanger (IFHX).
The lines are arranged so that water flows through the racks in parallel. LTL lines are
wrapped with insulation since the water temperature is below the dewpoint of the air in
the module. MTL lines are not insulated.
Tee sections are provided at each rack location and flex hoses are used to connect the
tubing at the tee sections to the individual racks. The flex hoses plug into the base of
the racks at the Rack Interface Panel (RIP) with self-sealing QDs. These flex hoses
and QDs are used during rack changeout or leak isolation activities. Vestibule jumpers
also are used to connect modules (for example, US Lab to Node 1).
Valves: The following valves regulate and direct the flow of water through each loop.
These valves are controlled by software in the MDMs and have manual override
capability:
• Rack Flow Control Assembly (RFCA) - Regulates water flow through payload racks.
• Manual Flow Control Valve (MFCV) - Provides fixed water flow through system
racks (these valves are not software-controlled). Next to each MFCV is a Rack
Standalone Temperature Sensor (RSTS), which is monitored by software in the
MDMs.
• System Flow Control Assembly (SFCA) - Regulates inlet pressure to the pump by
maintaining a constant differential pressure between the supply and return lines
through a software-controlled modulating valve. The SFCA also includes a Shutoff
Valve (SOV) to isolate the PPA.
• Loop Crossover Assembly (LCA) - Provides ITCS redundancy by allowing the MTL
and LTL to be connected in series (single-loop mode) to avoid a loss of cooling if a
PPA fails.
• Three-Way Mixing Valve (TWMV) - Maintains proper water temperature.
Heat Rejection ORUs

Interface Heat Exchanger: The IFHXs are the heat exchange interfaces between the
two ITCS loops and the EETCS (pre-12A.1) and ETCS (post-12A.1). The US Lab
IFHXs are mounted on the aft endcone external to the pressurized volume. By
assembly complete there will be a total of 10 IFHXs mounted on three separate
modules—the Node 2, US Lab, and Node 3.
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1.4.1.3 US Lab ITCS Interfaces
The ITCS interfaces with the following systems:
• EPS provides power to operate ITCS pumps and valves
• ECLSS-supplied nitrogen pressurizes the PPA accumulator
• C&DH MDMs provide commands and telemetry
1.4.2 USOS Early External Thermal Control System

Since the US Lab becomes operational before the permanent External Thermal Control
System (ETCS) is assembled, a temporary external cooling system is needed. External
cooling from the Russian segment is not possible because there are no operational
interfaces between the USOS and the ROS thermal systems. Instead, a modified
version of the Photovoltaic Thermal Control System (PVTCS) called the Early External
Thermal Control System (EETCS) acts as a temporary thermal system. The EETCS is
needed until the components of the permanent ETCS are launched and activated.
Once the permanent ETCS becomes operational on Flight 12A.1, the EETCS will be
deactivated. After deactivation, portions of the EETCS will be used as components on
PVTCS loops.
1.4.2.1 USOS EETCS Purpose

The EETCS provides temporary heat rejection for the US Lab using liquid ammonia to
perform heat transfer. Ammonia was chosen for its high thermal capacity and wide
range of operating temperatures. There are two identical loops (designated Loop A and
Loop B) designed to operate between 2° and 8.3° C (35° and 47° F). Each loop is
connected to an IFHX and both loops flow through the two radiators, providing a total of
14 kW of heat rejection for the US Lab, Node 1, and Airlock. Loop A interfaces with the
LTL IFHX and Loop B interfaces with the MTL IFHX (Figure 1-5). All EETCS
components are located outside the pressurized volumes to prevent crew contact with
ammonia.
1-11
Figure 1-5. USOS Early External Thermal Control System
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1.4.2.2 USOS EETCS Components
As with the ITCS, the major components of the EETCS may also be classified into three
functional groups: heat collection ORUs, heat transportation ORUs, and heat rejection
ORUs.

Interface Heat Exchangers: The two IFHXs mounted on the outside of the US Lab aft
endcone perform heat collection in the EETCS. The IFHXs include a heat exchanger
core, a bypass valve, an isolation valve, two temperature sensors, and two pressure
relief valves. While commands and telemetry are available for the bypass and isolation
valves, the pressure relief valves operate automatically.
Heaters: Each EETCS loop has heaters wrapped around portions of the tubing on the
P6 Truss that are used to maintain the minimum operating temperature. These heaters
are used during low heat load conditions and are turned on and off by software in the
MDMs.
Trace heaters are located on the EETCS plumbing to prevent ammonia freezing
and flexible hose damage during non-operational periods. These heaters are
thermostatically controlled and have no software interface.

Heat transportation components include pumps, flow control valves, accumulators, fluid
lines, and QDs. These components move and direct the flow of ammonia around the
loops.
Pump and Flow Control Subassembly: Circulation and temperature control of the
ammonia is provided by the Pump and Flow Control Subassembly (PFCS). The major
components in the PFCS include two pumps, a Flow Control Valve (FCV), and an
accumulator. Although the PFCS contains two pumps for redundancy, only one pump
will be operated at a time. Other PFCS items include an accumulator, filters, as well as
pressure, temperature, and accumulator quantity sensors.
The temperature of the ammonia is maintained by the FCV, which mixes “cool”
ammonia exiting the radiators with “warm” ammonia that was bypassed the radiators.
Control of the PFCS is accomplished via software in the MDMs. The software performs
many system functions, such as loop leak detection, pump control, heater control, and
loop temperature control.
Accumulators: Accumulators compensate for the expansion and contraction of

ammonia caused by the temperature changes and keeps the ammonia in the liquid
phase via the fixed charge of pressurized nitrogen gas on the backside of their bellows.
In case of a leak, the accumulators also contain additional volume to replace lost
ammonia. There are a total of 5 accumulators per EETCS loop—one in the PFCS, two
on the Z1 supply/return lines, plus one in each radiator.
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Fluid lines and QDs: EETCS equipment is located on the P6 truss, the Z1 truss, and
outside the US Lab endcone. The two radiators and two PFCSs are located on the P6
Truss. Insulated, stainless steel tubing carries ammonia between these components
and then transports the ammonia through the Z1 truss to the US Lab endcone where
the IFHXs are located. Connections between segments are made with flex hoses and
QDs. There are flex hoses and QDs between the P6 truss and Z1 truss, and between
the Z1 truss and the US Lab IFHXs.
Heat Rejection ORUs

Radiators: Heat collected from the IFHX by the EETCS ammonia loops is radiated to
space by two radiators (see Figure 1-6). Each radiator contains seven panels hinged
together and arranged in a folding array with flexible hoses connecting the panels. Both
loops flow through both radiators. The complete seven-panel radiator array is
considered an ORU.
Figure 1-6. EETCS radiators

The radiators are designed to be deployed or retracted by ground or crew commands or
manually by an Extravehicular Activity (EVA) crewmember in a contingency situation.
(The trailing EETCS radiator was successfully deployed on Flight 4A; the starboard
radiator on Flight 5A. Each took about 5 minutes to fully deploy. When the radiators
are retracted on Flight 12A.1, an EVA-operated cinching mechanism will hold them in
the stowed position until they can be relocated and used by the PVTCS.
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1.4.2.3 EETCS Interfaces
The EETCS interfaces with the following two systems:
• EPS provides power to operate EETCS pumps, valves, and radiators
1.4.3 USOS External Thermal Control System

The ETCS replaces the EETCS and, once operational, continues the critical functions
of collecting, transporting, and rejecting waste heat from USOS elements. Much like
the EETCS, it is a mechanically pumped, single-phase subsystem that also uses
ammonia as a coolant. However, the ETCS is designed to handle the heat loads for
the entire USOS at assembly complete. The major differences between the
temporary EETCS and the permanent ETCS are summarized in Table 1-1.
Table 1-1. EETCS/ETCS comparison
Temporary EETCS Permanent ETCS
Heat Collection Heat Collection

• Two IFHXs (US Lab) • 10 IFHXs – Node 3 (2), US Lab (2), and
Node 2 (6 total for Node 2, COL, and
JEM)
• Additional external equipment mounted on

coldplates
Heat Transportation Heat Transportation

• Two loops operating at 771 kg/hr • Two loops operating at
(1700 lb/hr) ~3629 kg/hr (~8000 lb/hr)
• One PFCS (two pumps) in each loop • One Pump Module (PM) (one pump) in
each loop
Heat Rejection Heat Rejection

• Two fixed radiators • Six movable radiators
• Each is approximately 13 m (44 ft) long • Each is approximately 23 m (75 ft) long
• Both loops flow through both radiators • Each loop flows through a separate set of
three radiators
• Total heat rejection capability is
14 kW • GNC software required to determine
radiator position
• Total heat rejection capability is

70 kW
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1.4.3.1 Purpose
The ETCS uses liquid ammonia, which was chosen for its high thermal capacity and
wide range of operating temperatures. There are two identical loops (designated Loop
A and Loop B) operating between 1.7° C and 3.9° C (37 ± 2° F). Each loop collects heat
from up to five IFHXs mounted on the Node 2, US Lab, and Node 3 as well as
externally mounted coldplates (see Figure 1-7). Each loop flows through a separate set
of rotating radiator wings mounted on the S1 (Loop A) and P1 (Loop B) truss segments
and is capable of providing a total of 35 kW of heat rejection (70 kW total for the entire
USOS). All ETCS components are located outside the pressurized volumes to prevent
crew contact with ammonia.
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Figure 1-7. USOS External Thermal Control System
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1.4.3.2 USOS ETCS Components
As with the ITCS and EETCS, the major components of the ETCS can be classified into
three functional groups: heat collection ORUs, heat transportation ORUs, and heat
rejection ORUs.

Interface Heat Exchangers: IFHXs are used to collect heat from USOS modules.
IFHXs are mounted on the Node 2, US Lab, and Node 3. The US Lab IFHXs are
connected to the EETCS through Flight 12A.1. The EETCS ammonia fluid line QDs will
be disconnected on Flight 12A.1 and reconnected to the ETCS. When Node 2 arrives
on Flight 10A, it is equipped with six IFHXs designed to provide cooling for itself, the
COL, and the JEM. Node 3 also contains a set of IFHXs, which are connected to the
ETCS when it arrives on Flight 20A.
Heaters: Each ETCS loop has electrically powered heaters wrapped around the supply
and return fluid lines on the S0 Truss to maintain the minimum operating temperature.
These heaters are used during low heat load conditions and are turned on and off by
software in the MDMs. These heaters can be operated in closed-loop mode
(temperature based) or open-loop mode (time based).
Numerous heaters are located on the ETCS plumbing on the S1 (Loop A) and P1
(Loop B) truss segments to prevent ammonia freezing and flexible hose damage during
nonoperational periods. These heaters are thermostatically controlled and have no
software interface.
Coldplates: Each ETCS loop provides cooling to externally mounted coldplates

located on the S0, S1 (Loop A), and P1 (Loop B) truss segments. These coldplates
contain Electrical Power System (EPS) equipment used to convert and distribute power
to downstream ISS loads. Each loop cools a total of three Direct Current-to Direct
Current Converter Units (DDCUs) and two Main Bus Switching Units (MBSUs).

Heat transportation components include pumps, flow control valves, accumulators, fluid
lines, and QDs. These components move and direct the flow of ammonia around the
loops. Pump control, valve control and instrumentation monitoring of the following
components are provided via MDMs.
Pump Module: Circulation, loop pressurization, and temperature control of the

ammonia is provided by the Pump Module (PM). The major components in the PM
include a Pump and Control Valve Package (PCVP), an accumulator, isolation and
relief valves, and various temperatures, flow, and pressure sensors. The accumulator
within the PM works in concert with the Ammonia Tank Assembly (ATA) accumulators
to compensate for expansion and contraction of ammonia caused by the temperature
changes and keeps the ammonia in the liquid phase via a fixed charge of pressurized
nitrogen gas on the backside of its bellows.
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A single pump in the PCVP provides circulation of the ammonia. The temperature
of the ammonia is regulated by the FCV located within the PCVP. The FCV mixes
“cool” ammonia exiting the radiators with “warm” ammonia that has bypassed the
radiators.
Ammonia Tank Assembly (ATA): The primary function of the ATA is to store the
ammonia used by the ETCS. The major components in the ATA include two ammonia
storage tanks, isolation valves, heaters, and various temperature, pressure, and
quantity sensors. There is one ATA per loop located on the zenith side of the S1
(Loop A) and P1 (Loop B) truss segments. Each will be used to fill their respective
ETCS loop on startup (loops are launched with nitrogen in the lines) and to supply
makeup fluid to that loop. It also assists the PM accumulator with ammonia inventory
management, and provides the capability to vent the PM and ATA by connection to an
external nonpropulsive vent panel. If required, it can be used to replenish the PVTCS
fluid lines.
Nitrogen Tank Assembly (NTA): The primary function of the NTA is to store the high-
pressure nitrogen that is used to control the pressurization of the ammonia tanks in the
ATA. The NTA mounts to the S1 (Loop A) and P1 (Loop B) truss segments and is
connected to the ATA by self-sealing QDs. The major components in the NTA include
a nitrogen tank, a Gas Pressure Regulator Valve (GPRV), isolation and vent valves,
heaters, and various temperature and pressure sensors. The nitrogen tank provides
the storage volume for high-pressure gaseous nitrogen. The GPRV provides pressure
control as well as high-pressure nitrogen isolation and overpressure protection of
downstream components.
Fluid Lines and QDs: Fluid lines and external QDs provide the transportation path
from the truss segments to the IFHXs. Connections between segments are made with
flex hoses and QDs. There are flex hoses and QDs between each truss, and between
the S0 truss and the various IFHXs.
Heat Rejection ORUs

Radiators: Heat collected by the ETCS ammonia loops is radiated to space by two
sets of rotating radiator wings—each composed of three separate radiator ORUs (see
Figure 1-8). Each radiator ORU is composed of eight panels, squib units, squib unit
firmware controller, Integrated Motor Controller Assemblies (IMCAs), instrumentation,
and QDs. Each radiator ORU can be remotely deployed and retracted.
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Figure 1-8. ETCS radiators

The squib units, IMCA, and firmware controller are all part of the deployment system.
The squib units are used to release the cinch mechanisms on initial deployment. An
IMCA is used to control the deployment and retraction of each radiator ORU.
Radiator Beam Valve Module (RBVM): Six RBVMs are mounted on the radiator
beams on the S1 and P1 truss segments. Two RBVMs service each radiator ORU.
Each RBVM consists of an isolation relief valve, an isolation valve, an IMCA, QDs, and
pressure and temperature sensors. The RBVM provides remotely controlled isolation
and emergency relief venting of the radiator ORU fluid supply and return lines, provides
return line pressure and temperature monitoring, provides automatic overpressure
relief, and provides insight into the temperature of the radiator assembly environment.
Thermal Radiator Rotary Joint (TRRJ): The rotation capability for each radiator
assembly is provided through a TRRJ. The TRRJ provides power, data, and liquid
ammonia transfer to the rotating radiator beam while providing structural support for the
radiator panels. Each TRRJ is composed of the following: a bearing assembly, two
Rotary Joint Motor Controllers (RJMCs), two Drive Lock Assemblies (DLAs), a Flex
Hose Rotary Coupler (FHRC), and a Power and Data Transfer Assembly (PDTA). The
bearing assembly is the rotary interface and primary structural component of the TRRJ.
The RJMCs provide control for the DLA system, which provides joint rotation and joint
locking capability. The FHRC provides the transfer of liquid ammonia across the rotary
joint and is capable of rotating 230 degrees, at ±115 degrees from its neutral position.
The FHRC consists of four flex hoses, two supply and two return. The PDTA provides
the data and power paths for transfer to and from the radiator beam. The TRRJ
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interfaces with the Guidance, Navigation, and Control (GNC) software that provides
pointing data used to optimize the heat rejection capability of the radiators.
1.4.3.3 USOS ETCS Interfaces

The ETCS interfaces with the following three systems:
• EPS provides power to operate ETCS pumps, valves, heaters, and radiators
• GN&C provides pointing support for the radiators in order to optimize heat rejection
1.5 USOS TCS SOFTWARE

This subsection contains an overview of TCS software in the USOS.
1.5.1 Purpose
TCS software is used to control and monitor the system. Actions such as system
startup, loop reconfiguration, and valve positioning for flow and temperature control are
executed by the TCS software automatically or via commands from crew laptops or
ground workstations. Telemetry from the various temperature, pressure, flow, and
quantity sensors is monitored by TCS software and displayed on crew laptops or
ground workstations. In addition, Fault Detection, Isolation, and Recovery (FDIR)
software is used to monitor the performance of the TCS and, if there is a problem, alert
the crew and flight controllers. In some cases FDIR software initiates recovery actions.
1.5.2 Architecture
Figure 1-9 shows how USOS TCS software is organized through Flight 12A.1 and
Figure 1-10 shows how the software is organized from Flight 12A.1 and beyond.
The Command and Control (C&C) software resides in the Tier 1 MDMs. It is at this
level that the crew and flight controllers send commands to and view telemetry from the
TCS. Software functions for the three C&C MDMs are redundant.
In Tier 2, software is housed in the Internal Systems MDMs (INT MDMs) for ITCS, the
Node 1 (N1) MDMs for EETCS, and the External (EXT) Systems MDMs for ETCS. The
software in the Tier 2 MDMs processes commands from the C&C software, executes
algorithms, and generates commands to the Tier 3 MDMs. Software functions for these
MDMs are also redundant.
The Tier 3 MDMs are the Laboratory Systems MDMs (LA MDMs) for ITCS, the PVCU
MDMs for EETCS, the S0 MDMs for ETCS IFHXs, the STR/PTR MDMs for the ETCS
radiators, and the S1/P1 MDMs for the remaining ETCS components. The software in
these MDMs interfaces directly with the ITCS, EETCS, and ETCS ORUs.
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Figure 1-9. USOS TCS software architecture (Flights 12A.1+)

US Lab ITCS Software: Commands from ground workstations or crew laptops as well
as commands generated by C&C software, are passed by the C&C MDM to the active
INT MDM (one MDM is active, with the other standing by to take over if necessary).
Software within the INT MDM processes the commands, executes algorithms, and
generates commands to the LA MDMs and the Pump/Fan Motor Controller (PFMC).
The PFMC (located in the PPA) processes commands from the INT MDM and
generates commands to the pump motors.
The LA MDMs process commands from the INT MDM, execute algorithms, and
generate commands to US Lab ITCS hardware. LA-1 interfaces with LTL hardware,
LA-2 interfaces with MTL hardware, and all three LA MDMs interface with different
RFCAs and RSTSs.
USOS EETCS Software: Commands from ground workstations or crew laptops as well
as commands generated by C&C software are passed by the C&C MDM to the N1
MDMs. The two N1 MDMs control IFHX valves and process telemetry from the IFHX
sensors. N1-1 interfaces with the IFHX in Loop A and N1-2 interfaces with the IFHX in
Loop B. FDIR software also resides in the N1 MDMs.
The two PVCU MDMs control the remaining EETCS functions. The PVCU MDMs
receive telemetry from and issue commands to the individual pumps and valves in the
PFCS as well as the radiator deployment and retraction motors. Normally, PVCU-4B is
primary, with PVCU-2B as backup.
Note: The PVCU MDMs also perform FDIR.
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USOS ETCS Software: Commands from ground workstations or crew laptops as well
as commands generated by C&C software are passed by the C&C MDM to the EXT
MDMs (see Figure 1-10). The EXT MDMs interface with the S0, S1, P1, PTR and STR
MDMs. The S0-1, 2 MDMs control all IFHX valves and process telemetry from all IFHX
sensors (these MDMs take over control of the US Lab IFHXs from the N1 MDMs at
Flight 12A.1). S0-1 interfaces with the IFHXs on Loop A and S0-2 interfaces with the
IFHXs on Loop B. FDIR software in the S0 MDMs provides protection against
undertemperature conditions and deadheading of the pump.
Figure 1-10. USOS TCS software architecture (Flight 12A.1+)

The two STR/PTR MDMs control the radiators and RBVMs. The STR controls the Loop
A radiator assembly and the PTR controls the Loop B radiator assembly. FDIR
software in the EXT MDMs monitors temperature and pressure sensor data sent from
the STR/PTR MDMs for undertemperature conditions to prevent the freezing of
ammonia as well as overpressurization of the fluid lines.
The S1-1 and P1-2 MDMs receive telemetry from and issue commands to the individual
pumps, heaters, and valves in the PM, ATA, NTA, and TRRJ. The S1-2 and P1-1
MDMs only interface with the TRRJ—providing a second level of redundancy for the
rotation capability of the radiator assembly—and a few redundant heaters located within
the PM, ATA, and NTA. FDIR in the S1-1 and P1-2 MDMs protects against undertem-
perature conditions and overpressurization of the ammonia.
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1.6 ROS THERMAL CONTROL SYSTEM
At assembly complete, the ROS will include the Functional Cargo Block (FGB), Service
Module (SM), Universal Docking Module (UDM), Research Modules (RMs), and Life
Support Modules (LSM). All these elements share common design characteristics.
1.6.1 Purpose
The purpose of the ROS TCS is to maintain equipment within an allowable temperature
range by collecting, transporting, and rejecting waste heat from ROS pressurized
elements. There are no interfaces between ROS TCS and the USOS TCS.
ROS pressurized elements are each outfitted with two internal and two external cooling
loops. The coolant in each internal loop travels through the pressurized modules where
it collects heat from systems equipment, avionics, and experiments. It then flows
through an IFHX where the heat load of the internal equipment is transferred to the
external system and is radiated and rejected to space.
The ROS TCS described in this manual is based on the FGB. TCS for the other ROS
modules is similar.
1.6.1.1 FGB TCS Subsystems

FGB TCS is subdivided into two major groups: Passive TCS and Active TCS.
FGB Passive TCS

FGB passive TCS design is similar to USOS PTCS. FGB passive TCS relies on
thermal blankets and surface coatings in order to maintain the temperatures of the
structure and external equipment within allowable limits.
Shell heat pipes acquire heat from the internal loop and circulate ammonia around the
exterior of the pressure shell. This prevents condensation by maintaining the
temperature of the interior of the pressure shell above the dew point of cabin air. The
shell heat pipes are used only for thermal conditioning and not for additional heat
rejection capability.
FGB Internal TCS

FGB internal TCS (Figure 1-11) consists of two independent loops. The FGB internal
TCS coolant (Triol) performs the three functions of heat collection, heat transportation,
and heat rejection. Only one loop is in operation at a time; the second internal
loop provides redundancy. Nominal internal loop operating temperature is 15° to
35° C (59° to 95° F).
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8 7 6 5 4 3 2 1
REVISIONS
DATE NAME VERSION:
11.02.99 A. Zorin 1.1
ÔÃÁ
D FGB Exterior D
Radiators (ÐTO)
Radiators (ÐTO)
Accumulators
(T1) (T2) (K1,K2) Electrical Pump
Liquid-Liquid Liquid-Liquid
Heat Exchanger 1 Heat Exchanger 2 Assembly
(ÝÍÀ) Liquid
From Other Flow Control
Internal Loop
Valve External Thermal Loop
(ÐÐÆ)
Accumulator (ÍÃÊ1)
(TTK)
(K) Propulsion
Body-Mounted LEGEND
System Thermal Coil
Heat Pipes (ÇÌ ÄÓ) Compressor
C Coldplates
(TÏ ÁÊ) unit coldplate Heat Collection Components C
Heat Transportation Components
Heat Rejection Components

Triol Fluid Lines
Coldplates
(TÏ) (ÇÌ ÃÀ) Polymethyl Siloxane Silicone Fluid
ARCU/RACU Lines
Coldplates
Gas-Liquid (Batteries)
(TÏ) Internal Pressurized
Heat Exchanger MÄM1(2), ÏÑ, Adapter Thermal Coil
ÓÑ-31
(ÃÆÒ)
Internal Termal Loop

(ÂÃÊ1)
B Electrical B
Heaters
(ÝÍ)
Gas-Liquid (Cabin Air) Electrical Pump
Heat Exchangers
[TCS1B-RS-FGB-8A_US]
Assemblies
(ÃÆÒ)
(ÝÍÀ)
Aft Endplate Termal Coils

(ÇÌ ÇÄÍ)
SIGNATURE DATE
GAGARIN COSMONAUT TRAINING CENTER
GCTC
(ÇÌ ÃÀ) A. Zorin 11.02.99
A External Pressurized GCTC V. Kolyasnikov 11.02.99

RS FGB LEVEL 1B A
(TTK) Adapter Thermal Coil GCTC A. Makarov 11.02.99 THERMAL CONTROL SYSTEM (ÑÎÒÐ)/
Body-Mounted BLOCK DIAGRAM
GCTC V. Cherkashin 11.02.99
Heat Pipes FLIGHT 8A
GCTC
A.Aleksandrov PROGRAM SIZE DWG NO. REV

RSC-E
ISS A3 TCS1B-RS-FGB-8A-US 1.1
GCTC E.Zhuk
SCALE
NONE
FILE TCS1B-RS-FGB-8A_US SHEET 1 OF 1
8 7 6 5 4 3 2 1
Figure 1-11. FGB Internal and External Thermal Control Systems

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In addition to fluid loops, a ventilation system is also a part of the FGB internal TCS.
The ventilation system consists of fans mounted on gas-liquid (cabin air) heat
exchangers, rigid and flexible distribution ducts, and portable fans. This function is
analogous to the Temperature and Humidity Control (THC) System in the USOS
ECLSS.
Heat Collection: The internal TCS loops acquire waste heat from coldplates and cabin
air heat exchangers. Coldplates collect heat from most electronic equipment, and are
similar in design and operation to the coldplates in the USOS. Air circulated through
the cabin by the ventilation system picks up heat from the crew and other operating
equipment. It then passes through the cabin air heat exchangers where its heat is
transferred to the coolant.
Heat Transportation: Heat transportation components include pumps, an
accumulator, lines, coils and valves. Each internal loop has two electrical pump
assemblies, each containing two pumps. The electrical pump assemblies are
replaceable on orbit and normally only one pump is active at a time. If a pump fails,
software automatically starts a dormant pump. The accumulator maintains line
pressure, accommodates volumetric changes in a loop caused by temperature
variations, and replenishes the loop with coolant if a leak occurs. The lines include
tubing, expansion joints, filters, fill and drain connections, and sensors. The internal
loops are routed through coils in the aft endcone, the pressurized adapter, and
propulsion units. Software-controlled heaters on the internal loops lines are used
during periods of low heat loads.
Heat Rejection: The internal loop coolant transfers the heat it has collected to the
external loop via an IFHX mounted on the outside of the FGB. The IFHXs are similar in
design and operation to the IFHXs in the USOS. Each internal loop flows through a
separate IFHX. Temperature control of the internal loop is accomplished by
regulating the temperature of the external loop.
FGB External TCS

The FGB external TCS (Figure 1-11) consists of two independent loops. It uses single-
phase polymethyl siloxane to perform the three functions of heat collection, heat
transportation, and heat rejection. Only one loop is operating at a given time; the
second external loop provides redundancy.
Heat Collection: The external loops acquire heat from the IFHXs. Both external loops
flow through both IFHXs.
Heat Transportation: Heat transportation components include pumps, lines, and

valves. Each external loop has three pump assemblies, each containing two pumps.
Only one pump is active at a time. One of the pump assemblies in each loop is
replaceable on orbit. If a pump fails, software automatically starts a dormant pump.
A flow control valve modulates flow through the radiators in order to maintain a
temperature setpoint (loop temperature is measured after the radiator flow and bypass
flow have mixed). Software maintains a temperature range of 15° to 35° C
(59° to 95° F). High internal heat loads will cause the internal coolant temperature to
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rise. The external system responds by allowing more coolant to flow through the
radiators. During periods of low heat loads, the external system allows more coolant to
bypass the radiators. The accumulators maintain inlet pressure to the pumps and
accommodate volumetric changes in a loop because of temperature variations, and, if a
leak occurs, the accumulators can replenish the loop with coolant.
Heat Rejection: Heat is rejected to space by body-mounted radiators (they are not
deployable). There are 12 external radiator panels, each of which interfaces with both
external loops. The radiators contain heat pipes that use ammonia as a working fluid.
Heat is transferred from the external loops to the ammonia within the radiators and the
ammonia is cooled by radiation to space.
1.6.1.2 Comparison of USOS and ROS TCS

Table 1-2 summarizes the differences between USOS TCS and ROS TCS.
Table 1-2. TCS comparison

USOS TCS ROS TCS
• Habitable elements have ITCS • Each habitable element has internal and
• Shared temporary EETCS external systems
• Shared permanent ETCS
USOS PTCS ROS PTCS
• MLI, coatings, heaters, and heat-pipe • MLI and coatings
radiators • Shell heat pipes
USOS Lab ITCS FGB Internal TCS
• Working fluid is water • Working fluid is Triol
• Two operating loops • One operating loop (second loop is
(MTL and LTL) backup)
• Redundancy via connecting loops • Redundancy via multiple pumps
• Loop temperatures independently • Loop temperature determined by external
controlled system
• Ventilation system (temperature and
humidity control)
USOS EETCS/ETCS FGB External TCS
• Two independent loops • One loop (second loop is backup)
• Redundancy via multiple pumps (EETCS • Redundancy via multiple pumps
only) • Common IFHXs
• Independent IFHXs • Working fluid is polymethyl siloxane
• Working fluid is ammonia • Fixed, body-mounted radiators
• Deployable/retractable radiators • Radiator heat pipes use two-phase
• Total heat rejection capability is ammonia
14 kW (EETCS) and 70 kW (ETCS) • Total heat rejection capability is 3.5 kW
1.7 FLIGHT-BY-FLIGHT OPERATIONS

TCS equipment is delivered over several flights. The FGB and Service Modules SMs
were launched with complete, independent TCS (passive and active systems).
Components of the USOS EETCS were then launched on Flight 4A. The US Lab
arrived on Flight 5A with its ITCS and two IFHXs. Outfitting flights have since added
racks (additional heat loads/payloads) and the US Airlock.
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Later in the sequence, the permanent ETCS is assembled over several flights, and on
Flight 12A.1 it is activated and replaces the EETCS.
On Flight 10A, Node 2 will be launched with its own ITCS and six IFHXs (two for its
ITCS, and two each for the COL and JEM). The COL and JEM are launched later in
the sequence, and the Node 3 is launched on Flight 20A with its ITCS and two IFHXs.
Table 1-3 summarizes the buildup of the ISS TCS.
Note: Not all assembly flights are shown; only flights that significantly increase TCS
capabilities are listed.
Table 1-3. TCS buildup
Flight Element TCS components

1A/R FGB ROS TCS
2A Node 1 and two Node 1 Shell Heaters and dry fluid lines,
PMAs PMA-1, 2 Shell Heaters
1R Service Module ROS TCS
3A Z1 Truss EETCS Z1 Accumulators, EETCS plumbing
2R Soyuz Permanent crew
4A P6 Truss Two radiators, two PFCSs, EETCS plumbing; checkout
EETCS loops, activate EETCS loops, deploy Trailing
radiator
5A US Lab ITCS, two IFHXs; connect utilities, prepare IFHXs, activate
ITCS, deploy starboard radiator
5A.1 MPLM US Lab outfitting (racks and other heat loads)
6A MPLM US Lab outfitting (racks and other heat loads), fill Node 1
lines with water (after orbiter departure)
7A High-pressure gas assembly (includes nitrogen for the
Airlock
Nitrogen Interface Assembly (NIA)); airlock heat loads
7A.1 MPLM US Lab outfitting (racks and other heat loads)
UF-1 MPLM US Lab outfitting (racks and other heat loads)
8A SO Truss Parts of the permanent ETCS
UF-2 MPLM US Lab Outfitting (racks and other heat loads)
ULF-1 MPLM US Lab outfitting (racks and other heat loads)
9A S1 Truss Major components of permanent ETCS Loop A (central
radiator will be deployed)
11A P1 Truss Major components of permanent ETCS Loop B (central
radiator will be deployed)
12A.1 P5 Truss Deactivate EETCS, Reconfigure US Lab IFHXs to ETCS
fluid lines and S0 MDM control, activate permanent ETCS
10A Node 2 ITCS, six IFHXs; connect utilities, prepare IFHXs, activate
Node 2 ITCS
9A.1 SPP ROS Central Heat Rejection System (CHRS)
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Table 1-3. TCS buildup (concluded)
Flight Element TCS components

1E COL ITCS; connect utilities, prepare IFHXs, activate ITCS
UF-3 MPLM US Lab outfitting (racks and other heat loads)
1J JEM ITCS; connect utilities, prepare IFHXs, activate ITCS
14A Cupola Connect utilities, cupola heat loads
20A Node 3 ITCS; connect utilities, prepare IFHXs, activate ITCS
1.8 TCS SUMMARY
1.8.1 USOS PTCS Summary

The PTCS is designed to provide thermal control of USOS components via MLI
blankets, surface coatings, heaters, and heat pipes. There are no active fluid
components in PTCS devices.
1.8.2 USOS ATCS Summary

When the environment of heat loads exceeds the capabilities of the PTCS, an ATCS is
required. An ATCS uses a pumped fluid to perform heat collection, heat transportation,
and heat rejection. The working fluids in the USOS and ROS remain in a liquid state
throughout the system.
1.8.2.1 US Lab ITCS Summary

Water cooled by the IFHX enters the racks containing heat-generating equipment and
payloads. Water passing through coldplates and heat exchangers collects the waste
heat then exits the racks. The water continues to the SFCA, which balances the ∆P
between the supply and return lines, and on to the PPA. After passing through the
PPA, the water continues back to the IFHX. The transfer of heat to the EETCS (ETCS)
occurs in the IFHX. The TWMVs control the temperature of each loop.
Redundancy is provided by having two PPAs. If a PPA fails, the ITCS switches from
dual-loop mode to single-loop mode. The LCA is part of the redundancy function since
it allows the two loops to be connected. The ability to tie the ITCS loops together and,
therefore, allow all heat to be rejected from a single IFHX provides redundancy in the
event of a loss of an external loop. This is especially important when the permanent
ETCS is activated due to the fact that each ETCS loop only contains a single pump.
1.8.2.2 USOS EETCS Summary

The EETCS provides temporary thermal control for the US Lab, Node 1, and Airlock
prior to the activation of the permanent ETCS. Waste heat from the ITCS is collected
at the IFHX. Circulation of the ammonia and regulation of the loop operating
temperature are provided by the PFCS pumps and FCV, which are located inside the
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PFCS ORU. Ammonia, pumped by the PFCS through the radiators, is cooled by
radiating its heat to space. The radiators are fixed and have the capability to reject
14 kW of heat.
Redundancy is provided by having two pumps in each PFCS. Both loops also flow
through both radiators.
Note: If an entire EETCS loop fails, the heat can still be collected from both internal
loops by switching the ITCS to single-loop mode. Heat rejection would occur in
the remaining IFHX.
1.8.2.3 USOS ETCS Summary

The ETCS provides the heat rejection capability for the entire USOS segment at
Assembly Complete (AC). Waste heat from the internal modules is collected at various
IFHXs mounted on Node 2, US Lab, and Node 3. Circulation of the ammonia and
regulation of the loop operating temperature are provided by a pump and FCV in the
PCVP, which is located inside the PM ORU. Ammonia is cooled as it is routed through
a set of rotating radiators where its heat is radiated to space. The ETCS radiators can
rotate and provide a maximum of 35 kW of heat rejection per loop.
1.8.3 USOS TCS Software Summary

TCS software is used to control and monitor the ITCS, EETCS, and ETCS, most of it
automatically. Telemetry from sensors is monitored by TCS software and displayed on
crew laptops or ground workstations. FDIR software is used to check the performance
of the system and alert the crew and flight controllers if there is a problem.
1.8.4 ROS TCS Summary

The ROS TCS is based on the Mir Space Station and is functionally similar to USOS
TCS. An internal TCS loop uses a coolant to collect heat generated by the crew and
equipment. The warm coolant is pumped to the IFHXs where heat is transferred to the
external system. The external loop circulates its operating fluid through radiators where
the heat is rejected to space. There are two internal loops and two external loops for
redundancy but only one internal and one external loop are active. Redundancy is
provided by multiple pumps in each loop.
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Questions
1. PTCS Multilayer Insulation (MLI) is analogous to
a. An ammonia coldplate
b. The Interface Heat Exchanger (IFHX)
c. A home’s insulation
2. Which of the following best describes surface coatings used throughout the ISS?
a. Must be resistant to atomic oxygen and radiation.
b. Must be common throughout the ISS.
c. Must have an emissivity greater than 1.0.
3. The ITCS is responsible for
a. Pumping ammonia coolant to the radiators.
b. Rejecting waste heat from pressurized elements to the EETCS.
c. Mixing the water leaving and bypassing the radiator to maintain the proper
coolant temperature.
4. The ITCS provides which of the following to the IFHX?
a. Heat collected from internal equipment.
b. Cooled single-phase ammonia.
c. Cooled two-phase water.
5. The EETCS provides
a. Permanent thermal control for the Russian elements.
b. Two-phase ammonia cooling.
c. Temporary cooling for the ISS until the ETCS is activated.
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6. Which of the following statements is incorrect?
a. The ETCS has larger radiators than the EETCS.
b. The ETCS has two pumps per loop and the EETCS has one pump per loop.
c. The ETCS provides cooling to external components via coldplates.
7. The Interface Heat Exchanger (IFHX)
a. Lies within the pressurized module.
b. Is completely external to the module.
c. Is part of the boundary between the inside and outside of the module.
8. The temperature of the ammonia in the EETCS and ETCS loops
a. Is not regulated.
b. Is regulated by the rate of flow of the pump package.
c. Is maintained by bypassing some of the ammonia around the radiators.
9. Which of the following statements best describes TCS software
a. Resides primarily in the Tier 1 MDMs.
b. Monitors and controls the system.
c. Always requires crew or flight controller inputs.
10. The FGB ITCS is responsible for
a. Pumping coolant to the radiators.
b. Rejecting waste heat to the EETCS.
c. Using both air and Triol to provide cooling.
11. The FGB ETCS
a. Flows through both IFHXs.
b. Has two loops operating simultaneously.
c. Operates at a higher temperature than the FGB ITCS.
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2.0 USOS TCS FUNCTIONAL DESCRIPTION
2.1 INTRODUCTION
This section provides detailed information on the United States On-Orbit Segment
(USOS) Internal Thermal Control System (ITCS), Early External Thermal Control
System (EETCS) and the permanent External Thermal Control System (ETCS). The
components and operational capabilities of the ITCS, EETCS and ETCS ORUs are
presented, as well as the various interfaces to other International Space Station (ISS)
systems. An overview of the USOS TCS software is also included.
2.1.1 Objectives
Upon completion of this section, you should be able to complete the following
objectives:
• Given a US Lab ITCS level 2 schematic, go around the loop identifying the
components and their functions.
• Given an EETCS level 2 schematic, go around the loop identifying the components
and their functions.
• Given an ETCS level 2 schematic, go around the loop identifying the components
and their functions.
• Given the loss of a major component in the internal or external TCS, identify the
impacts and how the system could be reconfigured to minimize those impacts.
• Describe how each of the following MDMs interface with the USOS TCS
components: C&C MDM, INT MDM, EXT MDM, LA-1, 2 MDMs, PVCU MDM,
S0 MDMs, N1 MDMs, S1/P1 MDMs, and the STR/PTR MDMs.
2.2 USOS LAB ITCS FUNCTIONAL DESCRIPTION

All habitable modules are equipped with internal water loops. The US Lab, Node 2,
Columbus Module (COL), Japanese Experiment Module (JEM), and Node 3,have
active, standalone systems capable of performing heat collection, transportation, and
rejection. Other modules are dependent (or flowthrough) elements like Node 1 and the
Airlock. Dependent elements have heat collection devices and a subset of heat
transportation devices (for example, coldplates and plumbing but no pumps), so they
must be connected with jumpers to an element with a standalone system to complete
the heat removal process.
This training manual will cover only the US Lab ITCS (see Figure 2-1).
2-1
Figure 2-1. US Lab Internal Thermal Control System
01.07.05(0)T0012
Basic
The Low-Temperature Loop (LTL) is designed to service equipment requiring low
temperatures, such as the ECLSS Common Cabin Air Assembly (CCAA), ECLSS
CDRA, and some payload experiments. Since the LTL is designed to operate below
the dewpoint of the air in the module, LTL plumbing is insulated to prevent
condensation. The MTL provides cooling for all US Lab-critical avionics equipment and
most payloads. Since the MTL operates above the dewpoint of the air in the module,
MTL plumbing is not insulated.
2.2.1 ITCS Heat Collection

Heat collection is the first step in the heat removal process. There are two heat
collection components, coldplates and heat exchangers. All heat collection
components are located in the racks and endcones inside the US Lab. Coldplates and
heat exchangers are flowthrough devices with no commands or telemetry.
2.2.1.1 Coldplates
Coldplates are the main heat collection device for the ITCS. When the US Lab is fully
outfitted, it will contain over 100 coldplates. See Figure 2-2 for the typical coldplate
design.
ORU
Equipment
mounting
surface
Threaded fitting
Flex hose
Manifold
Coldplate and equipment
mounting holes 01.07.05(0)T0012_007
Figure 2-2. Typical coldplate design
Purpose
The purpose of coldplates is to acquire heat from avionics and payload equipment,
located in racks and endcones, and transfer the heat to the water in the ITCS loops.
Coldplates have holes for mounting to support structure in racks and endcones and to
allow for attachment of ORUs. The preferred orientation is to locate the coldplates such
that the crew will be able to easily inspect the threaded fittings at both ends. The
2-5
01.07.05(0)T0012
Basic
manner in which the equipment is attached depends upon the amount of heat that
needs to be collected as well as the type and location of the equipment being cooled.
Operations
Heat-generating equipment is mounted to the coldplate where heat is transferred by
conduction to the coldplate surface and core. Water enters the inlet manifold and
makes a single pass through the core where it picks up heat by convection, and exits
the outlet manifold (see Figure 2-3).
Water Water
in out
ORU
Coldplate
01. 07.05(0) T0012_00 8
Figure 2-3. Coldplate functional schematic
Interfaces
Crew: Crews may be required to interface with coldplates in the event of a leak.
However, because the connections between the LTL (MTL) fluid lines and the
coldplates are two 1.27-cm (0.5-in.) diameter threaded fluid fittings vs. Quick
Disconnects (QDs), replacement will require loop shutdown and depressurization.
Coldplates do not have Electrical Power System (EPS) or Command and Data Handling
(CDH) interfaces.
2.2.1.2 Heat Exchangers

Heat exchangers are similar in function to coldplates, but provide a fluid-to-fluid transfer
of heat. Three types of heat exchangers are serviced by the US Lab ITCS:
• Water-to-water heat exchangers used in payload racks and in the ITCS
Regenerative Heat Exchanger (Regen HX).
• Air-to-water heat exchangers used in ECLSS equipment such as the Avionics Air
Assembly (AAA) and CCAA.
• Water-to-ammonia heat exchangers used in the transfer of heat from a modules
internal thermal control system to an external thermal control system. These water-
to-ammonia heat exchangers are called Interface Heat Exchangers (IFHXs) and are
discussed in Section 2.2.3.1.
The operation of all heat exchangers is basically the same; however, the following
discussion will cover only the water-to-water heat exchangers.
2-6
01.07.05(0)T0012
Basic
Purpose
The purpose of a heat exchanger is to transfer heat from one active cooling loop to
another. A heat exchanger acts as a heat rejection component for one loop and a heat
collection component for another. Heat exchangers are utilized when cooling provided
by a coldplate is not sufficient.
Payload heat exchangers and the Regen HX are constructed of top and bottom cover
sheets, a core (alternating layers of finned passages separated by thin metal parting
sheets), and two manifolds with inlet and outlet fittings. These components are
stainless steel and the internal fins are nickel. These heat exchangers also have
brackets with holes for mounting to support structure in racks or the endcones.
Operations
Payload heat exchangers and the Regen HX are counterflow, meaning the hot water
from a payload makes a single pass through the core and cold water from the ITCS
makes a single pass through the core in the opposite direction (see Figure 2-4). Heat is
transferred by convection to the parting sheets and is then transferred by conduction to
the fins in the core. Water flowing through the core picks up the heat by convection.
Figure 2-4. Heat exchanger functional schematic

When the ITCS is operating in dual-loop mode, the Regen HX is bypassed and not
required; however, it is essential when the ITCS is operating in single-loop mode.
Water flows through the LTL heat loads first such that it is warmed before it flows
through the MTL heat loads. If the water does not collect enough heat from the LTL
loads to warm it to the appropriate temperature, the Regen HX further warms the water.
This is done by routing water from the MTL return leg (at its hottest point) through the
Regen HX to heat water that has exited the LTL racks. If proper temperatures are not
maintained in the MTL lines, condensation may develop causing corrosion as well as
damage to electrical equipment.
2-7
01.07.05(0)T0012
Basic
Interfaces
The Regen HX does not have EPS or CDH interfaces. Payload heat exchangers are
generally part of a larger assembly inside a payload rack.
Crew: Crews may be required to interface with payload heat exchangers or the
Regen HX in the event of a leak. However, because the connections between the LTL
(MTL) fluid lines and the heat exchangers are four 1.91-cm (0.75-in.) diameter threaded
fluid fittings vs. QDs, replacement will require loop shutdown and depressurization.
2.2.2 ITCS Heat Transportation

The major heat transportation components in the ITCS include Pump Package
Assemblies (PPAs) and valve assemblies. These components move and direct the flow
of water around the loops.
2.2.2.1 Pump Package Assembly

For the whole process of heat collection, transportation, and rejection to work, the water
must be circulating. The PPA (Figures 2-5 and 2-6) provides this circulation at a
flowrate of approximately 1361 kg/hr (3000 lb/hr). There are two PPAs in the US Lab—
the MTL PPA is located in the LAB1S6 rack and the LTL PPA is located in the LAB1P6
rack.
Accumulator
Inl et
Fine filter
Gas trap
O u t le t
Flowmeter
Temperature sensor
Pump, motor, motor controller,
and pressure sensors (within cover)
0 1.0 7.05 (0 )T 00 1 2_ 0 10
Figure 2-5. Pump Package Assembly

In addition to the US Lab PPAs, there is one PPA for each independent MTL and LTL
in Node 2, COL, JEM, and Node 3. Early in the program, the Node 1, Airlock, and
Cupola are dependent upon the loops in the US Lab for active cooling. Later, when
Node 3 is added and activated, its ITCS will provide the cooling for the Node 1, Airlock,
and Cupola.
2-8
01.07.05(0)T0012
Basic
Figure 2-6. PPA cross-sectional view
Purpose
The PPA is responsible for circulating water, removing particulates and gas bubbles
from the water, accommodating the expansion/contraction of water, and providing
leakage makeup.
Operations
Figure 2-7 is a functional schematic of the PPA. Water passes through the
components described below.
Figure 2-7. PPA functional schematic

Fine filter: The fine filter is the first component in the flow path. It is located here to
prevent contaminants from reaching the gas trap or the pump. Figure 2-5 shows the
location and orientation of the fine filter. The fine filter is located on top of the PPA for
easy access during maintenance. The fine filter consists of a filter element, a filter
canister, probe-type QDs, and an engage/disengage mechanism.
2-9
01.07.05(0)T0012
Basic
$GLIIHUHQWLDOSUHVVXUH 3VHQVRU)LJXUH-7) measures the pressure difference
EHWZHHQWKHLQOHWDQGRXWOHWSRUWVRIWKHILOWHUDVVHPEO\7KHQRPLQDO 3LVH[SHFWHGWR
be 18.6 ± 3.4 kPa (2.7 ± 0.5 SVLDWDIORZUDWHRINJKUOEKU,IWKH 3
exceeds 27.6 kPa (4 psi) for an extended period of time, the filter is considered ready
IRUUHSODFHPHQWEXWLVQRWFRQVLGHUHGFORJJHG$ 3RIN3DSVLGRUJUHDWHU
will cause the software to issue a filter blockage advisory. Because the filter media
cannot be removed and cleaned on orbit, the entire filter assembly must be replaced.
The fine filter incorporates a check valve to provide uninterrupted flow to the pump if
replacement of the filter assembly is required or if the filter is clogged. If this situation
occurs, the water is rerouted through the check valve, bypassing the fine filter. The
check valve opens when 3 the across the fine filter reaches 53.8 ± 3.4 kPa (7.8 ± 0.5
psi). A reading greater than 71.0 kPa (10.3 psid) indicates a failure of the check valve
to open and software will issue a caution.
Gas trap: The gas trap is the next device the water passes through. The gas trap
protects the pump from performance degradation or stalling caused by Noncondens-
able Gases (NCGs) in the fluid stream. High concentrations can cause the pump to
stall, where flowrate drops drastically at a given speed. Possible sources of bubbles
include mating and demating of QDs and incomplete filling of racks or other ITCS
components.
The gas trap is capable of being replaced via probe-type QDs that are similar in design
to the fine filter. A guide in the unit ensures correct alignment and engagement when
mounting it to the PPA.
The gas trap design incorporates a bypass line with a check valve, as seen in
Figure 2-7KHFKHFNYDOYHFUDFNVLIWKH 3DFURVVWKHJDVWUDSH[FHHGVN3D
(7.0 psi), which corresponds to the point where bubbles begin to pass through the
hydrophilic membrane. The check valve also provides a flow path for the water in the
HYHQWRIJDVWUDSUHSODFHPHQW$ 3VHQVRUDFURVVWKHJDVWUDSSURYLGHVWHOHPHWU\WR
indicate the condition of the gas trap. Readings that approach the crack pressure of the
FKHFNYDOYHLQGLFDWHFORJJLQJDQGSHUIRUPDQFHGHJUDGDWLRQ$ 3RIN3D
(6.0 SVLGRUJUHDWHUZLOOFDXVHWKHVRIWZDUHWRLVVXHDJDVWUDSEORFNDJHDGYLVRU\$ 3
reading greater than 65.5 kPa (9.5 psi) indicates a failure of the check valve to open
and will cause the software to issue a caution.
Accumulator: The accumulator serves three purposes. The first is to maintain a

positive inlet pressure to the pump to prevent cavitation. The second is to allow for
thermal expansion and contraction of the water. Finally, the accumulator maintains an
adequate supply of water in the system in case of a leak.
The accumulator uses dynamic gas charging to pressurize an accordion-type bellows

with nitrogen. The bellows is located at the inlet to the pump to ensure the inlet
pressure is maintained above the vapor pressure of water at its operating temperature,
between 124.1 and 241.3 kPa (18 and 35 psi). Vapor entering the pump can cause
cavitation, resulting in performance degradation, pitting of the impeller, and vibration.
2-10
01.07.05(0)T0012
Basic
The Nitrogen Interface Assembly (NIA) regulates the nitrogen pressure to 165.5 to
193.1 kPa (24 to 28 psi). Inside the NIA, the Nitrogen Introduction Valve (NIV) opens
and closes intermittently to maintain a near constant accumulator pressure (see
Section 2.2.2.2). Accumulator quantity is measured to ensure water is not leaking from
the ITCS. The sensor is located in the accumulator on the nitrogen side.
Motor: For the PPA to perform its primary function of circulating ITCS water, a motor
must turn the pump impeller. The pump motor is a 120 V dc brushless design, chosen
for its long-term reliability. The pump motor can run at various speeds, depending on
the flowrate and pressure rise required by the ITCS.
The motor speed at the pump design point is 18,900 rpm and the motor can be
commanded to speeds in 157-rpm increments. The power consumed by the pump
motor is a function of the required flowrate at any given time and the condition of the
pump. As the pump performance gradually degrades with use, more current and more
power are necessary to provide the same flowrate. Telemetry indicating pump speed
as well as speed command capability is provided by the Pump/Fan Motor Controller
(PFMC).
Pump/Fan Motor Controller: The purpose of the PFMC is to accept speed commands
from the INT MDM and drive the pump at the commanded speed. Each PPA motor has
its own PFMC. The PFMC also provides overspeed and overtemperature protection for
the pump motor. Output data from the PFMC includes status and Built-in Test (BIT)
data on itself as well as motor speed, current, and temperature.
Coarse filter: The coarse filter prevents small particles from leaving the PPA and
migrating through the loop where damage to other ITCS components could occur. The
coarse filter is located at the outlet of the pump.
Unlike the fine filter, which is periodically maintained, the coarse filter is a stationary
component that cannot be removed or replaced. It contains no valves or sensors to
LQGLFDWHIORZUHVWULFWLRQ,IWHOHPHWU\IURP 3VHQVRUVDFURVVWKHILQHILOWHUJDVWUDS
and the pump are nominal, and there is a low flow reading from the flowmeter, it is likely
the coarse filter is clogged with broken impeller particles. If the impeller blades have
been damaged, the entire PPA must be replaced.
Check valve: The PPA includes a check valve to prevent water from entering the
pump if it is shut down.
Flowmeter: The flowmeter measures the flowrate of the water leaving the PPA and is
used to monitor pump performance.
The flowmeter is a simple design that has no moving parts. The flowmeter is a venturi
type, a short tube with flaring ends and a constricted throat. Water flowrate is
GHWHUPLQHGE\PHDVXULQJWKH 3EHWZHHQWKHYHQWXULLQOHW31) and the throat (P2). As
seen in Figure 2-8, the frontal area (a1) and throat area (a2) of the tube are known and
WKH 3LVGHWHUPLQHGE\DSUHVVXUHWUDQVGXFHU7KHYHORFLW\Y1) (water flowrate) is
calculated by using the continuity equation and Bernoulli’s equation (see Section 3).
2-11
01.07.05(0)T0012
Basic
Differential
pressure sensor
P
V1
Area a1 V2 Area a2
Pressure P2 Water flow
Pressure P1
01.07.05(0)T0012_013
Figure 2-8. Venturi flowmeter

The output to the LA MDM consists of two signals that correspond to the low-range and
high-range 3 sensors inside the flowmeter. The low-range data is used for system
startup/shutdown because it is more accurate below 498 kg/hr (1100 lb/hr). The high-
range flow is generally used to gauge the state of the system during nominal operations
since it can accurately measure up to 1406 kg/hr (3100 lb/hr). Pump flowrate is
calculated by software in the INT MDM.
Interfaces
CDH: The PPA has three types of interfaces with CDH, commanding, telemetry, and
power. These interfaces are shown in Figure 2-9. The PFMC is the only CDH/PPA
interface that uses a MIL-STD 1553 data bus because the PFMC is the only PPA
component that can be commanded. Commands to and telemetry from the PFMC are
routed through this interface.
2-12
01.07.05(0)T0012
Basic
Figure 2-9. PPA interfaces

All other interfaces between the other components (the PPA sensors) involve telemetry
and power only. Data is sent to the LA-1 (LTL) or LA-2 (MTL) MDM from the sensor as
an analog signal (usually a voltage), which is then converted by software in the MDM to
engineering units. Power is also supplied to all the sensors by the MDM.
EPS: The EPS provides 120 V dc to the PFMC through a dedicated power feed from a
12.0 amp Remote Power Controller Module (RPCM). PPA power consumption does
not exceed 450 W and total sensor power consumption does not exceed 4 W.
ECLSS: The ECLSS provides nitrogen to the PPA accumulator via the NIA.
Crew: PPAs can be replaced by disconnecting three 2.54 cm (1.0 in.) fluid QDs and
one 0.95 cm (0.375 in) gaseous nitrogen QD as well as several bolted connections.
The current operational plan is for a PPA to be replaced every three years due to
issues concerning sensor drift. The fine filter and gas trap are also considered ORUs.
The PPA is designed so that these two items can be removed and replaced via quick
disconnects without interruption of the PPA operation.
2-13
01.07.05(0)T0012
Basic
2.2.2.2 Nitrogen Interface Assembly
The NIA (Figure 2-10) provides an interface between the PPA accumulator and the
ECLSS nitrogen supply. There is one NIA for each PPA in the US Lab and each is
located in the same rack as the PPA. All NIAs are interchangeable and designed to be
replaced easily.
Figure 2-10. Nitrogen Interface Assembly
Purpose
The NIA regulates the nitrogen pressure in the PPA accumulator. It is also used to
prevent overpressurization of the accumulator and allows depressurization of the
accumulator when necessary.
Operations
The NIA functional schematic is shown in Figure 2-11. The NIV can be commanded
and monitored from a TCS display; however, it is normally operated by software in the
INT MDM. The software will open the NIV when the accumulator (pump inlet) pressure
drops below 124.1 kPa (18 psia). The switch (labeled ISO) on the front panel provides
visual position indication and manual override if there is a loss of CDH function.
2-14
01.07.05(0)T0012
Basic
Pressure
NIA Pressure
AVV Relief Valve
Regulator
N2 supply NIV To PPA

(ECLSS) accumulator
Acronyms
AVV - Accumulator Vent Valve
NIA - Nitrogen Interface Assembly
NIV - Nitrogen Introduction Valve
01.07.05(0)T0012_016
Figure 2-11. Nitrogen Interface Assembly functional schematic

The Accumulator Vent Valve (AVV) also can be commanded and monitored from a
TCS display. This valve is used to relieve overpressurization of the accumulator by
venting nitrogen into the cabin. Software in the INT MDM will open the AVV when the
accumulator pressure reaches 241.3 kPa (35 psia). The switch (labeled VENT) on the
front panel provides visual position indication and manual override if there is a loss of
CDH function.
The pressure relief valve is designed to open automatically at 227.5 kPa (33 psi) to
prevent overpressurization of the accumulator by venting nitrogen into the cabin. This
valve is a backup to the AVV. The pressure regulator steps down the nitrogen pressure
from 586.1 to 965.3 kPa (85 to 140 psia) to 165.5 to 193.1 kPa (24 to 28 psia). If a leak
is confirmed and cannot be isolated, the PPA will be shut down and the AVV will be
commanded open. This will drop the accumulator pressure to cabin pressure and can
thus be used to slow a water leak in the ITCS.
Interfaces
CDH: The NIA has two types of interfaces with CDH, telemetry, and power. CDH
directly interfaces with the NIV and the AVV through the LA-1 (LTL) and LA-2 (MTL)
MDMs. Telemetry from the LA-1, 2 MDMs is passed to the INT MDM where the data is
processed and commands to repress (Open NIV) and/or depress (Open AVV) are sent
to the LA-1, 2 MDMs as necessary. This software within the INT MDM is currently
inhibited because of a problem that is documented in Station Program Note 185911.
However, the valves remain powered and can be commanded as needed. The CDH
interfaces with the NIA are shown in Figure 2-12.
1
If the NIA software is enabled, it automatically performs a repress whenever the LTL or
MTL Pmp In Press is 18 psia for 6 seconds. The automatic repress function leaves
NIA control enabled at the conclusion of the repress. If low pump In Press is due to an
N2 leak, the accumulator pressure will again drop to 18 psia, and the NIA will
automatically perform another repress. Cyclic represses would occur, allowing the leak
to continue without any C&W messages and could deplete the AL N2 tanks. This
problem is scheduled to be fixed in Revision 2 of the INT SYS MDM software.
2-15
01.07.05(0)T0012
Basic
LTL LA-1
MTL LA-2
+15 V dc excitation 120 V dc NIV power

NIV position LTL RPCM_LAP61B_A
NIV commands 120 V dc AVV power MTL RPCM_LAS62B_A
NIA
+15 V dc excitation
AVV position
AVV commands
PPA Nitrogen Nitrogen ECLSS

accumulator 24-28 psia 85-140 psia supply
01.07.05(0)T0012_017
Figure 2-12. Nitrogen Interface Assembly interfaces

EPS: The EPS provides 120 V dc power to operate the solenoids in the NIV and AVV
(Figure 2-12).
ECLSS: The ECLSS provides nitrogen at 586.1 to 965.3 kPa (85 to 140 psia)
(Figure 2-12).
Crew: Crews can access the NIA valves by opening the LAB1S6 (MTL) or LAB1P6
(LTL) rack face panel and toggling the desired valve (see Figure 2-10) to the
designated position. Closed Loop control of the NIA software must be inhibited prior to
crew interaction with the valves. The NIAs are ORUs and can be replaced by
disconnecting two 0.95 cm (0.375 in.) gaseous nitrogen QDs as well as several bolted
connections.
2-16
01.07.05(0)T0012
Basic
2.2.2.3 Rack Flow Control Assembly

The Rack Flow Control Assembly (RFCA), Figure 2-13, is designed to control the flow
of water through a payload rack. There are 15 RFCAs in the US Lab, 13 in the
standoffs (one for each payload rack location) and two in the aft endcone (used to
control water flowing through Node 1 and its adjacent elements).
LTL connections
Bypass jumper
MTL connections
RFCA
01.07.05(0)T0012_022
Figure 2-13. Rack Flow Control Assembly

The endcone RFCAs are being utilized on-orbit to provide the proper flowrate to the
coldplates and heat exchangers located within Node 1, the Airlock, and the Cupola,
however, most payload rack RFCAs are not being used as originally intended. Most
payload rack users have chosen to install their own flow control devices. Therefore,
upon installation of a payload rack, the associated RFCA is commanded to the flow
mode and allowed to stabilized at the required flowrate. Once stable, the RFCA closed
loop control is inhibited so that the payload flow control device can continue to provide
the desired flowrate without interference. While this is the current situation on-orbit, the
following sections are included to provide the user with the basic details about the
RFCAs and how they can be utilized if needed in the future.
Purpose
The RFCA provides a way to control the flow of water through payload racks or the
Node 1 and Airlock modules.
Operations
The RFCA functional schematic is shown in Figure 2-14. The RFCA maintains a
constant flowrate or temperature of water by modulating the position of the Flow Control
Valve (FCV) based on a closed-loop software algorithm in the LA MDMs using
measurements made by either the temperature sensor or flowmeter. (Generally,
RFCAs will be set to control flowrate rather than temperature. Although more accurate,
2-17
01.07.05(0)T0012
Basic
controlling to a temperature setpoint causes more movement of the FCV, which
increases the wear on the mechanism.)
Figure 2-14. Rack Flow Control Assembly functional schematic

The FCV is a ball valve driven by an electromechanical actuator. The front panel has a
manual override knob that provides visual indication of valve position, and is available if
there is a loss of CDH or EPS function or if the actuator fails. Pulling the knob
disengages the actuator and rotating the knob moves the valve to the desired position.
The RFCA flowmeter design and operation is similar to the PPA flowmeter (see
Figure 2-8). The output to the MDM consists of two signals corresponding to the low-
range and high-range 3 sensors inside the flowmeter. Flowrate is calculated by
software in the LA MDMs.
Interfaces
CDH: The RFCA has two types of interfaces with CDH, telemetry and power. The
CDH interfaces with the RFCA are shown in Figure 2-15.
LA-1, 2, 3
+15 V dc excitation
Temperature
sensor signal 120 V dc FCV power
EPS
+15 V dc excitation
RFCA
Flowmeter low signal
Flowmeter high signal
FCV speed
FCV commands
01.07.05(0)T0012_020
Figure 2-15. Rack Flow Control Assembly interfaces

EPS: The EPS provides 120 V dc power to operate the motor and controller in the FCV
(Figure 2-15).
2-18
01.07.05(0)T0012
Basic
Crew: Crews may be required to interface with RFCAs when new payload racks are
installed. RFCAs can be connected to either the LTL or MTL return lines using flex
hoses and QDs as seen in Figures 2-13 and 2-16. If a payload rack requires LTL
cooling and the RFCA is currently connected to the MTL, then crews must reconfigure
the RFCA to the LTL return line (and vice versa for a payload rack requiring MTL
cooling). Since there is only one RFCA per payload rack, if cooling from both loops is
required, the bypass jumper is used to complete the other fluid connection.
Figure 2-16. RFCA connections

Figures 2-13 and 2-16 show an RFCA installed on the MTL return line with the LTL
return lines connected to the jumper assembly.
2.2.2.4 Manual Flow Control Valve

The Manual Flow Control Valve (MFCV) (see Figure 2-17) is a mechanical valve without
motor control or telemetry. There are 16 MFCVs in the US Lab, two in the aft endcone,
one in the forward endcone, and the rest are located inside the systems/avionics racks.
Most MFCVs are accompanied by a Rack Standalone Temperature Sensor (RSTS),
which provides temperature data to software in the LA MDMs.
2-19
01.07.05(0)T0012
Basic
Figure 2-17. Manual Flow Control Valve
Purpose
The MFCV provides a fixed resistance to control the flow through systems racks or
other ITCS components with little variability in heat loads. An MFCV is usually the last
component in a rack or endcone before water enters a return header.
Operations
The position of the MFCV is preset on the ground prior to launch. Valve position
depends on the heat loads of the components upstream of the MFCV. Normally, the
position of the valve does not change; however, the crew can manually change the
position using a standard Intravehicular Activity (IVA) tool if necessary.
Interfaces
There are no EPS or CDH interfaces with the Manual Flow Control Valve (MFCV).
Crew: Although most MFCVs are preset on the ground and should not require any
crew interface, there are three MFCVs that are planned to be operated by the crew on a
nominal basis. The two MFCVs located in the LAB1S6 and LAB1P6 racks that control
flow to the ECLSS CCAAs must be adjusted by the crew each time a CCAA is shut
down or started. When the CCAA is active, the MFCV must be opened. When the
CCAA is shut down, the MFCV must be closed to prevent water from flowing through
the inactive CCAA components. The third MFCV that will require crew interaction is the
High-Temperature Loop (HTL) MFCV located in the aft endcone. This MFCV is
launched in the closed position. When the Cupola arrives on Flight 14A, this valve
must be opened by the crew in order to allow “high” temperature water to the Cupola
and prevent condensation on the Cupola windows.
Note: This “high” temperature water is routed from the warmest part of the MTL return
line as seen in Figure 2-1.
2-20
01.07.05(0)T0012
Basic
2.2.2.5 System Flow Control Assembly
Because the RFCAs and payload flow control devices can vary the flowrate through
SD\ORDGUDFNVDVHTXLSPHQWLVWXUQHGRQDQGRIIWKH 3EHWZHHQWKHVXSSO\DQGUHWXUQ
lines can also vary. One function of the System Flow Control Assembly (SFCA)
(Figure 2-LVWREDODQFHWKH 3EHWZHHQWKRVHOLQHV7KHUHLVRQH6)&$LQHDFK
loop, and each is located in the same rack as the PPA. A second function of the SFCA
is to provide a means to bypass an inactive PPA.
Figure 2-18. System Flow Control Assembly
Purpose
The SFCA contains two valves and performs two separate functions. First, it uses a
modulating valve to maintain a constant pump inlet pressure as a function of rack flow
requirements, which allows the pump motor in the PPA to operate at its highest
efficiency. Secondly, when the PPA is not operating, flow is diverted by closing a
separate Shutoff Valve (SOV). Closing the SOV prevents water transfer between the
loops and prevents unnecessary wear on the gas trap when the pump is off.
Operations
The SFCA functional schematic is shown in Figure 2-19. The SFCA maintains a
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Modulation valve (Mod Vlv—sometimes referred to as the FCV) based on a closed-loop
software algorithm in the LA MDMs. The Mod Vlv allows some of the water in the
supply header (at high pressure) to bypass the racks and remix with the water in the
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Vlv is 75.8 kPa (11 psid).
2-21
01.07.05(0)T0012
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Figure 2-19. System Flow Control Assembly functional schematic

The Mod Vlv and SOV consist of ball valves driven by electromechanical actuators.
Both valves are similar in design; however, the SOV is not intended to vary the flowrate.
The SOV operates in either the fully open or fully closed positions. In the open position
water flows through the PPA, and in the closed position water bypasses the PPA and
rejoins the supply header.
The front panel of the SFCA has two manual override knobs. The manual override
knobs provide visual indication of valve position, and are available if there is a loss of
CDH or EPS function or if an actuator fails. Pulling the knob disengages the actuator
and rotating the knob moves the valve to the desired position.
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Interfaces
CDH: The SFCA has two types of interfaces with CDH, telemetry and power. The
CDH interfaces with the SFCA are shown in Figure 2-20.
LTL LA-1
MTL LA-2
+15 V dc excitation
DP sensor signal
Mod Vlv speed

Mod Vlv commands
SFCA 120 V dc Mod Vlv power
LTL RPCM_LAP61B_A
SOV speed 120 V dc SOV power MTL RPCM_LAS62B_A
SOV commands
SOV position
01.07.05(0)T0012_026
Figure 2-20. System Flow Control Assembly interfaces
2-22
01.07.05(0)T0012
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EPS: The EPS provides 120 V dc power to operate the motors and controllers in the
Mod Vlv and SOV (Figure 2-20).
Crew: If power or commanding capability is lost to either one of the TCS racks, crews
may be requested to manually position the SFCA SOV during any ITCS mode transition
sequence. Manual adjustment of the Modulation Valve may also be required. Both
valves are accessed by opening the front panel on the LAB1S6 (MTL) or the LAB1P6
(LTL) racks.
2.2.2.6 Three-Way Mixing Valve

Temperature control of the water in the ITCS is accomplished using three Three-Way
Mixing Valves (TWMVs) (Figure 2-21). One TWMV controls the LTL, the second
controls the MTL, and the third controls the MTL when the ITCS is in single-loop mode.
All three TWMVs are located in the US Lab aft endcone.
Figure 2-21. Three-Way Mixing Valve
Purpose
The LTL and MTL TWMVs maintain loop temperature by mixing cool water from the
IFHX with warm water bypassing the IFHX. When the ITCS is in single-loop mode a
third TWMV (Regen TWMV) maintains MTL temperature by controlling the amount of
warm water flowing through the Regen HX.
Operations
The TWMV functional schematic is shown in Figure 2-22. Setpoints for the MTL and
LTL are nominally 17.2° C (63° F) and 4.4° C (40° F), respectively. A temperature
sensor located near the outlet of the TWMV provides feedback to a closed-loop
software algorithm in the LA MDM that calculates and commands the required valve
position.
Note: Operationally, the LTL setpoint is between 7° and 11° C.
2-23
01.07.05(0)T0012
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Figure 2-22. LTL and MTL TWMV functional schematic

The Regen HX and associated Regen TWMV (Figure 2-23) are active only when the
ITCS is in single-loop mode and, in that instance, takes over responsibility of
maintaining MTL temperature (the MTL TWMV is not used and its valve is positioned so
that all water flows through the IFHX). The Regen TWMV controls the amount of warm
water flowing through the Regen HX. Closed-loop control is handled differently
because the software uses the outlet temperature of the Regen HX (supply to the MTL
racks). In single-loop mode the setpoint for the MTL is 17.2° C (63° F).
Figure 2-23. RHX TWMV functional schematic

The three-port valve in Figures 2-22 and 2-23 consists of a ball valve driven by an
electromechanical actuator. The front panel has a manual override knob that provides
visual indication of valve position. The knob is used if there is a loss of CDH or EPS
function or if the actuator fails. Pulling the knob disengages the actuator and rotating
the knob moves the valve to the desired position.
Interfaces
CDH: The TWMV has two types of interfaces with CDH, telemetry and power. The
CDH interfaces with the TWMV are shown in Figure 2-24.
2-24
01.07.05(0)T0012
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LTL LA-1
MTL LA-2
Regen HX LA-2
Valve speed
Valve commands
120 V dc power LTL RPCM_LA1B_F
Valve position MTL RPCM_LA2B_G
TWMV Regen HX RPCM_LA2B_G
01.07.05(0)T0012_030
Figure 2-24. Three-Way Mixing Valve interfaces

EPS: The EPS provides 120 V dc power to operate the motor and controller in each
TWMV (Figure 2-24).
Crew: Crews may be required to manually adjust a TWMV if power or commanding
capability is lost. Access to the MTL TWMV requires the rotation of the LAB1P6 rack
while access to the LTL TWMV requires the rotation of the LAB1D6 rack. The Regen
TWMV is located just below the aft deck hatch and requires the removal of a closeout
panel.
2.2.2.7 Loop Crossover Assembly

Normally, the MTL and LTL operate as complete, independent loops. However, in
order to provide redundancy for equipment failures, the Loop Crossover Assembly
(LCA) (Figure 2-25) allows the two ITCS loops to be connected. The LCA is located in
the US Lab aft endcone.
Figure 2-25. Loop Crossover Assembly
Purpose
The LCA provides the capability to reconfigure the ITCS between dual-loop mode and
single-loop mode. Single-loop mode can be used in the event of a pump failure in one
of the ITCS loops and for certain startup, reconfiguration, or pump replacement
activities. Single-loop mode also provides protection from the loss of an EETCS or
ETCS loop by allowing all heat collected from the internal equipment to be rejected
through a single IFHX.
2-25
01.07.05(0)T0012
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Operations
The LCA functional schematic is shown in Figure 2-26. The LCA contains two
independent assemblies consisting of ball valves driven by electromechanical
actuators. These valves have two positions, Dual or Single. The ITCS can be
configured into single-loop mode by positioning either valve to the Single position.
Figure 2-26. Loop Crossover Assembly functional schematic

When both valves are in the Dual position, the LCA isolates the MTL from the LTL and
allows independent operation of the two ITCS loops. This is the preferred mode
because a leak or contamination in one loop will not affect the other. If one or both of
the valves is in the Single position, the MTL and LTL are connected into one loop.
Procedurally, only one of the two valves will be used to reconfigure the ITCS. This will
reduce the risk of a failure preventing a valve from returning to the Dual position.
The front panel of the LCA has two manual override levers. The manual override levers
provide visual indication of valve position, and are available if there is a loss of CDH or
EPS function or if an actuator fails. Folding out the lever disengages the actuator and
rotating the lever moves the valve to the desired position.
Note: Operationally, only LCA Valve 1 can physically be moved. The lever on LCA
Valve 2 is blocked by a Vacuum System line and cannot be rotated far enough
to disengage the actuator (Figure 2-27).
2-26
01.07.05(0)T0012
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Figure 2-27. LCA valve configurations showing vacuum system interference
Interfaces
CDH: The LCA has two types of interfaces with CDH, telemetry and power. The CDH
interfaces with the LCA are shown in Figure 2-28. For redundancy, each valve is
connected to a separate LA MDM.
LA-1
Valve 1 speed
Valve 1 commands
120 V dc valve 1 power
Valve 1 position RPCM_LA1B_F
LA-2 LCA
Valve 2 speed 120 V dc valve 2 power

Valve 2 commands RPCM_LA2B_E
Valve 2 position
01.07.05(0)T0012_034
Figure 2-28. Loop Crossover Assembly interfaces

EPS: The EPS provides 120 V dc power to operate the motors and controllers in the
two valve assemblies (Figure 2-28). For redundancy, each valve receives power from a
separate power channel.
2-27
01.07.05(0)T0012
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Crew: If power or commanding capability is lost, crews may be required to manually
reconfigure the LCA valves. Access to the LCA requires the rotation of the LAB1P6
rack.
2.2.2.8 ITCS Operating Modes

The US Lab ITCS plumbing and flight software provide significant capability to manage
heat loads and off-nominal situations. To allow this flexibility, the ITCS can operate in
one of five operating modes.
Dual-loop mode (Dual): This is the preferred configuration. Both PPAs are operating
and the temperature in each loop is controlled by its own TWMV. All equipment in each
loop is being cooled.
Single-loop mode, LTL PPA operating (Single LT): In this configuration, the LTL
PPA is operational, the MTL PPA is shut down, the LCA is in Single, and the Regen
TWMV is controlling the temperature of the MTL. All equipment in each loop is being
cooled.
Single-loop mode, MTL PPA operating (Single MT): In this configuration, the MTL
PPA is operational, the LTL PPA is shut down, the LCA is in Single, and the Regen
TWMV is controlling the temperature of the MTL. All equipment in each loop is being
cooled.
The following two modes are used to shut down one loop and prevent the flight
software from transitioning to single-loop mode. A significant water leak, maintenance
activities, or a failure of the LCA are some examples of situations requiring a loop to be
shut down.
Dual-loop mode, LTL PPA failed (Dual LT Failed): In this configuration the MTL is
fully operational, the LTL PPA is shut down, and the LCA is in Dual. Equipment in the
MTL is being cooled; equipment in the LTL is not being cooled.
Dual-loop mode, MTL PPA failed (Dual MT Failed): In this configuration the LTL is
fully operational, the MTL PPA is shut down, and the LCA is in Dual. Equipment in the
LTL is being cooled; equipment in the MTL is not being cooled. However, since nearly
all systems and avionics equipment is normally cooled via the MTL, jumpers were
designed for this contingency situation. These jumpers can be used to connect certain
systems/avionics racks to the LTL plumbing such that the equipment within those racks
can continue to receive cooling. In this case, the LTL temperature setpoint must be
raised above the dewpoint in order to prevent condensation from forming on the
jumpered rack components.
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01.07.05(0)T0012
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The ITCS operating modes are summarized in Table 2-1.
Table 2-1. ITCS operating modes

LTL PPA MTL PPA LTL TWMV MTL TWMV CLC Regen TWMV
Mode LCA valves
speed speed CLC (Posn) CLC (Posn)
Dual 14,600 rpm 16,300 rpm Both in Dual Enabled Enabled Inhibited
(Bypass)
Single 18,900 rpm 0 Valve #1 - Single Enabled Inhibited (Flothru) Enabled
LT Valve #2 - Dual
Single 0 18,900 rpm Valve #1 - Single Enabled Inhibited (Flothru) Enabled
MT Valve #2 - Dual
Dual LT 0 16,300 rpm Both in Dual Enabled Enabled Inhibited
Failed (Bypass)
Dual MT 14,600 rpm 0 Both in Dual Enabled Inhibited Inhibited
Failed
2.2.3 ITCS Heat Rejection
2.2.3.1 Interface Heat Exchanger

The IFHXs (Figure 2-29) provide the interface between the ITCS and the EETCS
through Flight 12A.1 and the ETCS after Flight 12A.1. There is one IFHX per ITCS
loop; they are located on the US Lab external aft endcone (Figure 2-29). Because of
the highly toxic nature of ammonia, IFHX ORUs are mounted external to the
pressurized modules as a safety precaution.
Ammonia
supply/return
QDs (4)
MT IFHX
Isolation and Water in

relief valve
Ammonia in
Water out
Ammonia out
Bypass valve
QDs (4)
LT IFHX
View looking forward 01.07.05(0)T0012_035
Figure 2-29. Interface heat exchanger ORU
2-29
01.07.05(0)T0012
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Purpose
Heat collected by the ITCS water is transferred or rejected to the EETCS/ETCS
ammonia via the IFHXs. This section describes the IFHX functionality associated with
the ITCS water loops only. (Section 2.3.1.1 and 2.4.1.1 will cover the IFHX functionality
associated with the ammonia loops.)
Operations
The IFHX functional schematic is shown in Figure 2-30.
Figure 2-30. IFHX functional schematic

IFHX Core: Each IFHX core utilizes a counterflow design with 45 alternating layers.
ITCS water flows through 23 of the layers, while EETCS/ETCS ammonia flows through
the 22 alternate layers in the opposite direction. These alternating layers of relatively
warm water and relatively cold ammonia help to maximize the heat transfer between
the two fluids via conduction and convection. The heat exchanger core is a simple
flowthrough device with no command or telemetry capability.
The US Lab ITCS LTL interfaces with the EETCS/ETCS Loop A, while the US Lab
ITCS MTL interfaces with the EETCS/ETCS Loop B. Physically and functionally, there
is no difference between the LTL IFHX core and the MTL IFHX core; however, the MTL
IFHX is capable of transferring much more heat than the LTL IFHX because of the large
temperature difference between the two fluids.
Heaters: There are three heaters inside the IFHX, which are used to ensure that
stagnant water does not freeze. Two of the heaters are spiral-wound, one wrapped
around the water inlet pipe and one around the water outlet pipe. The third is a patch
heater attached to the surface of the IFHX core. These heaters are wired in parallel,
powered by one RPC, and commanded on and off by software based on heater on and
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01.07.05(0)T0012
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off setpoints. (Additional heaters and temperature sensors are located on the water
lines between the IFHX and the US Lab.)
Interfaces
CDH: The commands and telemetry for the IFHX ORU associated with the ITCS are
routed through the LA MDMs (Figure 2-31). The IFHX water inlet temperature sensor is
used by the INT MDM for IFHX heater control.
EETCS (ETCS*) interfaces ITCS interfaces

*At Flight 12A.1, the S0 MDMs take
over control of the IFHXs
INT SYS
Loop A N1-1(S0-1)
Loop B N1-2 (S0-2)
LTL LA-2
Heater commands
MTL LA-1
Ammonia outlet temperature
1 mA current
Isolation valve commands IFHX Water inlet temperature
Isolation valve position

120 V dc Isolation valve power
Bypass valve commands
120 V dc heater power LTL RPCM LA2B_G
Bypass valve position
MTL RPCM LA1B_F
120 V dc bypass valve power
01.07.05(0)T0012_037
Figure 2-31. IFHX interfaces

EPS: EPS supplies power for the three IFHX heaters through one RPC.
Crew: The IFHX ammonia supply/return lines were connected via EVA to the Z1
EETCS supply/return lines on Flight 4A. On Flight 12A.1, when the ETCS is activated,
EVA crewmembers will reconfigure the IFHX supply/return QDs to the ETCS supply/
return lines. These connections not only involve the connection of the fluid lines, but
also the power and data connections to the IFHX valves. Power and data are currently
provided by the N1 MDMs, but will be reconfigured on Flight 12A.1 to the S0 MDMs.
2-31
01.07.05(0)T0012
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2.3 USOS EETCS FUNCTIONAL DESCRIPTION
The EETCS provides temporary cooling to the US Lab prior to the activation of the
permanent ETCS. There are two identical ammonia loops. The loops provide a
maximum heat rejection capability of 14 kW. The EETCS has a design life of 15 years,
but is scheduled to operate from ISS assembly Flight 5A through Flight 12A.1.
As shown in Figure 2-32, the EETCS loops are designated Loop A and Loop B. Within
each loop are three primary ORUs. Heat is collected from the ITCS via the IFHXs as
discussed in Section 2.2.3. The motive force to transport the ammonia is provided by
the Pump and Flow Control Subassemblies (PFCS). Heat is rejected to space via
radiators.
2-32
Figure 2-32. Early External Thermal Control System
01.07.05(0)T0012
Basic
The PFCSs and radiators are located on the P6 Long Spacer (see Figure 2-33).
Starboard (normal) radiator
Loop B PFCS Z1 Truss interface
Loop A PFCS
Integrated Equipment Trailing (aft) radiator

Assembly (IEA) Interface
01 .0 7 .0 5( 0)T00 1 2_ 03 9
Figure 2-33. EETCS components on the P6 long spacer
2.3.1 EETCS Heat Collection

The IFHX provides the only interface between the ITCS and EETCS. There is one
IFHX for each EETCS loop. The IFHXs are the only EETCS ORUs that will become
part of the permanent ETCS.
Purpose
The IFHXs transfer heat from the ITCS water loops to the EETCS ammonia loops.
Operations
The IFHX functional schematic is shown in Figure 2-34.
2-35
01.07.05(0)T0012
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Figure 2-34. IFHX functional schematic

IFHX Core: See the description of the IFHX core in Section 2.2.3.1.
IFHX Bypass Valve: A bypass valve is located in the ammonia line upstream of the
IFHX to provide a bypass path for the ammonia coolant around the IFHX core. This
bypass valve is necessary to allow heat exchanger core isolation in cases of ammonia
leaks or ammonia temperatures below the freezing point of water. The IFHX bypass
valve is powered and commanded by the Node 1 MDM. It is a motor-driven valve that
has only two commandable positions, flowthrough and bypass. The valve takes
approximately 11 seconds to complete a transition from one position to the other.
IFHX Isolation Valve: An isolation valve prevents the backflow of ammonia coolant
into the IFHX core when the bypass valve is in the full bypass position. As with the
IFHX bypass valve, the IFHX isolation valve is powered and commanded by the Node 1
MDM. It is a motor-driven valve that has only two commandable positions, open and
closed. The isolation valve also takes approximately 11 seconds to complete a
transition from one position to the other.
IFHX Relief Valves: Isolated ammonia in the IFHX may be warmed by the ITCS water
and expand. This could create an overpressure condition in the lines. Two pressure
relief valves are used to prevent this overpressurization. These valves crack open
under high pressure and vent ammonia to space. The relief valves are driven by fluid
line pressure and have no command or telemetry capability. They crack open at a
pressure of 3344 kPa (485 psi) and they are fully open at 3447 kPa (500 psi).
IFHX Core Isolation: Ammonia temperatures below the freezing point of water could
freeze the ITCS water in the IFHX. Since water expands when it freezes, this could
cause the ITCS lines to overpressurize, and possibly burst. More serious would be
water freezing inside the core, rupturing the parting sheets and allowing ammonia to
come in contact with ITCS water. After thawing, water contaminated with ammonia
2-36
01.07.05(0)T0012
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would be carried into the US Lab. To protect the system against this, the Node 1 MDM
software commands the IFHX bypass valve to the bypass position and the IFHX
isolation valve to the closed position when the EETCS ammonia line outlet temperature
is below 1.1° C (34° F).
External Quick Disconnects: QDs provide the necessary interfaces between system
components and also provide a way to isolate leaks. Each half is self-sealing and
retains the fluid in the line after QD separation. QDs are located on the IFHX ORU, the
US Lab aft endcone shell (US Lab to Z1 connection), and the Z1 truss (Z1 to P6
connection).
Interfaces
CDH: The commands and telemetry for the IFHX ORUs associated with the EETCS
are routed through the Node 1 MDMs (see Figure 2-31). N1-1 MDM controls the
LTL/Loop A IFHX and N1-2 MDM controls the MTL/Loop B IFHX. Commanding is
available only for the IFHX Bypass valve and IFHX Isolation valve. The ammonia outlet
temperature sensor provides data to the Node 1 MDM on the functioning of the IFHX,
but is not used for any software functions. Two separate ammonia temperature
sensors located downstream of the PFCS on the P6 spacer are wired to the Node 1
MDMs (N1-1 for Loop A and N1-2 for Loop B) and are used to monitor for low-
temperature conditions. FDIR software in the MDM will bypass the IFHX core if such a
condition occurs. The positions of the Isolation and Bypass valves are read by Discrete
Input/Output (DIO) cards in the N1 MDMs.
EPS: Power for the Isolation and Bypass valves is supplied through Solenoid Driver
Output (SDO) cards in the Node 1 MDMs.
2.3.2 EETCS Heat Transportation
2.3.2.1 Pump and Flow Control Subassembly

The primary heat transportation component of the EETCS is the PFCS.
Purpose
The PFCS is responsible for circulation of the coolant, filtration of debris, regulation of
loop pressure, and control of loop temperature. All power, commands, and telemetry
for the radiator deploy/retract mechanism are also routed through the PFCS.
Operations
The PFCS functional schematic is shown in Figure 2-35.
2-37
01.07.05(0)T0012
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Figure 2-35. PFCS functional schematic

Pumps: Each PFCS ORU contains two identical pumps for redundancy; however, only
one pump will be operated at a time.
Note: There is no protection against commanding both pumps on.

The pump motor is a 120 V dc brushless design, chosen for its long-term reliability.
The impeller nominally operates at a fixed speed of 13,580 ± 975 rpm. Each pump is
capable of providing the required system flowrate of 771 kg/hr (1700 lb/hr) to ensure
proper ammonia circulation within the EETCS loop.
2-38
01.07.05(0)T0012
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Dual Check Valve: A dual check valve prevents coolant from flowing backward into
the nonoperating pump. It has no command or telemetry capability.
FCV: Each PFCS ORU contains a Flow Control Valve (FCV) for loop temperature
control. This temperature control is accomplished by mixing the warm ammonia that
bypasses the radiators, with the cool ammonia exiting the radiators, to maintain the
PFCS outlet temperature (default is 3.6° ± 0.83° C (38.5° ± 1.5° F)). The FCV position
is normally commanded by a closed-loop algorithm in the Photovoltaic Controller Unit
(PVCU) MDM. This algorithm uses feedback from the two PFCS outlet temperature
sensors to match the temperature setpoint. The FCV is positioned using a 28 V dc
brushless motor. Software control can be inhibited and the FCV can be commanded to
any position between about –10 and +100 degrees. The FCV position is available in
degrees; however, FCV commands must be normalized by dividing the desired position
by 90.
Note: Operationally, the loop setpoint is set at 5.8° C (42.4° F).
Accumulator: The PFCS accumulator serves the same functions as the ITCS
accumulators. One accumulator resides upstream of the pumps in each PFCS ORU.
A filter prevents particles from entering the accumulator and damaging the internal
bellows. The accumulator keeps the ammonia coolant in the liquid phase by
maintaining the coolant pressure above the vapor pressure of ammonia. This is
accomplished with pressurized nitrogen gas on the back of the metallic bellows. Unlike
the ITCS accumulators, the EETCS accumulators contain a fixed charge of nitrogen
gas and have no ECLSS interface. The accumulator also serves to absorb fluctuations
in the fluid volume through the expansion and contraction of its internal bellows, shown
in Figure 2-36. These volumetric fluctuations are due to temperature variations in the
ammonia. In the event of a small leak, the PFCS accumulator provides a limited
amount of ammonia to replace lost coolant.
Q Q
Nitrogen Gas Nitrogen Gas
Q Q
Bellows expanded
Bellows compressed
01.07.05())T0012_043
Figure 2-36. PFCS accumulator

Two quantity sensors are used to monitor accumulator bellows position. Accumulator
quantity from both sensors is available as a percentage, and is used by software for
leak detection.
SCI: The Signal Conditioning Interface (SCI) distributes electrical power to the PFCS
and Radiator components. A DC/DC converter in the SCI provides conditioned low-
voltage electrical power to the Local Data Interface (LDI) as well as radiator, pump, and
FCV motors.
2-39
01.07.05(0)T0012
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The SCI also provides signal conditioning for the PFCS and radiator sensors,
converting the analog data into digital data. It then passes this digital data to the LDI.
LDI: Control of the PFCS is accomplished by software in the PVCU MDM, which sends
commands to the LDI. The LDI converts PVCU commands into discrete signals that
are used by the radiator, pump, and FCV motor controllers. The LDI relays PFCS and
radiator sensor data (received from the SCI) to the PVCU MDM.
Debris Screens and System Filters: The PFCS has five debris screens and two
system filters. The debris screens protect components from damage by contaminants
introduced into the flow path. These contaminants would most likely originate from the
failure or disintegration of components in the loop. A system filter is located on the inlet
of each pump. It provides fine filtering to protect the delicate components of the pump.
No commands or telemetry are available for the debris screens or filters.
Flowmeter: A venturi flowmeter is located at the PFCS outlet. The 3 across a

venturi tube is measured and converted to a flowrate by software in the Portable
Computer System (PCS) or ground displays, which is used to monitor the performance
of the operating pump. PFCS flowmeter design and operation is similar to the PPA
flowmeter (see Figure 2-8).
Temperature Sensors: There are four temperature sensors in the PFCS. Two are
located at the inlet of the FCV. These sensors provide telemetry on ammonia
temperature from the bypass line and the radiators. The two sensors located at the
outlet provide data to the PVCU MDM for use in the software that controls the FCV.
These sensors are also used by FDIR software to prevent cold ammonia (at or below
the freezing point of water) from reaching the IFHX and to prevent damage to the PFCS
due to very high or low ammonia temperatures.
Pressure Sensors: One pressure sensor is located at the inlet from the radiators, the
other is located at the outlet just downstream of the dual check valve.
Fluid Quick Disconnect Couplings: The PFCSs and radiators connect to EETCS
fluid lines through a special kind of QD, a Fluid Quick Disconnect Coupling (FQDC).
The FQDCs were part of the Photovoltaic Thermal Control System (PVTCS) design and
provide the same functional capability as the external QDs found in other EETCS loop
locations. Unlike external QDs, FQDCs have dual flow paths (two inlet and two outlet
ports). An EVA crewmember must manually connect/disconnect both paths
simultaneously via a standard EVA power tool.
Interfaces
CDH: The commands and telemetry associated with the PFCS (and radiators) are
routed to the PVCU MDM (Figure 2-37) using a MIL-STD-1553 databus. Control and
FDIR for the PFCS (and radiators) are accomplished by software in the PVCU MDMs.
All commands and telemetry pass through the LDI.
2-40
01.07.05(0)T0012
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Primary PVCU-4B
Secondary PVCU-2B
PFCS
MIL-STD-1553
120 V dc power Loop A RPCM_4B_A
Loop B RPCM_2B_A
SCI Telemetry
Power
Radiator telemetry
PFCS telemetry (speed,
temperature, pressure, etc)
FCV commands LDI

Pump commands
Radiator Radiators
Radiator commands
commands
01.07.05(0)T0012_044
Figure 2-37. Pump and flow control subassembly interfaces

EPS: Secondary power is supplied to the SCI through the P6 Remote Power Controller
Modules (RPCMs). The SCI then distributes conditioned low-voltage electrical power to
the LDI, pumps, FCV motors, and radiators.
2.3.2.2 Line Heaters

There are two line heater clusters for each EETCS loop with the capability to produce a
total of 1550 W. Each cluster is composed of ten heaters that wrap around the EETCS
tubing. Due to space limitations, both line heater clusters could not be physically
located on the radiator bypass line. Therefore, one cluster is located on the radiator
bypass line and the other is on the IFHX return line.
Purpose
Line heaters are used to help the PFCS FCV maintain a minimum outlet temperature
during low heat loads or a cold environment by adding additional heat into the system.
Operations
The heater control algorithm in the PVCU MDM monitors the PFCS outlet temperature
and automatically turns the line heaters on at 5.3° C (41.5° F) and off at 5.6° C (42° F).
Each cluster is powered by a separate RPC. To activate and deactivate the line
heaters, the software in the PVCU MDM commands the RPC connected to the line
heaters to close or open.
Prior to commanding the line heaters on, the control logic verifies that the pump is on
(i.e., pump speed is greater than 12,000 rpm) and that sufficient flow exists in the
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01.07.05(0)T0012
Basic
radiator bypass line (i.e., FCV position is greater than 72 degrees). This is done to
prevent damage to the plumbing insulation. The heater control software can be
inhibited and the line heaters commanded on or off.
2.3.2.3 Trace Heaters

Trace heaters are either patch heaters on flex hoses and ORUs, or spiral-wound
heaters wrapped around tubing. Each EETCS loop has a pair of flex hoses at the
P6-to-Z1 interface and the US Lab-to-Z1 interface. Trace heaters are also located on
radiator equipment (deploy/retract motor and controller, FQDC tube, accumulator
shroud, etc.) and the PFCS.
Purpose
Trace heaters are used to prevent ammonia from freezing during nonoperational
periods. Trace heaters have lower wattage than in-line heaters because they are
designed for a no-flow condition.
Operations
Trace heaters maintain the ammonia temperature in the system above -51.1° C
(-60° F). These heaters are thermostatically controlled and have no software interface.
The temperature setpoints are defined and set pre-launch. The Z1 and radiator/PFCS
heater sets in each loop are powered by two separate RPCs.
2.3.2.4 EETCS Outlet Line Temperature Sensors

Four additional temperature sensors in each loop provide insight to the temperature of
the ammonia as it exits the PFCS.
Purpose
These sensors are used by FDIR algorithms to prevent introducing cold ammonia
(below the freezing point of water) into the IFHX. These sensors are located on the
ammonia lines between the PFCS and the Z1 truss.
Operations
One temperature sensor is directly wired to the PVCU-4B MDM and another to the
PVCU-2B MDM. They are known as the Loop Outlet Line Temperature sensors. The
PVCU MDM will turn off the pumps and remove power from the PFCS based on a Loop
Outlet Line Temperature below 1.1° C (34° F).
The remaining two sensors are directly wired to the Node 1 MDMs (Loop A sensors go
to the N1-1 MDM and Loop B sensors go to the N1-2 MDM). They are known as the
IFHX Inlet Temperature sensors. If either one of the IFHX Inlet Temperatures falls
below 1.1° C (34° F), the Node MDM will issue bypass/close commands to the affected
IFHX valves.
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01.07.05(0)T0012
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2.3.2.5 Z1 Accumulators
Purpose
The Z1 Truss Segment contains two accumulators in each loop that are identical to the
PFCS accumulators. The Z1 accumulators maintain the liquid state of the ammonia,
replace lost coolant, and absorb fluctuations in fluid volume. They also provided
ammonia to complete the IFHX fill after the Z1-to-US Lab ammonia connections were
made on Flight 5A.
Operations
Each Z1 accumulator has two quantity sensors; however, only one of the two sensors is
wired to the PFCS SCI. Telemetry is available, but these sensors are not used by leak
detection software.
2.3.3 EETCS Heat Rejection
2.3.3.1 Radiators
The EETCS is configured with two deployable radiators, one trailing radiator on the aft
side of the P6 Long Spacer and one normal radiator on the starboard side (see
Figure 2-38). The radiators are mounted in fixed positions and do not rotate. They are
pointed in different directions to optimize heat rejection. Both EETCS ammonia loops
(A and B) flow through both radiators to maximize cooling and to provide redundancy.
The aft radiator is identified as the Trailing Thermal Control Radiator (TTCR); the
starboard radiator is identified as the Starboard Thermal Control Radiator (STCR).
1
13.6 m
2
3
4
5
Scissors beam 6
Flex hose between panels 7 3.12 m
Panel hinges
01.07.05(0)T0012_045
Figure 2-38. Early External Thermal Control System radiator
2-43
01.07.05(0)T0012
Basic
Purpose
The EETCS radiators reject waste heat to space via radiation, the transfer of thermal
energy by electromagnetic waves (see Appendix C).
Operations
The radiator functional schematic is shown in Figure 2-39.
Figure 2-39. EETCS Radiator functional schematic

Panels: Each radiator has seven panels hinged together and arranged in a folding
array. The radiator panels are constructed of aluminum. Each panel contains 24 flow
tubes, 12 of the tubes for Loop A and 12 tubes for Loop B. Flow tubes are connected
along the edge of each panel by manifolds. Flex hoses connect the manifold tubes
between panels. The loops flow through the radiators in parallel. Ammonia from Loop
A and Loop B both flow up the same side of the radiator, across the panel through
alternate flow tubes, and then return down the other side of the array. The EETCS
radiator panels are designed to be freeze-tolerant. The manifolds are not freeze
tolerant and are protected by allowing a small amount of ammonia to bypass the PFCS
(see Figure 2-35), thereby providing a continuous flow of ammonia through the
radiators.
Base Structure: The base structure provides the structural support for the
deploy/retract mechanism. The base structure also has fittings that allow the radiator to
be fastened to the P6 Long Spacer.
Deploy/retract mechanism: The deploy/retract mechanism is driven by a 120 V dc

brushless motor with a controller. The radiators can be commanded to deploy or
retract. Nominal radiator deployment takes from 5-6 minutes. Deployment and
retraction can be accomplished manually by an EVA crewmember in the event of a
motor failure or other anomaly. There are four basic configurations for the radiators. A
stowed radiator is retracted and cinched (see below). A retracted radiator is retracted
and uncinched. A radiator that is not fully retracted nor deployed is in transition, and a
deployed radiator is fully extended.
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01.07.05(0)T0012
Basic
Cinching/Winching Mechanism: Six cinches are used to hold each radiator ORU in
the stowed position to facilitate transportation, storage, alignment, and installation
(Figure 2-40). The deploy/retract mechanism is not capable of retracting the radiators
to the cinching position. A winch mechanism is used to tightly retract the radiators to
allow the attachment of cinch cables for stowage. The radiators must be uncinched in
preparation for deployment.
Fluid Quick Disconnect

Coupling (FQDC)
shown with
cover removed
Cinches (6)
shown in stowed position
Electrical connections (3)

to PFCS 01.07.05(0)T0012_047
Figure 2-40. EETCS radiator (stowed)

Radiator Accumulators: There are two accumulators within each radiator (one per
loop) located at the inlet. As with the PFCS and Z1 accumulators, the radiator
accumulators maintain the liquid state of ammonia, replace lost coolant, and absorb
fluctuations in fluid volume. Each radiator accumulator is of the same design as the
PFCS accumulators with the exception that only one quantity sensor is active. The
radiator accumulator quantity sensors were intended for use in the leak detection
software; however, due to a miswiring of the sensors, they have been “deselected” from
the software algorithm and are no longer being monitored for leaks.
Fluid Quick Disconnect Couplings: Radiator Fluid Quick Disconnect Couplings (FQDCs)
are exactly the same design and have the same function as the PFCS FQDCs.
Interfaces
CDH: The command and telemetry paths for the radiator components are shown in
Figure 2-41. All radiator commands are passed through the LDI in the PFCS. The
radiator telemetry is first sent to the SCI, where it is converted from analog to digital.
The digital data is then passed to the LDI en route to the Photovoltaic Controller Unit
(PVCU) MDM.
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01.07.05(0)T0012
Basic
PFCS Radiator
Accumulator quantity
Deployed limit switch
SCI Retracted limit switch
Power
Deploy/
LDI retract
Radiator commands actuator
Note:
Loop A PFCS is connected to the TTCR
Loop B PFCS is connected to the STCR
01.07.05(0)T0012_048
Figure 2-41. Radiator interfaces

EPS: Secondary power is supplied to the PFCS SCI, which distributes conditioned low-
voltage electrical power to the radiator deploy/retract mechanism.
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2.4 USOS ETCS FUNCTIONAL DESCRIPTION
The External Thermal Control System (ETCS) provides cooling to the entire United
States On-Orbit Segment (USOS) after Flight 12A.1. As shown in Figure 2-42, the
ETCS consists of two independent loops, designated Loop A and Loop B. The system
is designed to collect heat from the Internal Thermal Control Systems in the US Lab,
Node-2, COL, JEM, and Node-3, via IFHXs. The Pump Module (PM) provides the
motive force to transport the ammonia around the loop. Heat is rejected to the space
environment as each loop flows through a separate set of rotating radiator assemblies
mounted on the S1 (Loop A) and P1 (Loop B) truss segments. The heat rejection
capability is 35 kW per loop (70 kW total for the USOS).
2-47
Figure 2-42. External Thermal Control System
01.07.05(0)T0012
Basic
The majority of ETCS components are located on the S1 (Loop A) and P1 (Loop B)
truss segments (see Figure 2-43). ETCS fluid lines are routed from the various USOS
modules through the S0 Truss to the S1/P1 truss segments.
S3
S0
Fwd Radiator
Ammonia Tank Radiator

Assembly (ATA)
Radiator
Radiator Beam Valve

Nitrogen Tank Modules (RBVMs) (6)
Assembly (NTA)
Thermal Radiator
Rotary joint (TRRJ)
Pump Module (PM)
Note: Loop A components on the S1 Truss segment shown. Loop B

components on the P1 Truss segment are identical; however, the
orientation is reversed. All three radiators are retracted.
01.07.05(0)T0012_116
Figure 2-43. ETCS components
2.4.1 ETCS Heat Collection

When the ISS is fully assembled, the ETCS will collect heat from ten IFHXs mounted
on Node-2, the US Lab, and Node-3 as well as from coldplates located on the S0, S1,
and P1 truss segments. The coldplates provide cooling to external Electrical Power
System (EPS) equipment used to convert and distribute power to downstream ISS
loads.

The IFHXs provide the interface between a module’s internal TCS and the ETCS.
There are five IFHXs for each ETCS loop. Some IFHXs are plumbed in series such
that the cool ammonia flows through a module’s Low Temperature Loop (LTL) IFHX
prior to flowing though another module’s Moderate Temperature Loop (MTL) IFHX (see
Figure 2-42). All IFHX ORUs are mounted external to the pressurized modules as a
safety precaution due to the highly toxic nature of ammonia.
Purpose
The IFHXs transfer heat from the internal loops of the USOS modules to the ETCS
ammonia loops.
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Operations
The 10 ETCS IFHXs (Figure 2-44) are identical to the two US Lab IFHXs serviced by
the EETCS. See Section 2.3.1.1 for details on the IFHX components. The difference
between the early system and the permanent system is the permanent system IFHXs
are controlled by the S0 MDMs instead of the Node 1 MDMs.
Figure 2-44. Typical IFHX functional schematic

IFHX Core Isolation: Ammonia temperatures below 0° C (32° F) could freeze the
ITCS water in an IFHX. Since water expands when it freezes, this could cause the
ITCS lines to over-pressurize, and possibly burst. More serious would be water
freezing inside the core, rupturing the parting sheets and allowing ammonia to come in
contact with a module’s water. After thawing, water contaminated with ammonia would
be carried into the module. Several layers of protection are built into the ETCS
software to protect against this catastrophic hazard including.
a. PCVP Firmware - The Pump and Control Valve Package (PCVP) firmware will
command the pump speed to zero when any one of the three sensors located
within the PCVP indicates a temperature below 1.7° C. The firmware nominally
monitors all three sensors but can be commanded to monitor any single sensor if
needed. In addition, the firmware sets an undertemperature flag (PCVP Out Temp
Low), which triggers actions within the EXT MDM.
b. S1-1/P1-2 MDMs - The S1-1 (Loop A) and P1-2 (Loop B) MDMs monitor a sensor
located near the exit of the Pump Module and will unpower the entire PCVP if the
temperature falls below 1.1° C. In addition, the MDM will set an undertemperature
flag (PM Outlet Temp Low), which triggers actions within the EXT MDM.
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c. EXT MDM - The EXT MDM monitors for under-temperature flags set by the PCVP
firmware and the S1/P1 MDMs. Once a flag is set, the EXT MDM will send
commands to the S0-1 (Loop A) or S0-2 (Loop B) MDM to move IFHX bypass/
isolation valves on the affected loop to the bypass/close position. This is a
secondary response to the power removal actions taken by the S1/P1 MDM and
PCVP firmware.
d. S0 MDMs - The S0-1 (Loop A) and S0-2 (Loop B) MDMs monitor a separate sensor
located downstream of the pump for an ammonia temperature below 1.1° C. If the
condition is true, the S0 MDM will issue a command to unpower the entire S11A
(Loop A) or P12B (Loop B) power bus. This action will unpower all ETCS
components on the affected loop (Pump Module, Nitrogen Tank Assembly,
Ammonia Tank Assembly, Thermal Radiator Rotary Joint, etc.) as well as other
non-ETCS components such as heaters, cameras, and MDMs. In addition, the S0
MDM that detected the low temperature condition will command all IFHX bypass
valves in that loop to the bypass position.
Note: Responses A and B are the primary means of protecting the IFHXs.
Interfaces
CDH: The commands and telemetry for the IFHX ORUs associated with the ETCS are
routed through the S0 MDMs. The S0-1 MDM controls all Loop A IFHXs and the S0-2
MDM controls all Loop B IFHXs (see Figure 2-31). A separate ammonia temperature
located downstream of each PCVP (within each Pump Module) is tied to the S0-1 (Loop
A) or S0-2 (Loop B) MDM and is used to monitor for undertemperature conditions,
which would force the MDM to bypass the IFHXs.
EPS: Power for each Isolation and Bypass valve is supplied through a Solenoid Driver
Output (SDO) card in the S0-1 (Loop A) and S0-2 (Loop B) MDMs.
2.4.1.2 External Coldplate ORUs

There are five coldplate ORUs in each ETCS Loop that provide cooling to external EPS
equipment mounted on the S0, S1 (Loop A), and P1 (Loop B) truss segments (see
Figure 2-42). Loop A and Loop B each provide cooling to three DC to DC Converter
Units (DDCUs) and two Main Bus Switching Units (MBSUs). Figure 2-45 illustrates a
typical installation of a DDCU on its coldplate.
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01.07.05(0)T0012
Basic
Jackscrew and microhandle (2)
DDCU
Guide rail (4)
Coldplate
Support structure
(S0, S1, P1) Ammonia QDs (2)
Electrical connectors (2)
01.07.05(0)T0012_050
Figure 2-45. DDCU coldplate ORU installation
Purpose
The coldplate ORUs provide for the transfer of excess heat from external DDCUs and
MBSUs to the ammonia of the ETCS.
Note: Without cooling, the DDCUs and MBSUs on the affected loop will overheat in
about an hour. To prevent damage, up to four EPS power channels may have
to be shut down.
Operations
The primary components of each coldplate ORU include the coldplate, electrical and
fluid QD couplings, a flow control orifice, strip heaters, and a temperature sensor. A
metal frame provides structural mounting of the assembly to the truss by EVA-
compatible bolts. The entire assembly is referred to as an ORU since it is designed to
be replaceable by EVA or robotics.
Note: The DDCU/MBSUs are not part of the coldplate ORU.
Coldplate: The DDCU/MBSUs are attached to the coldplates by EVA/robotics-

compatible jackscrews. When the jackscrews are fully engaged, the fins of the
DDCU/MBSUs will be positioned adjacent to corresponding coldplate fins to facilitate
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01.07.05(0)T0012
Basic
heat transfer by radiation between the DDCU/MBSUs and the coldplates. Heat is
transferred by conduction to the ammonia lines.
Quick Disconnects: Fluid QDs are used to connect the coldplate ORU inlet and outlet
lines to the ETCS ammonia lines. The male half of each coupling is supplied as a part
of the coldplate ORU. Electrical QDs provide interfaces to the heaters (RPCM) and
temperature sensor (MDM). The QDs are EVA-compatible.
Flow Control Orifice: A flow control orifice is located in the ammonia inlet feed
between the inlet QD coupling and the coldplate. This orifice is designed to allow the
proper flow to the coldplate—approximately 57 kg/hr (125 lb/hr) for the DDCU
coldplates and approximately 36 kg/hr (80 lb/hr) for the MBSU coldplates.
Survival Strip Heaters: Strip heaters are used for extreme cold conditions. For each
DDCU coldplate there are two 40 W strip heaters and for each MBSU coldplate there
are three 40 W strip heaters attached to the external surface of the cold plate. The strip
heaters are wired in parallel to make up the total heater power of 80 W for DDCUs and
120 W for MBSUs. Each heater strip has an associated temperature sensor that is
monitored by an S0, S1 or P1 MDM.
Interfaces
CDH: The S0-2 and S1-2 MDMs monitor the temperature sensors for the Loop A
DDCUs/MBSUs located on the S0 and S1 truss segments. The S0-1 and P1-1 MDMs
monitor the temperature sensors for the Loop B DDCUs/MBSUs located on the S0 and
P1 truss segments. These MDMs send the temperature data to the C&C MDM where it
is then passed to the Power Management and Control Unit (PMCU) MDM. The PMCU
MDM contains the control algorithm used to determine when to turn these heaters
o o
on/off based on temperature setpoints (default -25 C/-20 C).
EPS: Table 2-2 shows the EPS interfaces to the S0, S1, and P1 coldplate heaters.
Table 2-2. Coldplate ORU Electrical Power Interfaces

Coldplate(s) Power source for strip heaters
S0: DDCU S01A, DDCU S04B RPCM S03A_E
S0: MBSU 1A/1B, MBSU 4A/4B RPCM S03A_F
S0: DDCU S02B, DDCU S03B RPCM S04B_E
S0: MBSU 2A/2B, MBSU 3A/3B RPCM S04B_E
S1: DDCU S14B RPCM S13A_G
P1: DDCU P13A RPCM P14B_G
2.4.2 ETCS Heat Transportation

The ETCS heat transportation components include the Pump Module (PM), which
provides the motive force to circulate the fluid, the Ammonia Tank Assembly (ATA),
which provides ammonia to fill the loops and maintain a minimum system pressure, and
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01.07.05(0)T0012
Basic
the Nitrogen Tank Assembly (NTA), which provides storage for the nitrogen used to
pressurize the ATA.
2.4.2.1 Pump Module

The primary ETCS heat transportation component is the Pump Module (PM)
(Figure 2-46). There are two PM ORUs, one located on the S1 (Loop A) Truss and the
other on the P1 (Loop B) Truss.
Ammonia
connections (4)
Accumulator
PCVP
Accumulator
heater strip
PM vent
Isolation valves (3)
Note: Enclosure removed for clarity.

01.07.05(0)T0012_078
Figure 2-46. Pump Module
Purpose
The Pump Module ORU circulates liquid ammonia at a constant flowrate to a network of
coldplates and heat exchangers located on the external trusses and USOS modules,
respectively.
Operations
The PM contains an accumulator, instrumentation, isolation and relief valves, various
heaters, and a Pump and Control Valve Package (PCVP). The PM functional
schematic is shown in Figure 2-47.
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01.07.05(0)T0012
Basic
Figure 2-47. ETCS PM functional schematic

Pump and Control Valve Package: Each PM contains a Pump and Control Valve
Package (PCVP). The PCVP is not an ORU, but is an integral part of the PM ORU.
The PCVP is responsible for regulating the flowrate, filtering impurities to protect loop
components, and for controlling temperature.
PCVP Pump: The PCVP contains a single pump with an integral filter that provides the
motive force for circulating the fluid. Each pump is capable of providing the required
system flowrate of 3700 kg/hr (8200 lb/hr) for Loop A, and 4000 kg/hr (8900 lb/hr) for
Loop B. Pump speed can be set between 11,250 and 18,000 rpm.
PCVP FCV: The PCVP contains a Flow Control Valve (FCV) for loop temperature
control. This temperature control is accomplished by mixing the warm ammonia, which
bypasses the radiators, with cool ammonia exiting the radiators to maintain the pump
outlet temperature. Closed-loop control may be inhibited and the FCV commanded
between -2 and +92 degrees. FCV position commands and telemetry are in degrees.
PCVP Firmware: Control of the pump and FCV is accomplished by the PCVP firm-
ware. The PCVP firmware also contains FDIR algorithms to protect the hardware and
provides command/telemetry communication with the S1 (Loop A) and P1 (Loop B)
MDMs.
Note: The default loop temperature setpoint in the PCVP firmware is 2.8 ± 1.1° C
(37° ± 2° F).
Accumulator: The accumulator resides upstream of the PCVP in each PM ORU. The
accumulator keeps the ammonia in the liquid phase by maintaining the pressure above
the vapor pressure of ammonia and provides makeup ammonia in case of a leak. The
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01.07.05(0)T0012
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accumulator works in conjunction with the ATA to absorb fluctuations in the fluid volume
due to varying heat loads through the expansion and contraction of its internal bellows.
Accumulator Heater - The PM accumulator is equipped with a dual-element survival
heater strip designed to maintain the PM above its minimum operating temperature.
The heater is wrapped around the accumulator (see Figures 2-46 and 2-47). Heater 1
is rated at 160 W, heater 2 is rated at 105 W. Each heater is controlled by a separate
temperature sensor (monitored by separate MDMs) mounted side by side, but not to
the accumulator itself. The sensors are mounted to the structure. This is important as
the temperature being displayed is not the accumulator temperature; rather, it is a
temperature of the PM ORU as a whole. This is because the heaters were not
specifically designed to heat the accumulator. The heaters act as survival heaters for
the entire PM ORU.
In-Line Heaters: Each PM is equipped with two 900 W heaters located on the bypass
line to ensure that there is a net positive heat load on the ETCS at low heat load or cold
startup conditions. The heaters are sized to increase the loop temperature to 2.2° C
(36° F). The in-line heaters are commanded on by software in the S1/P1 MDMs if the
FCV position is 1 degree or less; and are commanded off if the FCV position is
3 degrees or more.
Isolation and Relief valves: There are a total of five isolation and relief valves within
each PM ORU: an Accumulator Fill and Vent valve, a Pump Outlet Isolation valve, a
Radiator Bypass Isolation valve, a Radiator Return Isolation valve, and an Ammonia
Tank Inlet Isolation valve. The Accumulator Fill and Vent valve is used for manual
ground filling and venting of the nitrogen to the PM accumulator. The Pump Outlet,
Radiator Bypass, and Radiator Return isolation valves isolate the PM outlet port, the
radiator bypass port, and the radiator return port, respectively, from the rest of the
system. The Ammonia Tank Inlet Isolation valve isolates the ammonia tank supply
from the rest of the system and provides over pressure relief of the system from both
sides. The response time of each valve for a change of position from close to open and
from open to close is 5-11 seconds. Each valve has an open and close position
indicator.
Instrumentation: There are 12 temperature sensors, 5 pressure sensors, and 2
flowmeters in each PM. These sensors provide insight into how the PM is operating.
The flowmeters provide insight into the ammonia bypass flow around the radiators as
well as the total pump outlet flow to the system. Each sensor receives power via a Low
Level Analog (LLA) card within its respective MDM.
Interfaces
CDH: All commands and telemetry associated with the PM are routed through the S1-1
(Loop A) and P1-2 (Loop B) MDMs with two exceptions. First, a single temperature
sensor located just downstream of the PCVP is monitored by the S0-1 (Loop A) and
S0-2 (Loop B) MDM for undertemperature conditions. Second, the redundant
accumulator heater strip and associated temperature sensor are controlled by the S1-2
(Loop A) and P1-1 (Loop B) MDM. The CDH interfaces with the PM are shown in
Figure 2-48.
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01.07.05(0)T0012
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Loop A S1-1
Loop B P1-2
120 V dc power Loop A RPCM S14A_G
PM
MIL-STD-1553
Loop A S0-1 In-line heaters Loop B RPCM P13B_G
Loop B S0-2
120 V dc power Loop A RPCM S12A_A
PCVP Out Accum heater 1 Loop B RPCM P11B_A
Temp
Accum heater 2, Loop B RPCM P12B_A
Valve (4) commands
byp FM
Valve (4) position
120 V dc power Loop A RPCM S11A_C
Temperature sensors (7)* Out FM/temp Loop B RPCM P12B_A
Pressure sensors (5)
Flowmeters (2)
PCVP telemetry (speed, 120 V dc power Loop A RPCM S11A_D

temperature (4), FCV posn, etc) Loop B RPCM P12B_D
PCVP
PCVP commands (FCV, pump, Ammonia
ATA
sensor select, etc.) 0-390 psia
*Note: One of the Accumulator heater RTDs is connected

to the S1-2/P1-1 MDM for redundancy.
01.07.05(0)T0012_053
Figure 2-48. PM interfaces

All commands to the pump and FCV pass from the S1-1/P1-2 MDMs to the PCVP
firmware controller. In addition to processing commands, the PCVP firmware controller
processes and packages the telemetry to be sent to the S1-1/P1-2 MDMs. Commands
and telemetry use a MIL-STD-1553 interface.
Note: The S1-2 and P1-1 MDMs do not have control over the PM ORU components,
with the exception of one redundant heater; however, they can be configured to
communicate with the PCVP firmware in a contingency situation.
EPS: Figure 2-48 illustrates the power connectivity for Loop A and Loop B PM ORU
components.
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2.4.2.2 Ammonia Tank Assembly
There are two ATA ORUs, one located on the S1 (Loop A) Truss and the other on the
P1 (Loop B) Truss. The ATA is shown in Figure 2-49.
Ammonia
tanks
Isolation
and vent
valves (3)
Pressure
sensors (4)
ECU
(3)
Ammonia
Nitrogen QDs (2) QDs (2)
(from NTA)

01.07.05(0)T0012_054
Figure 2-49. Ammonia Tank Assembly
Purpose
The primary function of the ATA is to contain the liquid ammonia used by each ETCS
loop. The ATA stores liquid ammonia for transport between the ground and orbit. This
ammonia is used to fill the ETCS loop at startup and supply makeup fluid to the loop
during nominal operations. The ATA also acts in concert with the PM accumulator for
ammonia inventory management, and provides the capability to vent the PM and ATA
by connection to an external nonpropulsive vent. If required, the ammonia in the ATA
can be used to replenish the Photovoltaic Thermal Control System (PVTCS) fluid lines.
Operations
The ATA contains two tanks, two isolation valves, one vent valve, heaters, and
instrumentation. Multilayer Insulation (MLI) applied to the exterior surfaces of the ORU
is provided to guard against excessive heat loss. The ORU is protected against Micro-
Meteoroid/Orbital Debris (MM/OD) by shielding on the exterior of each tank and the
ORU itself. The ATA functional schematic is shown in Figure 2-50.
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To PM To vent
panel
Vent
valve
Nitrogen from NTA
Isolation
valves
Nitrogen from NTA
01.07.05(0)T0012_038
Figure 2-50. Ammonia Tank Assembly functional schematic

Ammonia Tanks: The ammonia tanks provide the storage volume for the liquid
ammonia. Each ammonia tank consists of a storage (pressure) vessel, collapsible
metal bellows, a quantity sensor, four mounting flanges, and MM/OD shielding. The
ammonia is located external to the metallic bellows while the pressurized gaseous
nitrogen is contained within the bellows along with the quantity sensor. The gaseous
nitrogen supplied to each tank is regulated to provide the appropriate pressure
differential to drive the ammonia out of the tank or to draw the ammonia into the tank.
The useable capacity of each ammonia tank is 135 kg (298 lbm). The capability to
monitor pressure, temperature, and quantity in the ammonia tanks during ground fill
and on orbit operations is provided.
Isolation Valves: The isolation valves accommodate bi-directional flow, and are
utilized to isolate and permit transfer of liquid ammonia to and from the ammonia tanks.
Each valve consists of a ball valve with a remotely activated electric stepper motor. An
Electronic Control Unit (ECU) along with a power and instrumentation cable control the
movement of each valve. The response time of the valve for a change of position from
close to open is 60 ± 10 seconds and from open to close within 5 to 11 seconds. Each
valve has an open and close position indicator.
Vent Valve: The ATA has no ORU-specific pressure relief capability. It relies on relief
valves within the PM (ammonia side) and in the NTA (nitrogen side) for pressure relief.
The ATA does, however, have a vent valve. This valve, nominally closed, allows
ammonia to be directed to a vent panel on the S1/P1 truss. This vent panel allows
ammonia to be vented (nonpropulsively) from the ETCS to space and provides a
connection to the PVTCS. The vent valve is identical in construction to the ATA
isolation valves.
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Heaters: Each ammonia tank is equipped with a dual-element survival heater strip
designed to maintain the ATA ORU above its minimum operating temperature. The
individual heaters are 53 W each in series, 106 W total. The heater strip is wrapped
around the base of the ammonia tank as seen in Figure 2-51.
Figure 2-51. ATA Heaters

The ammonia tank heaters consist of two groups, Group 1 and Group 2. Each group
contains one of the two heaters in each element. This is done so that loss of a single
power bus does not prevent a tank from having a heater. Temperature sensors for
monitoring of baseplate temperature are also provided via MDM interfaces. The
temperature sensors are attached to the ORU structure and not the ammonia tanks.
This is because the heaters are designed as ORU survival heaters similar to the PM
ORU heaters.
Instrumentation: Each tank is equipped with a quantity sensor that measures the
quantity of ammonia in percent, an absolute pressure sensor that measures the
pressure within each tank, a 3 sensor that measures the difference between the
nitrogen inlet pressure and the ammonia outlet pressure, and an outlet temperature
sensor that monitors the temperature of the ammonia as it exits the tanks. Each sensor
receives power via a LLA card within its respective MDM.
Interfaces
CDH: The ATA interfaces with the S1-1 (Loop A) and P1-2 (Loop B) MDMs for all
commands and telemetry, with the exception of the redundant heater elements and
sensors that are controlled by the S1-2 (Loop A) and P1-1 (Loop B) MDMs. The CDH
interfaces with the ATA are shown in Figure 2-52.
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Loop A S1-1
Loop B P1-2
ATA 120 V dc power Loop A RPCM S11A_A

Valve (3) commands Group 1 heaters Loop B RPCM P12B_A
Valve (3) position
120 V dc power Loop A RPCM S12B_A
Temperature sensors (4)* Group 2 heaters Loop B RPCM P11A_A
Pressure sensors (2)
Delta pressure sensors (2)
Quantity sensors (2)
Ammonia
PM 0-390 psia
Nitrogen
NTA
0-390 psia
Vent Ammonia
panel 0-390 psia
*Note: One of the Accumulator heater RTDs is connected

01.07.05(0)T0012_056
Figure 2-52. ATA interfaces

EPS: The Loop A ATA receives power for all of its components through the S11A
power bus, with the exception of the redundant heater elements that receive power
from the S12B power bus. The Loop B ATA receives power for all of its components
through the P12B power bus, with the exception of the redundant heater elements that
receive power from the P11A power bus.
2.4.2.3 Nitrogen Tank Assembly

The NTA provides storage for the nitrogen used to pressurize the ammonia tanks within
the ATA. There are two NTA ORUs, one located on the S1 (Loop A) Truss and the
other on the P1 (Loop B) Truss. The NTA is shown in Figure 2-53.
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Connections
to ATA (2)
Nitrogen tank
Isolation valves
Nonpropulsive vent
GPRV

01.07.05(0)T0012_057
Figure 2-53. Nitrogen Tank Assembly
Purpose
The NTA stores high-pressure nitrogen gas used to pressurize the ATA, thus providing
pressurization of each loop. Additionally, it has the capability to isolate and vent the
nitrogen as well as regulate the nitrogen supply pressure. The NTA is capable of
expelling up to 270 kg (596 lb) of ammonia from the ATA as well as expelling its entire
nitrogen source through a nonpropulsive vent.
Operations
The NTA contains a single nitrogen tank, a Gas Pressure Regulator Valve (GPRV)
assembly, two isolation valves, a ground fill valve, a nonpropulsive vent, heaters, and
instrumentation. The NTA functional schematic is shown in Figure 2-54.
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Nitrogen out to ATA
Nitrogen out to ATA
Nonpropulsive vent
01.07.05(0)T0012_080
Figure 2-54. NTA functional schematic

Nitrogen Tank: The nitrogen tank provides the storage volume for the gaseous
nitrogen. The useable capacity of each nitrogen tank is 25 kg (55 lbm) at a maximum
pressure of 20684 kPa (3000 psia) at 60° C (140° F).
Gas Pressure Regulator Valve (GPRV) Assembly - The GPRV assembly provides
the pressure control function as well as nitrogen isolation and overpressure protection
of downstream components. The GPRV assembly consists of a latching solenoid
isolation valve, a fixed pressure regulator, a resettable (or commandable) pressure
regulator, a relief valve and a pressure sensor (see Figure 2-55). The isolation valve
allows for the nitrogen tank to be isolated from the rest of the system. The fixed
pressure regulator steps down the high-pressure nitrogen from the storage tank. The
resettable (commandable) pressure regulator further steps down the pressure to an
electronically adjustable setpoint (0 to 2690 kPa (0 to 390 psia). A relief valve provides
overpressure protection for the tube from the regulator to the NTA outlet and for the
nitrogen side of the ATA. The GPRV outlet pressure sensor is nominally used to
measure the final regulated nitrogen pressure of the GPRV and is used to control the
movement of the GPRV resettable valve. If the GPRV outlet pressure sensor is biased
or failed, any pressure sensor in the ATA or PM can be used.
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GPRV commanded valve
Nitrogen out
(to isolation valves) Resettable
regulator
Electronics control unit
GPRV outlet pressure sensor
Nitrogen out
(to isolation valves)
Fixed regulator
Relief
valve
Nitrogen supply valve
Nitrogen in
(from tank)
Nonpropulsive vent
01.07.05(0)T0012_058
Figure 2-55. NTA Gas Pressure Regulator Valve Assembly

Isolation Valves: The NTA outlet isolation valves allow the nitrogen feeds to the ATA
to be isolated from the rest of the system. The valves are identical to those used in the
PM and ATA ORUs. The response time of each valve for a change of position from
close to open and from open to close is 5-11 seconds. Each valve has an open and
close position indicator.
Ground (Manual) Fill Valve: The ground fill valve is a manually operated valve used
to fill the nitrogen tank while on the ground. It has redundant pressure caps to provide
three verifiable seals against leakage.
Nonpropulsive Vent Valve: The nonpropulsive vent allows nitrogen to escape to

space at a flowrate of 34 kg/hr (75 lbm/hr).
Heaters: The NTA has dual-element heater patches designed to maintain the whole
ORU above the minimum temperature requirements. One heater patch (31 W) is
attached to the structure near the tank and the other heater patch (15 W) is attached to
the GPRV (see Figure 2-56). A heater group consists of one patch element wired in
series with the other patch element for a total heater power of 46 W. This way, only
one power bus is needed to apply power to an element in each heater group.
Base survival heater
GPRV survival heater
01.07.05(0)T0012_059
Figure 2-56. NTA Heater Patches
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Instrumentation: The NTA is equipped with an absolute pressure sensor that
measures the nitrogen pressure between the nitrogen tank and the GPRV nitrogen
supply valve, and an outlet temperature sensor that monitors the temperature of the
nitrogen as it exits the tanks. Each sensor receives power via a LLA card within its
respective MDM.
Interfaces
CDH: The NTA interfaces with the S1-1 (Loop A) and P1-2 (Loop B) MDMs for all
commands and telemetry, with the exception of the redundant heater elements and
associated sensors that are controlled by the S1-2 (Loop A) and P1-1 (Loop B) MDMs.
The CDH interfaces with the NTA are shown in Figure 2-57.
Loop A S1-1
Loop B P1-2
NTA 120 V dc power Loop A RPCM S12B_A

Isol valve (2) commands Group 1 heaters Loop B RPCM P11A_A
Isol valve (2) position
GPRV commands Group 2 heaters Loop B RPCM P12B_A
(open, close, setpoint)
GPRV telemetry
(position, pressure)
Temperature sensors (3)*
Outlet pressure
ATA Nitrogen
0-390 psia
*Note: One of the NTA heater RTDs is connected

01.07.05(0)T0012_060
Figure 2-57. NTA interfaces

EPS: The Loop A NTA receives power for all of its components through the S11A
power bus, with the exception of the redundant heater elements, which receive power
from the S12B power bus. The Loop B NTA receives power for all of its components
through the P12B power bus, with the exception of the redundant heater elements,
which receive power from the P11A power bus.
2.4.3 ETCS Heat Rejection

Heat rejection for the ETCS is accomplished by two rotating radiator wing assemblies
on the S1 (Loop A) and P1 (Loop B) truss segments. The Radiator ORUs reject excess
heat to the surrounding space environment. The Radiator Beam Valve Modules
(RBVMs) control the flow of fluid to and from the radiator panels, and the Thermal
Radiator Rotary Joint (TRRJ) provides structural support as well as the ability to rotate
the radiators to optimize the overall heat rejection.
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2.4.3.1 Radiators
The primary heat rejection component for each loop is the radiator wing assembly
(Figure 2-58). Each radiator wing consists of three separate Radiator ORUs.
Radiator ORU (8 panels)
Radiator beam
Note: All three radiators shown deployed. 01.07.05(0)T0012_070
Figure 2-58. ETCS radiator wing assembly
Purpose
The ETCS radiators reject heat to space via radiation, the transfer of thermal energy by
electromagnetic waves (see Appendix C).
Operations
Each radiator ORU is composed of panels, flex hoses, squib fire units, deployment
scissor beams and hinges, and an Integrated Motor Controller Assembly (IMCA).
Panels: Each radiator ORU has eight panels hinged together and arranged in a folding
array. Flow is split into two separate flow paths prior to entering the radiator panels
(see Figure 2-59). Each panel contains 22 Inconel flow tubes or passages
(11 passages per flow path). Flow tubes are connected along the edge of each panel
by manifolds. Flex hoses connect the manifold tubes between panels. The ETCS
radiator panels are designed to operate with partial freezing during periods of low heat
loads or off-nominal environmental conditions.
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Figure 2-59. Radiator ORU functional schematic

Squib Fire Units: The SFUs are used to release the cinch mechanisms that hold the
radiator ORU in place. The cinches must be released prior to deployment of a radiator.
These SFUs release the cinches upon command. If there is a problem with an SFU, a
manual EVA override can be used to uncinch the radiator.
Integrated Motor Controller Assemblies: Each radiator ORU has one IMCA used to
control its deployment and retraction. The IMCA consists of a motor and controller. Its
output shaft drives a series of cables and pulleys used to deploy or retract the radiator.
A gear/clutch assembly in the IMCA reduces motor power and prevents back driving.
Deployment is only allowed if no other Radiator ORU IMCA is powered, if the deployed
limit switch indicates false, and if the radiator cinches have been released (squibs fired).
Heaters: Several heaters are installed to prevent stagnant ammonia from freezing and
to keep the electronics above their minimum operating temperatures. Primary and
backup heaters are located on the IMCA and are also wrapped around the flex hoses
connecting the radiator to the RBVM.
Interfaces
CDH: All commands and telemetry to/from the radiators is via the STR (Loop A) and
PTR (Loop B) MDMs. The CDH interfaces with one radiator ORU are shown in
Figure 2-60.
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01.07.05(0)T0012
Basic
Loop A STR Radiator

120 V dc power Loop A RPCM S12B_B
Loop B PTR Loop B RPCM P11A_B
Rad ORU pri htrs
MIL-STD-1553 Temperature 120 V dc power

Rad ORU sec htrs Loop A RPCM S11A_C
Loop B RPCM P12B_C
SFU power* SFU power*
SFU Radiator beam
Radiator beam fluid line
fluid line heaters*
heaters*
IMCA power
IMCA
IMCA commands
(deploy retract) Ammonia RBVM
IMCA telemetry 0-390 psia
(position, status)
*Note: Launch configuration shown. After SFU firing,

connectors are moved to power heaters. 01.07.05(0)T0012_063
Figure 2-60. Radiator ORU interfaces

EPS: Secondary power is supplied to the IMCA motor and the SFUs via SDO cards in
the STR (Loop A) and PTR (Loop B) MDMs.
2.4.3.2 Radiator Beam Valve Modules (RBVMs)

For each radiator ORU, there are two RBVMs (one per flow path) that allow or prevent
the transfer of ammonia to/from the radiator panels. Figure 2-61 shows the physical
locations of the six RBVMs on the radiator beam.
RBVMs
01.07.05(0)T0012_064
Figure 2-61. Radiator Beam Valve Modules
Purpose
The RBVMs provide remotely controlled isolation and overpressure relief of the radiator
ORU as well as the fluid supply and return lines. The RBVMs are instrumented to
monitor radiator return line pressure and temperature as well as the temperature of the
surrounding environment.
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Operations
Each RBVM consists of an isolation/vent valve, an isolation valve, two relief valves, an
IMCA, instrumentation, and QDs. An RBVM functional schematic is shown in
Figure 2-62.
Figure 2-62. RBVM functional schematic

Isolation/Vent Valves: Each RBVM has a supply line isolation/vent valve and a return
line isolation valve. Both valves are linked and driven by the IMCA—they cannot move
in different directions. The supply line isolation/vent valve is connected to a vent line
that allows the entire ammonia volume of one radiator flowpath to be vented to space in
a contingency or radiator replacement situation.
Relief Valves: Each RBVM has two relief valves—a bypass relief valve and a vent
relief valve. The bypass relief valve provides overpressure protection of the radiator in
the event it is isolated (both isolation valves in the closed position). It is in parallel with
the return line isolation valve. Should the radiator be overpressurized, ammonia will be
relieved from the radiator to the ETCS. No loss of ammonia will occur. The vent relief
valve provides overpressure protection of the RBVM and/or the ETCS. Should
pressure rise above the relief setpoint (3240.5 kPa (470 psia)), this valve will relieve
ammonia overboard via a nonpropulsive vent.
IMCA: The IMCA consists of a motor and controller. Its output shaft drives the RBVM
valves. The IMCA accepts commands from the MDM and the motor/gearbox is used to
move the RBVM valves to one of the following three positions:
a. Open - Both the Isolation/Vent Valve (Supply) and Isolation Valve (Return) are
open allowing the free flow of ammonia.
b. Closed - Both the Isolation/Vent Valve (Supply) and Isolation Valve (Return) are
closed isolating the radiator from the ETCS.
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c. Vent - The Isolation/Vent Valve (Supply) vents the radiator side to space. The
Isolation Valve (Return) remains closed to ensure that only the radiator is vented.
Instrumentation: Instrumentation within the RBVMs provides insight into the absolute
pressure and temperature of the ammonia in the return line as well as the temperature
of the radiator environment.
Three Limit Switches provide discrete valve positioning as shown in Table 2-3.
Table 2-3. RBVM limit switch position vs. valve configuration

CW valve travel Limit switches
RBVM configuration
from OPEN 1 2 3
OPEN Return Iso Valve Open
– Closed Open Open
Supply Iso/Vent Vlv Open
CLOSED Return Iso Valve Closed
65 deg Open Closed Open
Supply Iso/Vent Vlv Closed
VENT Return Iso Valve Closed
130 deg Open Open Closed
Supply Iso/Vent Vlv Vent
The limit switches are only mounted on the Return Isolation Valve. Should a gear drive
failure occur, discrete valve indication for the Supply Isolation/Valve might be suspect.
Heaters: Heaters provide protection from undertemperature conditions. Each RBVM

utilizes two sets of heaters. One heater is used to heat the IMCA. The other set
consists of 10 heaters, one per isolation valve and two per QD. The QDs must be
maintained above -62.2° C (-80° F). The heater elements are thermostatically
o o
controlled to on/off setpoints (IMCA heater: -56.7 C/-52.8 C, QD heaters:
o o
-41.1 C/-37.2 C). Power to the thermostats is supplied through a single RPC, which
feeds an SDO card in the STR (PTR) MDM.
Interfaces
CDH: All commands and telemetry to/from the RBVMs is via the STR (Loop A) and
PTR (Loop B) MDMs. The CDH interfaces with an RBVM are shown in Figure 2-63.
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Loop A STR
Loop B PTR
RBVM 120 V dc power Loop A RPCM S11A_C

Temperature Heaters Loop B RPCM P12B_C
Environment temperature
Pressure
IMCA power
IMCA commands IMCA
Open, Close, Vent
IMCA telemetry
Position, status
Ammonia
TRRJ
Ammonia 0-390 psia
Radiator 0-390 psia
01.07.05(0)T0012_065
Figure 2-63. RBVM interfaces

EPS: Secondary power is supplied to each RBVM IMCA motor and heaters via SDO
cards in the STR (Loop A) and PTR (Loop B) MDMs.
2.4.3.3 Thermal Radiator Rotary Joint (TRRJ)

The TRRJ (Figure 2-64) provides controlled rotation of the ETCS radiators, allows the
transfer of power, data, and ammonia across the rotating interface, and provides the
structural support between the S1/P1 truss segments and the associated radiator wing
assembly.
Torque box (structurally connected to
radiator beam)
Drive Lock Assembly

(DLA) (2)
Bearing assembly
Flex Hose Rotary

Coupler (FHRC)
Note: RJMC-1 and -2 not shown. 01.07.05(0)T0012_066
Figure 2-64. Thermal Radiator Rotary Joint (TRRJ)
Purpose
The TRRJ is capable of rotating within a ±105-degree operational range (±115 degrees
hardware limit) while transferring liquid ammonia to and from the radiators at a rate of
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01.07.05(0)T0012
Basic
3675 kg/hr (8100 lb/hr). The ability to rotate the radiators means the ETCS is able to
maintain the radiator outlet temperature within a range that maximizes heat rejection
while at the same time prevents freezing of the ammonia within the Radiator ORUs.
Operations
Each TRRJ is composed of a bearing assembly, a Flex Hose Rotary Coupler/Power
and Data Transfer Assembly (FHRC/PDTA), two Drive Lock Assemblies (DLAs), two
Rotary Joint Motor Controllers (RJMCs), heaters, and cable harness that provides
instrumentation and connectivity between the DLAs and RJMCs. Figure 2-65 shows a
schematic of the TRRJ.
To From
RBVMs RBVMs
Ammonia in
(from heat loads) DLA 2 SM SM DLA 1
T TM TM T
T T
RJMC 2 RJMC 1
T TRRJ T
Ammonia out
T TRRJ Cradle (to PM)
Acronyms
DLA - Drive Lock Assembly
PM - Pump Module
RBVM - Radiator Beam Valve Module
RJMC - Rotary Joint Motor Controller
SM - Stepper Motor
TM - Torque Motor
TRRJ - Thermal Radaitor Rotary Joint
01.07.05(0)T0012_068
Figure 2-65. TRRJ Functional Schematic

Bearing Assembly: The bearing assembly provides the rotary interface and structural
support to the TRRJ and radiator wing assembly.
Flex Hose Rotary Coupler/Power Data Transfer Assembly (FHRC/PDTA): The

FHRC/PDTA provides two discrete isolatable flow paths for the liquid ammonia as well
as secondary power and data transfer across the rotary interface. The PDTA also has
two joint resolvers (one for each “string”) that provide TRRJ angular position.
Drive Lock Assembly (DLA): Each TRRJ has two redundant DLAs controlled by
separate MDMs. Each DLA contains a torque motor (rotates the radiator beam), a
stepper motor (used to put the DLA in lock, neutral or engage), a locking assembly, a
motor resolver, and a gearbox. For nominal TRRJ rotation, one DLA must be engaged
and the other in neutral. The DLA locked position prevents rotation of the TRRJ during
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Basic
EVA operations or during certain on-orbit conditions. The gearbox provides the drive
torque to the rotary joint and the motor resolver provides the rate of the output gear.
Rotary Joint Motor Controller: There are two RJMCs per TRRJ that provide the
interface between the MDM and the DLAs. The RJMCs are nonprogrammable
firmware controllers located near the TRRJ. Each RJMC drives the DLA motors and
monitors the resulting motion. Each MDM/RJMC/DLA set is called a “string” (two
strings per TRRJ). Software only allows commanding on the string selected as the
“command path;” however, monitoring both strings is allowed via redundant
instrumentation. The RJMC can only control the torque motor on its own string, but can
drive either DLA stepper motor through a redundant control path.
Heaters: Each RJMC has two 77W redundant heaters and each DLA has one 39W
heater on its stepper motor windings used to prevent damage to the hardware during
non-operational or extreme cold conditions. Each heater is controlled to default on/off
setpoints (-40o C/-37.2o C) by separate MDMs for redundancy. In addition to the RJMC
and DLA heaters, the TRRJ cradle (structural support) has four 79 W heaters wired in
parallel (total heater power 316 W) that are controlled via a single MDM interface to
default on/off setpoints (-9.4o C/-6.67o C).
Interfaces
CDH communicates directly with the RJMCs within each TRRJ. Redundant heaters for
each RJMC as well as a DLA heater and cradle heater are also directly controlled via
an MDM interface. The TRRJ is the only ORU in the ETCS that can be monitored and
controlled by redundant MDMs. Figure 2-66 and Table 2-4 summarize the CDH and
EPS connectivity for each TRRJ component.
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Loop A S1-1 TRRJ

Loop B P1-2
RS-485 Telemetry
120 V dc power Loop A RPCM S11A_C
120 V dc power Heaters Loop B RPCM P11A_B
Motor/heaters
RJMC-1
Commands
RJMC-1
telemetry DLA-1
120 V dc power Loop A RPCM S12B_B
Heaters Loop B RPCM P12B_C
Loop A S1-2
Loop B P1-1
RJMC-2
RS-485
Telemetry
Commands DLA-2
RJMC-2
telemetry
120 V dc power
Motor/heaters
MIL-STD-1553 bus from/to EXT MDM MIL-STD-1553 bus from/to STR(PTR) MDM
120 V dc MDM/heater power PDTA 120 V dc MDM/heater power
System Ammonia 0-390 psia Ammonia 0-390 psia

FHRC RBVMs
(PM, heat loads)
01. 07.05(0)T0012_069
Figure 2-66. TRRJ interfaces
Table 2-4. TRRJ EPS/CDH connectivity

TRRJ components Loop A Loop B
RJMC 1 Power Bus S11A Power Bus P12B
RJMC 1 Heater 1 S1-1 MDM P1-2 MDM
DLA 1 Heater
Cradle Heater
RJMC 2 Power Bus S12B Power Bus P11A
RJMC 2 Heater 1 S1-2 MDM P1-1 MDM
DLA 2 Heater
RJMC 1 Heater 2 Power Bus S11A Power Bus P12B
S1-2 MDM P1-1 MDM
RJMC 2 Heater 2 Power Bus S12B Power Bus P11A
S1-1 MDM P1-2 MDM
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2.5 USOS TCS SOFTWARE OVERVIEW

This section contains an overview of TCS software in the USOS.
2.5.1 Purpose
TCS software provides information on the state of the system and allows control of
system startup, loop reconfigurations, pump speed, valve positions, etc. Failure
Detection, Isolation, and Recovery (FDIR) software monitors the performance of the
TCS. If there is a problem, FDIR detects out-of-limit conditions, sets a flag that notifies
the C&C MDM of a C&W event, and (in some cases) initiates recovery actions.
2.5.2 TCS Software Architecture

Figure 2-67 shows how USOS TCS software is organized through Flight 12A.1, when
the US Lab ITCS interfaces with the Early External Thermal Control System (EETCS).
Tier 1 MDMs (Control)
z Ground workstations C&C-1, 2, 3
z Crew laptops
Tier 2 MDMs (Local)

z FDIR software
z System control software INT-1, 2 N1-1, 2
PFMC IFHX Heaters
Tier 3 MDMs (User)

z Interface with
LA-1, 2, 3 PVCU-2B, 4B
individual ORUs
Valves, heaters, etc. Sensors PFCS Heaters
Legend
Commands Radiators Sensors
Data
01.07.05( 0) T0012_005
Figure 2-67. USOS TCS software architecture (Flights 5A through 12A.1)

Once the permanent ETCS system is installed and activated on Flight 12A.1, the
US Lab ITCS interface heat exchangers are reconfigured to interface with the ETCS
fluid lines and additional MDMs begin to control the components within the TCS.
Figure 2-68 shows the TCS software architecture from the time the ETCS is activated
through assembly complete.
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Tier 1 MDMs (Control)
z Ground workstations C&C-1, 2, 3
z Crew laptops
Tier 2 MDMs (Local)

z FDIR software
z System control software INT-1, 2 EXT-1, 2
PFMC
Tier 3 MDMs (User)

z Interface with
LA-1, 2, 3 S0-1, 2 STR/PTR
individual ORUs
Valves, heaters, etc. Sensors IFHXs, heaters Sensors Radiators, RBVMs Sensors
S1-1, P1-2 S1-2, P1-1
Legend
Commands
Data TRRJ PM ATA NIA Heaters Sensors TRRJ Heaters Sensors
01.07.05(0)T0012_006
Figure 2-68. USOS TCS Software Architecture (Flight 12A.1+)
2.5.3 C&C MDM Software

Commands from ground workstations, crew laptops, and the C&C MDM software are
passed from the C&C MDM to the active INT MDM for ITCS components, to the primary
N1 MDM for EETCS components, and to the active EXT MDM for ETCS components.
The Command and Control Software (CCS) responds to TCS failures and hazardous
conditions through its Thermal Safing algorithm that performs the following safing
functions:
a. Loop Load Reduction (initiates ITCS reconfiguration actions and reduces heat
loads on failed loops or loops with diminished heat rejection capacity)
b. IFHX Leak Response (bypasses/isolates the IFHXs from the EETCS/ETCS

ammonia loops)
In addition to these safing functions, the C&C MDM provides the interface between the
Guidance and Navigation Control (GNC) MDMs and the EXT MDMs once the ETCS is
activated. The GNC MDM generates pointing data that is passed through the C&C
MDM to the EXT MDM and used to determine the optimal position for the ETCS
radiators.
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2.5.4 US Lab ITCS Software
2.5.4.1 INT SYS MDM Software (INT MDMs)

There are two redundant INT MDMs—one is active while the other is standing by
(unpowered) to take over, if necessary. Software within the INT MDM processes
commands from the C&C MDM, executes algorithms, provides FDIR and associated
C&W messages, and generates commands to the LAB SYS (LA) MDMs and the
Pump/Fan Motor Controllers (PFMCs). In addition to passing commands and data
to/from the upper and lower tiered MDMs, the INT MDM software performs the following
five important functions for the ITCS:
System Control - This function can be divided into two separate categories:
a. Startup - The Startup command initiates the execution of a software algorithm that
issues all commands necessary to take the ITCS from a nonoperational state to a
fully operational system running in a specified mode (see Table 2-5). The US Lab
ITCS Startup algorithm can be initiated only by a command.
b. Mode Transitions - A Mode transition command initiates the execution of a software
algorithm that issues all commands necessary to reconfigure the system from one
mode into another mode. Crew, controllers, or FDIR software can request
automatic mode transitions. The mode transition algorithm, however, will be
executed only after the Startup command has successfully completed its initial
configuration of the system.
Table 2-5. ITCS operational modes

Mode Description
Dual Separate loops – Both pumps operating. Preferred nominal mode
Sngl LT Joined loops – LTL pump operating. Operationally, this mode occurs if there is a
problem with the MTL pump
Sngl MT Joined loops – MTL pump operating. Operationally, this mode occurs if there is a
problem with the LTL pump
Dual LT Fail Separate loops – LTL pump is OFF and LTL loop is considered “Failed.” Operationally,
this mode occurs if there is a leak in the LTL
Dual MT Fail Separate loops – MTL pump is OFF and MTL loop is considered “Failed.”
Operationally, this mode occurs if there is a leak in the MTL
Failure Recovery: Continuously monitors the pumps, SFCA shutoff valves, and LCA
valves for failures during startup, stable operations, and mode transitions. Valve
failures will only be detected if a valve is commanded and then fails to move to the new
position. In the event of a pump or valve failure, the Failure Recovery software will
request mode transitions or perform pump retry algorithms based on the type of failure
detected and the state of the system at the time the failure occurred. Failure Recovery
also protects the SFCA P sensor in each loop.
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Leak Recovery: Monitors the PPA accumulator quantities for rapid decreases. If a
leak is detected, the Leak Recovery software isolates the leak to the loop level, shuts
down the PPA in the leaking loop, and removes the nitrogen pressure from the
associated accumulator. Leak Recovery software then inhibits the Failure Recovery
software from transitioning the loops to single-loop mode in the event of subsequent
failures. Leak Recovery software is automatically inhibited during US Lab ITCS Startup
in order to prevent volumetric shifts from activating the leak response software.
Passive TCS Control: Utilizes temperature data to control the heater systems located
on the PMA-2 shell, APAS, Node 2 shell, LTL IFHX, and MTL IFHX. Software performs
closed-loop control of the heaters to maintain temperatures between upper and lower
limits. The software also performs day/night cyclic load management of the US Lab
shell heaters, which are thermostatically controlled. The software removes power from
the thermostats (preventing them from turning ON) while the ISS is in eclipse.
Pump Control: Performs pump startup/shutdown, closed-loop control, and fault

detection/masking processes, as well as accumulator depress/repress. This software
issues commands to and receives data from the Pump/Fan Motor Controller (PFMC) to
control the operation of the pump.
2.5.4.2 LAB SYS MDM Software (LA MDMs)

The three LA MDMs process commands from the active INT MDM, execute algorithms,
and generate commands to US Lab ITCS hardware. There are no FDIR algorithms in
the LA MDMs; however, Caution and Warning messages are generated for out-of-
tolerance conditions. The LA MDM software performs the following functions for the
ITCS:
Valve Control: Performs startup/shutdown, closed-loop control, and valve positioning

for the various valves located throughout the system. The LA-1 MDM interfaces with all
of the LTL valves and LCA valve 1. The LA-2 MDM interfaces with all MTL valves and
LCA valve 2. All three LA MDMs interface with RFCAs.
Sensor Control: Passes sensor data for the LTL PPA (LA-1), MTL PPA (LA-2), as well
as various RTDs located in systems racks and endcones to the INT MDM. The PPA
data includes fine filter 3, gas trap 3, pump 3, pump inlet pressure, high/low rate
flowmeter, pump outlet temperature, and average accumulator quantity. The LA MDMs
do not generate any C&W messages for the PPA sensors (this is done by the INT MDM
once the data has been processed).
Passive TCS Control: Monitors RTDs, which provide temperature data to the INT
MDM for use in controlling the heater systems on PMA-2 (LA-1), APAS (LA-1), Node 2
(LA-2), US Lab Window Heaters (LA-1), LTL IFHX (LA-2), and MTL IFHX (LA-1).
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2.5.5 EETCS Software
2.5.5.1 Node 1 MDM Software (N1 MDMs)

The two Node 1 MDMs control shell heaters and IFHX valves and process telemetry
from the IFHX sensors. FDIR software also resides in the Node 1 MDMs. The Node
Control Software (NCS) performs the following functions:
Heater Control: Regulates the operation of shell heaters for Node 1, PMA-1, and
PMA-3. NCS acquires temperature data from Resistive Temperature Devices (RTDs)
and commands the heaters on or off based on setpoints. These setpoints can be
changed.
IFHX Control: Provides commanding and monitoring of US Lab IFHX valves and
sensors. Checks are made to ensure the ammonia temperature is above a minimum
value (default is 1.1° C) before allowing the bypass valve to be placed in the Flow-
through position. This is to prevent introducing cold ammonia into the IFHX core. An
additional software check ensures that the Bypass Valve is in the Bypass position
before allowing the Isolation Valve to be closed in order to prevent deadheading the
pump and/or overpressurizing the EETCS lines. The N1-1 MDM controls and monitors
the LTL IFHX and the N1-2 MDM controls and monitors the MTL IFHX. This software is
not active after Flight 12A.1.
IFHX FDIR: The N1 MDMs provide IFHX freeze protection by monitoring the value and
validity of the ammonia inlet temperature sensors, which are located downstream of the
Pump Flow Control Subassembly (PFCS). If either of the ammonia inlet temperatures
is less than 1.1° C, the software will automatically reconfigure the IFHX valves to
bypass/close in order to isolate the external loop from the IFHX core. This provides one
of three independent legs of IFHX freeze protection. This software is not active after
Flight 12A.1.
2.5.5.2 Photovoltaic Controller Unit MDM Software (PVCU MDMs)

The two PVCU MDMs receive telemetry from and issue commands to the Local Data
Interfaces (LDIs) in the two PFCSs. This software is not active after Flight 12A.1.
Software in the PVCU MDM performs the following functions:
EETCS Temperature Sensor Validation and Selection: The PVCU MDM performs
both intrasensor and intersensor validation for the two PFCS outlet temperature
sensors. The intrasensor validation compares the current sensor value for each sensor
with the previous value of that sensor to determine if the difference between the values
is within a specified error limit. The intersensor validation determines if the difference
between the two outlet temperature sensors is within a specified error limit. It also
performs the intrasensor check on the EETCS outlet line sensor that is tied directly to
the PVCU MDM (i.e., this sensor data does not go through the PFCS LDI). In all cases,
if the sensors are not within the specified error limit, the sensor is declared invalid.
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EETCS Leak Detection: The PVCU MDM software detects ammonia leaks based
upon a PFCS Accumulator Filtered Average Quantity that is derived from the two
quantity sensors located on the PFCS accumulator. (Originally, the average quantity
was based on the two PFCS accumulator quantities as well as the quantity sensors in
the Trailing and Starboard radiators. These radiator quantities were miswired to the
wrong PFCS LDI on the ground prior to launch; hence, they have been deselected from
the algorithm). If the average quantity falls below 10 percent, the PVCU MDM issues a
caution message, but no recovery action is taken. (The PFCS LDI, however, shuts
down the pump at when either sensor is less than 4%.)
EETCS Control: The PVCU MDM calculates the FCV position using a closed-loop
temperature control algorithm, which is based on the lower of the two PFCS outlet
temperature sensors. The PFCS Outlet Filtered Lower Temperature is compared to a
temperature setpoint and the difference is used to calculate the FCV position. In
addition to commanding the FCV, the PVCU MDM utilizes the same temperature to
command the line heaters on/off. This aids in maintaining the external loop
temperature during periods of low heat loads. Prior to commanding the heaters on,
additional checks are made to ensure the pump is operating and ammonia is flowing
through the lines that bypass the radiators.
EETCS FDIR: The PVCU MDM software performs a wide variety of fault detection
including overtemperature and undertemperature protection for both the hardware limits
and freeze protection limits. It monitors the pumps for failures and will command on the
secondary pump if the primary pump fails. Additionally, it monitors the pump speed in
relation to the flowrate in order to provide protection against a possible deadhead
condition.
2.5.6 ETCS Software
2.5.6.1 External MDM Software (EXT MDM)

The External MDM receives commands from and interfaces directly with the C&C MDM
and provides data connectivity and software control to the ETCS equipment located on
the S1, P1, and S0 Truss segments. There are two, fully redundant EXT MDMs—one
MDM is normally powered and active while the other MDM is unpowered. The C&C
MDM handles automatic recovery of a failed EXT MDM. In addition to being the
passthrough MDM that allows commands and data to pass to/from the upper and lower
tier MDMs, the EXT MDM software performs the following important functions for the
ETCS:
ETCS Manager: The ETCS Manager provides high-level control (data acquisition,
command validation, control and monitoring functions) for all ETCS components on
both external loops. The ETCS Manager provides FDIR for Radiator and Heat
Exchanger temperature violations as defined below.
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To protect the radiators from an under-temperature condition, the EXT MDM will initiate
loop shutdown and radiator venting if the filtered Fluid Temperature Control (FTC) value
(average of all six RBVM return line temps) is below -62.2° C (-80° F) for more than
90 minutes. Two levels of Caution messages are annunciated at 15 minutes and 60
minutes prior to the actual shutting down of the loop and radiator vent.
To protect the IFHXs from under-temperature and over-temperature conditions, the

EXT MDM will send commands to the S0 MDM to bypass/isolate all IFHXs on the
affected loop if:
a. ETCS Loop A(B) PCVP Temp Low flag is set - Issued by S1/P1 MDM when a
PCVP low temp fault (PCVP Out Temp < 1.7° C, 35° F) is annuciated.
b. ETCS Loop A(B) PM Outlet Temp Low flag is set - Issued by S1/P1 MDM when
ETCS PM Outlet temperature is < 1.11° C (34° F).
c. ETCS Loop A(B) PM Outlet Temp High Shutdown flag is set - Issued by S1/P1
MDM when ETCS PM Outlet Temp is > 18.3° C (65° F).
The EXT MDM will also send commands to the S0 MDM to bypass/isolate all IFHXs on
the affected loop if the loop is in Shutdown mode.
Radiator Goal Angle Calculation (RGAC): The RGAC function generates a goal
angle (gamma) that is used to position the thermal radiators. The preferred thermal
environment is one that allows for adequate heat rejection and avoids freezing of the
ammonia contained within the radiators. RGAC orients the thermal radiator panels to
face Earth whenever the ISS is in eclipse and points the edge of the radiator panels
towards the Sun when the ISS is in insolation.
The RGAC generates a starboard and port thermal radiator goal angle based upon
inputs provided by the Guidance Navigation and Control (GN&C) MDM and various
measurements of the mass flowrate and ammonia fluid temperatures in the ETCS
cooling loop.
Thermal Radiator Rotary Joint (TRRJ) Manager: The TRRJ Manager function
provides high-level control and monitoring for the rotational position of the ETCS
radiators. The TRRJ Manager uses the RGAC goal angle to generate the rotation
angle command for each TRRJ, which is then passed to the appropriate S1/P1 MDM.
The S1/P1 MDM TRRJ Control function (discussed below) then processes the angle
command and directs the hardware to actually move to the desired position. The TRRJ
Manager can operate in one of several modes, including autotrack, and directed
position, similar to the EPS Beta Gimbal Assembly (BGA).
The TRRJ Manager function also responds to failure flags set by the S1/P1 MDM TRRJ
Control function and attempts to safe the system.
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2.5.6.2 S1 Truss/P1 Truss MDM Software (S1/P1 MDMs)

The S1/P1 MDMs provide control, monitoring, and FDIR capability for the ETCS
components, including the PM, the ATA, and the NTA.
Only the S1-1 and P1-2 MDMs interface with these ETCS components; the S1-1 MDM
is dedicated to the Loop A components and the P1-2 MDM is dedicated to the Loop B
components. In a contingency situation, the S1-2 and P1-1 MDMs can be reconfigured
to allow for limited commanding of the PCVP. Both S1/P1 MDMs (S1-1, 2 and P1-1, 2),
however, provide the capability to control and monitor the TRRJ. All four S1/P1 MDMs
are normally powered and active. The functions of the S1/P1 MDMs can be grouped
into the following categories:
Pump and Tank Control: The ETCS Pump and Tank Control (PTC) capability
interfaces with the ATA, NTA, and PM. Some of the major functions that the PTC
capability performs are the following: filling a thermal loop with liquid ammonia using
the ATA and NTA; returning ammonia to the ATA tanks; direct control of the NTA Gas
Pressure Regulating Valve (GPRV) assembly; control of the Pump and Control Valve
Package (PCVP) firmware via a 1553 interface to initiate loop startup or shutdown and
to monitor and respond to subsystem anomalies; interface with the electrical power
system to request power to selected SDO cards, the PCVP, flowmeters, and the startup
heaters. In addition to all these capabilities, the S1/P1 MDMs perform FDIR functions
including large leak monitoring and safing, automatic system safing due to TRRJ and/or
pump failures, as well as over and under temperature safing functions.
Thermal Radiator Rotary Joint (TRRJ) Control: The TRRJ Control function provides
control and monitoring for both the starboard (loop A) and port (loop B) thermal radiator
wing assemblies. The S1/P1 MDMs send commands and receive responses from the
Rotary Joint Motor Controllers (RJMCs). They also receive switch and temperature
sensor data from TRRJ sensors. Each S1/P1 MDM is connected to a separate RJMC,
which in turn, is connected to a separate DLA torque motor that controls the TRRJ
rotation.
This one MDM/RJMC/DLA combination is called a string. Only one string per loop is
utilized at any one time; hence, only one MDM can be designated for commanding.
The other MDM is typically available for monitoring only. Table 2-6 shows the
MDM/RJMC/DLA string combinations.
Table 2-6. TRRJ string definitions
TRRJ string MDM RJMC DLA
ETCS Loop A (Starboard) String 1 S1-1 RJMC-1 DLA-1
ETCS Loop A (Starboard) String 2 S1-2 RJMC-2 DLA-2
ETCS Loop B (Port) String 1 P1-1 RJMC-1 DLA-1
ETCS Loop B (Port) String 2 P1-2 RJMC-2 DLA-2
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2.5.6.3 Starboard/(Port) Thermal Radiator MDM Software (STR/PTR MDMs)
The STR/PTR MDMs receive commands from and interface directly with the EXT MDM.
They provide the capability to control and monitor the Radiator ORUs and RBVM
ORUs. The STR and PTR MDMs are not redundant since the STR MDM monitors and
controls radiator functions on ETCS Loop A and the PTR MDM monitors and controls
radiator functions on ETCS Loop B. Both MDMs are normally powered and active. The
functions of the STR/PTR MDMs can be grouped into the following four categories:
Radiator IMCA Control: The STR/PTR MDMs send commands to the Radiator IMCA
firmware controllers to deploy and retract the radiators. There are a total of three
radiator ORU IMCAs per loop (one per Radiator ORU). STR/PTR software ensures
only one Radiator ORU is being deployed and that the maximum system pressure (172
kPa) has not been exceeded prior to accepting a command to deploy the radiator.
Radiator Beam Valve Module (RBVM) IMCA Control - The STR/PTR MDMs send
commands to the RBVM IMCAs to position the supply and return line isolation valves.
There are a total of six RBVM IMCAs per loop (one per RBVM, two RBVMs per
radiator). The IMCA is used to configure the RBVM to three positions; open, closed or
vent. The valve position is read by the IMCA as closure of one of three limit switches
(open, closed, and vent).
Note: Only one of the nine radiator IMCAs per loop can be powered at a time.
Squib Firing Units (SFUs): Power to the squib fire units is applied via STR/PTR MDM
SDO cards.
Sensor Monitoring: Temperature and pressure sensor data from the RBVMs,
heaters, and TRRJ Flex Hose Rotary Coupler are received via LLA and HLA cards in
the STR/PTR MDMs.
2.5.6.4 S0 Truss MDM Software (S0 MDMs)

The S0-1 and S0-2 MDMs are responsible for monitoring and controlling fluid line
heaters, coldplate temperature sensors, and all IFHX valves and sensors. The
functions of the S0 MDMs are grouped into the following four categories:
Fluid Line (Umbilical) Heater Control: Regulates the fluid line heaters to the ETCS
supply and return umbilicals located on the S0 Truss segment. Each loop has three
separate heater strips mounted on the umbilical secondary structure (one 8W heater
strip and two 12W heater strips). Each strip provides heat to both the supply and return
fluid lines and is equipped with three Resistance Temperature Devices (RTDs), which
are monitored by the S0 MDMs. The S0 MDM commands the heaters on/off based
upon setpoints (-51.1° C/-48.3° C). These heaters are normally not required when fluid
is flowing but may be needed after a period of no flow. The S0-1 MDM monitors and
controls the Loop B fluid line heaters and the S0-2 MDM monitors and controls the
Loop A fluid line heaters. Power to the heaters is routed through the S0 MDMs via
SDO cards.
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External Coldplate Sensor Monitoring: Each external coldplate on the S0 Truss (two
MBSUs and two DDCUs) is equipped with a baseplate heater and temperature sensor.
The temperature sensors on the Loop A coldplates are monitored by the S0-2 MDM
and the sensors on the Loop B coldplates are monitored by the S0-1 MDM. The S0
MDMs are only responsible for reading the temperature sensors and then feeding that
telemetry back to the C&C MDM. The C&C MDM then passes the information to the
Power Management and Control Unit (PMCU) MDMs where the actual heater control
software resides.
IFHX Control: Provides commanding and monitoring of all IFHX valves and sensors.
At assembly complete, there are a total of five IFHXs per ETCS loop—one each for the
US Lab, Node 2, COL, JEM, and Node 3. Checks are made to ensure that the
ammonia temperature is above a minimum value (default is 1.1° C) before allowing the
bypass valve in any IFHX to be placed in the flowthrough position. This is to prevent
introducing cold ammonia into an IFHX core. The S0-1 MDM controls and monitors all
Loop A IFHXs and the S0-2 MDM controls and monitors all Loop B IFHXs.
IFHX FDIR: The S0 MDMs provides protection of the IFHX core by monitoring the
value and validity of the PCVP Out Line temperature sensor that is located downstream
of the PCVP and provides a good indication of the temperature of the ammonia prior to
entering the IFHX cores. If the PCVP Out Line temperature is less than 1.1° C, the S0
MDM will remove power from the bus feeding the PCVP (the entire S11A or P12B
power bus) to stop the flow of cold ammonia through the loop. The S0 MDM will
automatically reconfigure all IFHX bypass valves on the affected loop to isolate the
external loop from the IFHX cores. This provides an additional layer of protection
against the catastrophic hazard of freezing and rupturing an IFHX core. It does,
however, cause an abrupt shutdown of all equipment powered by the S11A (Loop A) or
P12B (Loop B) power bus. This includes all ETCS equipment on the affected loop as
well as the S1(P1) and STR(PTR) MDMs, and additional non-TCS equipment such as
heaters and communications equipment.
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2.5.6.5 Power Management and Control Unit MDM Software (PMCU MDMs)
The PMCU MDMs control the cycling of the heaters in the MBSU and DDCU coldplates
on the S1, P1, and S0 truss segments. The PMCU software triggers coldplate heater
on/off commands based on the coldplate temperature sensor readings as compared to
changeable setpoints (default values of -31.67° C/-28.89° C).
The PMCU MDMs do not have direct control over the coldplate temperature sensors or
the heaters. Converted coldplate temperature data is made available to the PMCU
MDMs via the C&C in Broadcast Ancillary Data messages. All temperature data and
heater commands must pass through the C&C to/from the S1-2, S0-1, S0-2, or P1-1
MDMs which have direct control of the temperature sensors and heater RPCs. In
response to receipt of a coldplate heater on/off command, the C&C issues a corre-
sponding command to the MDM controlling the RPCM. This command then turns the
associated ORU coldplate heater on or off. Unlike other commands, the coldplate
heater commands flow from a lower tier MDM (PMCU) to a higher tier MDM (C&C), and
as such, must be polled by the higher tier MDM using a separate pipe and command
buffer.
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QUESTIONS
1. Complete the exercise below by matching the descriptions on the right with the
components on the left. (Use Figure 2-1 as a reference, if needed.)
_____SFCA Mod Vlv a. Provides temperature control for the ITCS

fluid loops
_____PPA b. Provides circulation, filtration, and
pressurization for the ITCS fluid loops
_____LCA c. Maintains a constant delta pressure across
the supply/return lines
_____IFHX d. Provides a means to connect the two
internal loops into a single loop
_____TWMV e. Provides the interface between the internal
and external thermal loops
_____SFCA SOV f. Provides the means to raise the
temperature of Low Temperature Loop
(LTL) coolant entering the Moderate
Temperature Loop (MTL) while in single
loop mode
_____Regen HX g. Provides a means to isolate an inactive
pump assembly
_____ Line Heaters A. Provides a means to isolate the interface

heat exchanger core from possible
backflow
_____ PFCS B. Provides circulation, filtration, loop
pressurization, and temperature control for
the EETCS
_____ IFHX Isolation Valve C. Provides additional heat during periods of
low-heat loads or system startup
_____ IFHX Bypass Valve D. Provides the means to reject the heat
collected throughout the system to the
surrounding space environment
_____ Radiators E. Provides a means to bypass the interface
heat exchanger core
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_____PM a. Provides structural support and rotational

capability for each ETCS radiator wing
_____NTA b. Provides circulation and temperature
control of the ETCS fluid
_____Radiators c. Provides the fluid needed to fill and
pressurize the ETCS fluid lines
_____TRRJ d. Provides controlled pressurization of the
ETCS ammonia tanks
_____ATA e. Provides the means to reject the excess
heat to the surrounding space environment
_____RBVM f. Controls the flow to the radiator ORUs and
provides the means to isolate and vent the
radiators
4. Which MDM provides system level control of the ITCS, including loop
startup/transition routines, FDIR, and leak detection?
a. LA-1
b. LA-2
c. INT
5. Which MDM communicates with the majority of the MTL ORUs?
a. LA-1
b. LA-2
c. INT
6. Which MDMs control the IFHXs prior to the activation of the ETCS?
a. N1-1 and N1-2
b. S0-1 and S0-2
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7. Which MDM controls the majority of the ETCS ORUs on Loop A.
a. P1-1
b. P1-2
c. S1-1
d. S1-2
8. Which MDM monitors both internal and external thermal systems for
incompatibilities and initiates load sheds when required?
a. EXT
b. INT
c. C&C
9. What is the impact of the loss of the ITCS LTL pump?
a. Low temperature cooling to the LTL racks will no longer be possible
b. Software will automatically transition the ITCS to single loop mode and maintain
cooling to all equipment
c. No impact–backup pump will automatically take over
10. What is the impact of the loss of the ETCS Loop A pump?
a. Low temperature cooling to the LTL racks will no longer be possible due to the
loss of the external loop
b. The ITCS can be placed in single loop mode and maintain cooling to all
equipment through ETCS Loop B. However four of the eight US power
channels may eventually have to be shut down due to the loss of cooling to the
EPS equipment located externally on the S0 truss.
c. No impact—backup pump will automatically take over
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3.0 TECHNICAL SUPPORT

3.1 INTRODUCTION
This section provides a detailed discussion of the individual components in the Lab
ITCS, the EETCS, the permanent ETCS, and the PTCS heaters. A detailed discussion
of the TCS software, as well as the commands and telemetry available from the PCS, is
also included.
Objectives
Upon completion of this section, you should be able to
• Explain how each ORU operates
• Identify what telemetry and commanding is available to aid in the monitoring and
control of the TCS components
• Identify the TCS-specific software functionality contained within each MDM

associated with the TCS
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3.2 LAB ITCS COMPONENTS
This section presents more details on the Lab ITCS hardware components.
3.2.1 ITCS Plumbing

ITCS plumbing consists of the tubing (pipes or flex hoses) and fittings (Gamah fittings,
welded fluid fittings, or self-sealing quick disconnects) that convey coolant between
components.
Tubing
The ITCS uses titanium tubing with 0.0559 cm (0.022 in.) wall thickness. The majority
of the ITCS tubing is located in the US Lab module standoffs, where the rack interfaces
reside and in the endcones. Tubing is 2.54 cm (1.0 in.) in the racks containing the
PPAs to accommodate the 1361 kg/hr (3000 lb/hr) flowrate. Tubing in all other racks is
1.27 cm (0.5 in.) to accommodate lower flowrates.
The LTL lines are insulated with a 1.91 cm (0.75 in.) thick layer of Solimide to prevent
condensation from forming on the outside of the lines. Figure 3-1 shows the physical
layout of the LTL plumbing within the US Lab module.
AFT
X4 (OP)
X3 (PD)
X2 (SD)
LT Loop
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Figure 3-1. LTL plumbing isometric
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Basic, CPN-1
The MTL plumbing does not need to be insulated because the temperature of the MTL
fluid should always remain above the dew point. Figure 3-2 shows the physical layout
of the MTL plumbing within the US Lab module.
AFT
X4 (OP)
X3 (PD)
X2 (SD)
LT Loop
010705(0)T0012_161
Figure 3-2. MTL plumbing

Flex Hose
Flex hose assemblies offer flexible plumbing for rack tilt capability and to facilitate ORU
removal. Flex hose assemblies utilize either a Teflon or stainless steel inner core for
long life and durability and incorporate Nomex, stainless steel, or Kevlar braiding to
reduce weight and bend radius. The end fitting is configured with orbital weld stubs for
fluid fitting and QD attachment.
Gamah Fitting
Gamah fittings are threaded fluid fittings that provide a means of connecting and
disconnecting fluid systems components to perform scheduled and nonscheduled
maintenance and replacement. Gamah fittings are used in areas where there is a low
3-3
01.07.05(0)T0012
Basic, CPN-1
frequency of crew interaction due to the reliability of the components that are served,
such as coldplates and heat exchangers. Gamah fittings do not prevent leakage when
disconnected, so any maintenance involving Gamah fittings will require shutdown and
depressurization of the loop.
Welded Fitting
A welded fitting is any fitting such as a tee, union, elbow, etc. that is welded directly to a
length of smooth pipe. Welded fluid fittings are used in the ITCS for permanent
connections of various components of the fluid distribution system.
Internal Quick Disconnects
QDs provide a quick and easy means of connecting and disconnecting fluid system
components to perform scheduled and nonscheduled maintenance and to facilitate fluid
system configuration. Each QD pair (male and female half) incorporates two
independent (redundant) seals for each leak path while coupled. Uncoupled QD halves
have at least one independent seal for each leak path. Pressure caps are used for
uncoupled QD halves as an extra seal. All TCS QDs are constructed of either titanium
or 316 L stainless steel.
3.2.2 ITCS Water
After Flight ULF1, the Lab ITCS LTL contains approximately 64 liters (L) (17 gal) of
water and the ITCS MTL contains approximately 220 L (58 gal) of water. This includes
all fluid in the Lab, Node 1, and the Airlock, including all payload and system rack
volumes. The ITCS water is compatible with stainless steel and nickel-based and
titanium alloys. The ITCS water is not compatible with aluminum and copper-based
alloys.
The water in the ITCS is treated to prevent corrosion and microbial growth. The pH is
adjusted using sodium hydroxide. After treatment, the water has a pH ranging from
8.8 to 10.1. A recent addition to the ITCS is the capability to perform on-orbit sampling
of the ITCS coolant. The sample tool consists of two QDs, a metering valve, SOV, and
male Luer Lock interface as shown in Figure 3-3.
01.07.05(0)T0012_083
Figure 3-3. ITCS sampling tool
3-4
01.07.05(0)T0012
Basic, CPN-1
There are two sampling tools currently installed in the US Lab. Samples are taken on a
periodic basis and returned on each visiting orbiter for ground analysis. Figure 3-4 and
Figure 3-5 show how the LTL and MTL sampling tools are installed in the standoffs
leading to the LAB1D6 (AR) and LAB1D5 (AV-1) racks.
Ins ulation Jacket
1/2-Inch IT CS
IT CS s ample s ample adapter
bag interface
AR rack interface
panel clos eout
AR rack
interface
AR panel
rack
mitten
01.07.05(0)T 0012_135
Figure 3-4. LTL sampling tool installation in AR rack

(LAB1D6)
1/2-inch ITCS
sample adapter
ITCS sample
bag interface
AV-1 rack
interface panel
Standoff X3
MTTCS return
hose
01.07.05(0)T0012_136
Figure 3-5. MTL sampling tool installation in AV-1 rack

(LAB1D5)
3-5
01.07.05(0)T0012
Basic, CPN-1
3.2.3 Coldplates
Coldplates are constructed of a baseplate, a core (finned internal passages), two
manifolds, inlet and outlet tubes with 1.27cm (0.5 in) Gamah fittings, and a cover.
These components are stainless steel with the exception of the core, which contains
internal fins made of nickel. The coldplate itself is approximately 0.51 cm (0.2 in.) thick
and comes in various lengths and widths as seen in Figure 3-6.
T hicknes s = 0.195 + 0.005

Heat flux = 1.75 W/in2
T hicknes s = 0.21 + 0.01

T hicknes s = 0.183 + 0.025/-0

Note: Dimens ions are in inches .

01.07.05(0)T 0012_082
Figure 3-6. Coldplate characteristics
3-6
01.07.05(0)T0012
Basic, CPN-1
3.2.4 Pump Package Assembly
Table 3-1 identifies the various PPA components. The PPA has a weight of 77.2 kg
(170.3 lb) and an envelope of 72.9 by 45.0 by 45.7 cm (28.7 by 17.7 by 18 in.).
Table 3-1. PPA components
Component Function
Fine filter Filters contaminants greater than 2 µm
Gas trap Removes gas bubbles from water
Accumulator Maintains positive pump inlet pressure
Allows for thermal excursions
Provides makeup water
Impeller Provides motive force for circulating water
Motor Turns the pump impeller
Pump/fan motor controller Accepts speed command from MDM
Provides PFMC status and BIT data
Provides shutdown of motor for off-nominal conditions
Coarse filter Filters large particles from water
Power/data connectors Interface with EPS (power) and CDH (commands and data)
QDs (3) Interface with the fluid loop supply and return lines, 2.54 cm
(1.0 in.), and the NIA, 0.95 cm (0.375 in.)
Fine Filter
This filter removes particles from the water to protect the pump and gas trap. Some of
the expected sources of contamination are corrosion from ITCS hardware, weld
fragments, and seal fragments from the ITCS loops. The fine filter has been sized to
retain particulates just larger than the smallest orifice of the pump, ranging from 2.54 µm
to 7.62 µm. This is the basis for the 2-µm filtration rating. The fine filter is illustrated in
Figure 3-7.
W ater in
W ater out
01.07.05(0)T0012_084
Figure 3-7. Fine filter

Because the filter media cannot be removed and cleaned on orbit, the entire filter
assembly must be replaced. The PPA has a bypass line with a pressure relief and
check valve to allow for continuous operation of the pump if the filter is clogged. The
filter can be replaced within 30 seconds, using probe-type QDs at the filter assembly
3-7
01.07.05(0)T0012
Basic, CPN-1
inlet and outlet, and an engage/disengage mechanism. By turning the manual
engage/disengage mechanism, the probe-type QDs connect or disconnect from the
PPA. The QDs are self-sealing.
Water is circulated through a filter element, which is composed of a glass-fiber-

impregnated epoxy resin (trade name Ultipore). Figure 3-8 shows how water is
circulated through the filter assembly. Water enters through the filter assembly inlet port
and is channeled to the outside of the cylindrical filter element. The pressure at the inlet
of the filter assembly forces the water through the filter element to the center of the filter
assembly. The water is then forced up to the outlet port, where it continues to the gas
trap.
Probe-type quick
disconnect
Water in Filter element

Manual
engage/disengage
Fine filter-to-PPA mechanism
threaded fitting
Probe-type quick
disconnect
Water out Filter element
Filter canister
01.07.05(0)T0012_085.
Figure 3-8. Fine filter cross section

As illustrated in Figure 3-9, this media is supported on each side by a stainless steel
wire cloth. Figure 3-9 also shows the cylindrical shape of the filter element and a cross
section of the filter element.
Figure 3-9. Fine filter details
3-8
01.07.05(0)T0012
Basic, CPN-1
A delta pressure sensor measures the pressure difference between the inlet and outlet
ports of the filter assembly. The output signal range of the differential pressure (dP)
sensor is -5 to +5 V dc. The sensor receives 15 V dc from the MDM. Accuracy is
± 3.4 kPa (± 0.5 psi), which includes the effects of nonlinearity, hysteresis, resolution,
and repeatability only. Fine filter characteristics are summarized in Table 3-2.
Table 3-2. Fine filter characteristics
Filtration rating 2 µm absolute
Nominal pressure drop 36.5 kPa at 1361 kg/hr (5.3 psi at 3000 lb/hr)
Envelope 10.7 x 13.0 cm (4.2 x 5.1 in.)
Weight 3.6 kg (8.0 lb) (dry with QDs)
Components Filter canister, filter element, pressure relief valve, dP
sensor
Filter canister material 300 series stainless steel
Filter element material Glass-fiber-impregnated epoxy resin
Manufacturer AiResearch
Life expectancy 1000 mating/demating cycles
Filter element replaced when dP is greater than 27.6 kPa
(4.0 psi) continuously
Nominal dP 18.6 ± 3.4 kPa (2.7 ± 0.5 psi)
Pressure relief valve crack pressure 53.8 ± 3.4 kPa (7.8 ± 0.5 psi)
Blockage advisory dP level 57.2 kPa (8.3 psi)
Blockage caution dP level 71 kPa (10.3 psi) – Indicates failure of check valve to
open
Gas Trap
Experience with radial pump stalling on the Apollo spacecraft indicated the need for
NCG removal from fluid loops. A trade study was conducted with the ITCS pump to
determine pump performance as a function of volumetric NCG concentration. The
pump withstood a 1 percent gas concentration without significant performance
degradation. As a result, the gas trap for the ISS was designed to remove all bubbles
larger than 100 µm while keeping the NCG concentration below 0.5 percent.
Some of the possible sources of NCGs (nitrogen or air) in the ITCS are listed below.
a. The mating and demating of QDs when ORUs or payloads are changed out. Each
QD action has been estimated to inject 0.2 cc of air into the ITCS water.
b. Each ORU has been designed with a 5 percent volume margin to allow for the
thermal expansion of the water during storage. The LCA has the largest ORU
volume in the system at 1.15 L (70 in.3). This results in 57 ml (3.5 in.3) of NCG
volume.
c. When the ITCS is filled with water on the ground, an estimated 3 percent of the
system volume remains unfilled resulting in 4.9 L (300 in.3) of air volume.
Items b and c occur only during system startup; therefore, ITCS startup is the worst-
case performance state for the gas trap.
3-9
01.07.05(0)T0012
Basic, CPN-1
The technology chosen to meet the gas trap requirements discussed above involves
using filter membrane technology. The gas trap uses two types of membrane materials.
One type is described as hydrophilic because it allows water that comes in contact with
it to pass through, while blocking the passage of any NCGs. The second is a
hydrophobic membrane that is not wettable by water, but allows NCGs to travel through.
Figure 3-10 illustrates how the hydrophilic and hydrophobic membranes work together
to remove NCGs from the ITCS. There are two concentric cylinders. The walls of the
outer cylinder are made up of the hydrophilic membrane. The walls of the inner cylinder
are made up of the hydrophobic membrane. The water/gas mixture enters the annulus
of the two concentric cylinders. The inner cylinder is blocked at the entrance but is
open at the other end. The annular space is open at the entrance, but closed on the
opposite end.
Figure 3-10. Two-membrane gas trap design
3-10
01.07.05(0)T0012
Basic, CPN-1
The water/gas mixture enters the annular space made by the concentric cylinders at a
pressure, P1. The water/gas mixture comes into contact with both the hydrophobic and
hydrophilic membranes. A 137.9 kPa (20 psi) pressure differential across the
hydrophobic membrane (P1 - P2) forces the gas bubbles to contact and pass through
the hydrophobic membrane. The gas then flows through the inner tube where it is
vented to the module atmosphere. The water passes through the hydrophilic
membrane driven by a pressure drop (P1 - P2) of 3.4 kPa (0.5 psi). The gas trap is
made up of a number of these concentric cylinders.
Figure 3-11 shows a cross section of the gas trap. The water/gas mixture enters the
center of the gas trap on the left. The NCGs exit these cylinders to the right and are
vented to the module atmosphere. The water exits the membrane cylinders on the
sides. The water is collected in another larger cylinder that encloses the grouped
membrane cylinders. The filtered water exits the gas trap to the left and flows back into
the PPA plumbing.
Water out
Water out
NCG
Water/gas
out
mixture in
(to cabin)
Water out
01.07.05(0)T0012_088
Figure 3-11. Gas trap cross section

Long-term contact between the hydrophobic membrane and water causes membrane
water saturation that reduces the capability to filter NCGs. This situation causes a
buildup of NCGs in the annular space between the hydrophobic and hydrophilic tubes.
NCG buildup increases the pressure drop across the hydrophilic membrane. At some
point, the pressure drop is large enough to force gas bubbles through the hydrophilic
membrane, resulting in the need for gas trap replacement. The PPA has a bypass line
with a pressure relief valve similar to the fine filter bypass, which provides a flow path
for the water during gas trap replacement.
A P sensor is located across the inlet and outlet ports of the gas trap. Readings that
approach the crack pressure of the relief valve indicate clogging and performance
degradation. Gas trap characteristics are summarized in Table 3-3.
3-11
01.07.05(0)T0012
Basic, CPN-1
Table 3-3. Gas trap characteristics
Nominal pressure drop 34.5 kPa at 1361 kg/hr (5.0 psi at 3000 lb/hr)
Envelope 15.3 x 43.2cm (6.0 x 17.0 in)
Weight 6.4 kg (14.1 lb) (dry with QDs)
Components Housing, hydrophobic and hydrophilic membranes,
pressure relief valve, dP sensor
Gas trap housing material Titanium 300 series stainless steel
Hydrophobic and hydrophilic membrane material Polypropylene (0.2 µm) and Nylon (3 µm)
Leakage 0.1 cc/24 hr at 586 kPa (85 psi)
Manufacturer AiResearch
Pressure relief valve crack pressure 48.3 ± 3.4 kPa (7.0 ± 0.5 psi)
Blockage advisory dP level 41.3 kPa (6.0 psi)
Blockage caution dP level 65.5 kPa (9.5 psi) – Indicates failure of check valve
to open
Accumulator
The PPA accumulator provides the PPA with reservoir capability. It accommodates fluid
expansion and contraction caused by thermal excursions and provides water make-up
capability, due to loss from leakage during disconnection of fluid connectors and/or
effects of evaporation. The accumulator is comprised of welded Inconel bellows with a
cover canister and is attached to the suction side of the pump. The bellows in the
accumulator contracts and expands because of varying heat loads in the ITCS. If the
water temperature decreases (Figure 3-12 View B), its volume decreases and the
bellows expands, increasing the water pressure at the pump inlet to make sure it never
drops below 124.1 kPa (18 psi). If the water temperature increases (Figure 3-12
View C), its volume increases and the bellows contracts, ensuring the pressure does
not exceed 241.3 kPa (35 psi). Bellows movements shown in Figure 3-12 are greatly
exaggerated to help illustrate the movement caused by thermal expansion and
contraction. On the US Lab these movements are small. These thermal excursions are
expected to use 7.5 percent of the volume of the accumulator. The total usable volume
of the accumulator is 11.1 ± 0.5 L (approximately 3 gal).
Nitrogen is used to maintain pressure within the ITCS via the accumulator. Nitrogen
pressure is ported onto the dry side of the accumulator from the NIA via a 0.95 cm
(0.375 in.) QD.
View A View B View C

(Nominal) (W ater temperature decreases) (W ater temperature increases)
Outlet To Outlet To Outlet N2 To

Water N 2 gas N 2 gas
NIA NIA NIA
Inlet Q Inlet Q Inlet gas Q
Welded bellows Bellows expanded Bellows compressed

01.07.05(0)T0012_089
Figure 3-12. Accumulator bellows functional schematic
3-12
01.07.05(0)T0012
Basic, CPN-1
Accumulator quantity is measured by a spring-loaded potentiometer that winds or
unwinds as thermal excursions cause the bellows to move. As shown in Figure 3-13, a
steel wire is connected to the top of the bellows. As the top of bellows changes position
in height, the length of steel wire on the potentiometer changes accordingly. Expansion
or contraction of the bellows winds or unwinds the potentiometer reel, creating a
resistance in the potentiometer that is scaled to match 5 to 100 percent. This
corresponds to a bellows displacement of 22.9 cm (9.0 in.). This resistance is
measured and converted to a voltage. The output signal is 0 to 1 V dc, correlating
linearly to the minimum and maximum values of accumulator capacity. The sensor
receives 15 V dc from the MDM. Measurements are displayed in percent volume of
water in the accumulator. Accuracy is ± 1 percent of full scale maximum (corresponding
to a movement in the bellows of 0.25 cm). The sensor is sampled at 10 Hz, and
software in the LA MDMs computes an average quantity based on 10 valid samples.
Accumulator
housing
Water side
Bellows
movement
N2 side
Hooks and
eyelets Bellows
surface
Steel wire
Reel Guidewheel
Potentiometer Potentiometer
housing (not to scale)
01.07.05(0)T0012_090
Figure 3-13. Accumulator quantity sensor

Thermal excursions are expected to move the accumulator bellows approximately 1.8 cm
(0.7 in.) from its neutral position. The quantity sensor is monitored over time to determine a
leak rate. Software within the INT MDM will take action to isolate and/or shut down a
leaking loop based upon limits defined within the MDM (see Section 3.6.2).
Accumulator physical characteristics are summarized in Table 3-4.
3-13
01.07.05(0)T0012
Basic, CPN-1
Table 3-4. Accumulator physical characteristics
11.1 ± .5 L (680 ± 30 in. ) (approximately 3 gal)
3
Usable volume
Size (outside dimensions) 29.1 × 15.5 cm (11.46 × 6.12R in.)
Weight 14.5 kg (32.0 lb) (dry)
Bellows material Inconel 718
Accumulator housing material Inconel 718
Neutral bellows position 25 percent N2 gas, 75 percent water
Components Housing, bellows, quantity sensor, absolute pressure
sensor
Manufacturer John Crane Belfab
Life expectancy 5000 full stroke cycles
25 million cycles of less than 0.25 in.
Pump Impeller and Motor
The purpose of the pump impeller is to provide the motive force for circulating water in
the ITCS loops. The PPA must have the capacity to deliver a given flowrate of water at
a given pressure. The necessary flowrate is governed by the maximum heat transfer
requirements of the electronics and payloads serviced by the ITCS. The flow resistance
of the system governs the pressure rise that the pump impeller must deliver.
The impeller is about the size of a United States (U.S.) quarter, as shown in
Figure 3-14. A characteristic of radial impellers is that even very small ones can provide
large pressure rises and flowrates. This is because of the radius change that the fluid
undergoes as it flows outward from the impeller center to the exit of the diffuser-shaped
vane passages. The small impeller size translates into a compact lightweight pump
design that is advantageous in aerospace applications.
BE R TY
LI
01.07.05(0)T0012_091
Figure 3-14. Impeller

Water is directed into the center of the impeller and as the impeller spins, the water is
radially forced out through the vanes, as shown in Figure 3-15. The vanes are shaped
so that the space enclosed by them is seen by the water as a diffuser. (A diffuser is an
enclosed passage of a gradually expanding cross-sectional area that is designed to
raise the pressure of fluids that flow through it.) The area of the channel between the
vanes grows larger as the water moves from the center to the exit of the impeller. As
3-14
01.07.05(0)T0012
Basic, CPN-1
the water moves through the vane passages, the velocity decreases and the pressure
increases.
W ater
out
W ater out
W ater in
Direction of rotation 01.07.05(0)T0012_092
Figure 3-15. PPA impeller

Figure 3-16 shows a cross section of the pump portion of the PPA. Water flows to the
center of the impeller through a nozzle and then flows radially outward through the
impeller blades. Upon exiting the impeller blades, the water flows through a diffuser
that connects back into the PPA plumbing.
Figure 3-16. Pump cross section

The impeller is attached to the end of a shaft that is supported by a hydrodynamic
journal bearing, as shown in Figure 3-17. The other end of the shaft is connected to the
rotor of an electric motor that turns the impeller. A hydrostatic thrust bearing, located
around the shaft in front of the electric motor, takes the axial load created by the stream
of water entering the pump through the diffuser. The contacting surfaces of both
3-15
01.07.05(0)T0012
Basic, CPN-1
bearings are carbon graphite. During operation, the shaft does not contact either the
sleeve of the journal bearing or the face of the thrust bearing. Instead, the shaft rides
on a thin film of water that is supplied by a passage leading from the impeller to the
sleeve of the journal bearing. The life of the pump is determined by the life of the
bearings. The most likely cause of bearing failure is disruption of the fluid film that is
used by the bearings to prevent direct contact between the shaft and the carbon
graphite material by particles in the water. (The fine filter is designed to prevent
particles above 2 µm from entering the pump.)
Submerged components Dry components
Pump Motor
impeller stator
Journal bearing
Thrust bearing Rotor
Motor
stator
Hermetic fluid barrier

01.07.05(0)T0012_094
Figure 3-17. Impeller/motor diagram

The pump motor employs a wet rotor/dry stator design. Figure 3-17 shows the
submerged components, including the impeller, shaft, bearings, and motor rotor to the
left of a fluid barrier. To the right of the fluid barrier are the dry components, which
include the motor stator. A design of this type increases the pump life because it
eliminates the need for a rotating seal around the shaft that prevents a dry rotor motor
design from failing because of fluid contamination. The rotating seal tends to be the first
part to wear out in more traditional pump designs.
A pump inlet pressure sensor is located at the inlet to the pump impeller. Low inlet
pressure may be an indication of pump cavitation. The output signal is -5 to 5 V dc.
The sensor receives 15 V dc from the MDM. Accuracy is ±1 percent of full-scale
maximum. A dP sensor is located across the pump impeller and a temperature sensor
is located on the outlet line plumbing. An outlet temperature higher than 49° C (120° F)
may be an indication of pump bearing wear. Additional pump characteristics are shown
in Table 3-5.
3-16
01.07.05(0)T0012
Basic, CPN-1
Table 3-5. Pump characteristics
Type Brushless dc motor; centrifugal impeller
Flowrate 1361 kg/hr (3000 lb/hr)
Pressure rise 446 kPa (64.7 psi)
Voltage 120 V dc
Speed 18,900 rpm (Single Loop)
16,300 rpm* (Dual Loop – MTL pump)
14,600 rpm* (Dual Loop – LTL pump)
Power consumption 453 W @ 18,900 rpm (470 W max)
Nominal inlet pressure 124 – 186 kPa (18-27 psi)
Pump dP range 0 – 689.4 kPa (0 – 100 psi)
o o
Outlet temp range 17 – 49 C (35 – 120 F)
Operational life 10 years
Manufacturer Allied Signal
*Default speeds for dual-loop mode are 17200 rpm for the MTL and 15880 rpm for
the LTL. Values listed in the table are the current operational values being used on
board the ISS.
Pump/Fan Motor Controller
The PFMC measures 14.0 by 14.0 by 8.6 cm (5.52 by 5.52 by 3.40 in.) and weighs
2.1 kg (4.6 lb). The PFMC sits on a small coldplate (heat sink) in the PPA housing.
Water flowing through the pump is routed to the coldplate. The coldplate is designed to
cool the PFMC and the pump motor (50 W and 9 W, respectively).
Details of PFMC firmware operation are in Appendix D.
Coarse Filter
The stainless steel, woven-wire-mesh material used in the coarse filter looks similar to a
screen used on doors or windows. The coarse filter is located immediately after the
pump, has a mesh size of 812 µm (0.032 in.), and a diameter of approximately 2.8 cm
(1.1 in.). The coarse filter is located after the pump to collect large particles such as
pump impeller fragments that result from cavitation.
Check valve
The PPA check valve ensures that ITCS coolant only flows in one direction. In the
event that a pump is not operating, the check valve ensures that ITCS coolant from the
operating pump does not flow back through the nonoperating pump.
Flowmeter
:DWHUIORZUDWHLVGHWHUPLQHGE\PHDVXULQJWKH 3EHWZHHQWKHYHQWXULLQOHW31) and

the throat (P2). As seen in Figure 2-8, the frontal area (a1) and throat area (a2) of the
tube are known and P2 - P1 is determined by a dP transducer. The velocity (v1) (water
flowrate) is calculated by using the continuity equation.
3-17
01.07.05(0)T0012
Basic, CPN-1
• a1v1 = a2v2
and Bernoulli’s equation
• P1 + ½ ρ(v1)2 = P2 + ½ ρ(v2)2
The throat velocity (v2) is expressed as (a1v1)/a2. This is then substituted into Bernoulli’s
equation, which leaves one unknown v1. Using the continuity equation and Bernoulli's
equation for this application assumes an incompressible flow because the fluid is water
(ρ is a known value). The resulting flowrate computation is
2 ⋅ ∆P
• v1 =
(
ρ ⋅ 1 − A2 )
where
• P = P2 - P1 (from dP sensor)
• A = a1//a2 (known area ratio)
The flowmeter monitors the water flowrate exiting the PPA and transmits two 0 to 20 mA
signals to the MDM. The flowmeter utilizes a high-range flow sensor (0 to 1406 kg/hr
(0 to 3100 lbm/hr)) and a low-range flow sensor (0 to 590 kg/hr (0 to 1300 lbm/hr)). The
low-range signal is used when the PPA flowrate is less than 498.9 kg/hr (1100 lbm/hr).
Between 498.9 and 634.9 kg/hr (1100 to 1400 lbm/hr), a weighted average of the two
signals, is used. Above 634.9 kg/hr (1400 lbm/hr), the high-range signal is used to
determine the flowrate. The PPA flowmeter is shown in Figure 3-18.
Electrical
connector
Signal
conditioning
electronics
Absolute pressure
sensor
Low-range differential
pressure sensor
Temperature
sensor
Water flow
High-range differential
pressure sensor and
absolute pressure sensor
01.07.05(0)T0012_095
Figure 3-18. PPA flowmeter cross section
3-18
01.07.05(0)T0012
Basic, CPN-1
Flowmeter physical characteristics are shown in Table 3-6.
Table 3-6. PPA flowmeter physical characteristics

Size (outside dimensions) 23.9 × 7.6 × 12.7 cm (9.4 × 3.0 × 5.0 in.)
Weight 1.8 kg (4.0 lb) (dry)
Pressure drop 6.9 kPa (1.0 psi) max
Accuracy ±10 percent (low range);
± 5 percent (high range)
Manufacturer Tavis
Quick Disconnects
Each PPA interfaces with the ITCS via three 2.54 cm (1.0 in) fluid QDs and with the
Gaseous Nitrogen (GN2) of the Atmosphere Control System (ACS) via a 0.95 cm
(0.375 in.) QD.
3.2.5 Pump Bypass Assembly

When water must bypass the PPA due to maintenance, failure, or reconfiguration of the
system, a single mechanical check valve in the Pump Bypass Assembly (PBA), pictured in
Figure 3-19, is used in conjunction with the SOV of the SFCA. The check valve is
located in the standoff below the rack and opens automatically when the pump inlet
pressure is greater than the pump outlet pressure. Isolation of the PPA inlet by closing
the SFCA SOV, failure of a pump, or clogging of the pump filter can cause the pump
inlet pressure to increase and open the check valve, allowing flow to bypass the PPA.
Outlet Inlet
housing housing
Water flow
Poppet (when PPA
is operating)
Poppet
guide 01.07.05(0)T0012_096
Figure 3-19. Pump bypass assembly
3-19
01.07.05(0)T0012
Basic, CPN-1
3.2.6 Nitrogen Interface Assembly
Table 3-7 identifies NIA components. The NIA has a dry weight of 6.8 kg (15 lb) and an
envelope of 44.5 by 10.67 by 22.86 cm (17.52 by 4.2 by 9.0 in.).
Table 3-7. NIA components

Component Function
Nitrogen Introduction valve (NIV) Allows nitrogen gas into the PPA accumulator; repress rate – 13.8
kPa/min (2.0 psi/min), depress rate – 55.2 kPa/min (8.0 psi/min)
Accumulator Vent Valve (AVV) Relieves accumulator pressure; flowrate = 0.09 kg/min (0.2 lb/min)
Pressure relief valve Cracks at 227.5 kPa (33.0 psia); Reseats at 193.1 kPa (28 psia);
flowrate = 0.10 kg/min (0.22 lb/min)
Pressure regulator Decreases ECLSS nitrogen pressure to 165.5 to 193.1 kPa
(24-28 psia); flowrate = 0.05 kg/min (0.11 lb/min)
Power/data connector Interface with EPS (power) and CDH (commands and telemetry)
QDs (2) Interface with nitrogen distribution system and PPA accumulator,
0.95 cm (0.375 in.)
The NIV and AVV are both the same type of latching solenoid valve. The valve
contains a permanent magnet and two electromagnetic coils (see Figure 3-20).
Magnetic forces hold the valve in its current position. Optical sensors provide position
feedback. In order to change valve position, a TOGGLE command must be sent.
When a TOGGLE command is sent, the opposing electromagnet is energized to drive
the valve into its new position. Once the valve is in its new position, power is removed
from the electromagnet. The valve remains in its last commanded position if power is
removed.
Inlet
Closed
Coil Manual
operation
Armature
Optical switch lever

Permanent magnet
Open
Coil
Poppet
Seat
Outlet 01.07.05(0)T0012_097
Figure 3-20. NIV/AVV cross section
3-20
01.07.05(0)T0012
Basic, CPN-1
If both the NIV and AVV are opened at the same time, nitrogen will flow into the US Lab.
The pressure regulator determines the maximum rate: 0.05 kg/min (0.11 lb/min).
The NIV and AVV each have a manual override switch. This switch is a lever
mechanically linked to the valve poppet. A crewmember can use this switch to toggle
the valve open or closed in the event that power or data connectivity is lost.
Each valve uses 15 mW, which is required for the optical position sensors. The valve
uses 3 W of power when enabled and 5 W when the solenoid is toggling the valve
position. The maximum flowrate through these valves is 2.7 kg/hr (6.0 lbm/hr).
3.2.7 Rack Flow Control Assembly

Table 3-8 identifies the RFCA components. The RFCA weighs approximately 7.1 kg
(15.5 lb) and an envelope of 37.3 by 17.8 by 23.5 cm (14.7 by 7.0 by 9.25 in.).
Table 3-8. RFCA components

Component Function
Flow control valve Regulates water flow
Controllable range: 45.4 - 557.8 kg/hr (100 - 1230 lb/hr)
Flowmeter Provides two analog dPs to the MDM for flowrate computation
Temperature sensor Provides analog temperature to the MDM
o o
Operational range: 0.6 - 50 C (33 - 122 F)
o o
MTL CLC range: 18.9 - 48.8 C (66 - 120 F)
o o
LTL CLC range: 6.2 – 21.1 C (43 - 70 F)
QDs (2) Interface with rack and return headers, 1.27 cm (0.5 in.)
Flow Control Valve
The RFCA FCV uses a 120 V dc brushless motor with controller to turn a ball valve.
Mechanical stops are located at the end of the shaft at the valve open and closed
positions. Optical sensors detect end of travel at the open and closed position. The
signals from the optical sensors are sent to the controller, which removes power from
the motor when the valve reaches the fully open or closed position. The position sensor
signals are not available to the LA MDMs.
Normally, FCV position is determined by Closed-Loop-Control (CLC) software in the LA

MDMs in either flow or temperature mode. Valve position also can be changed by
sending a voltage and duration to the controller. The valve can be commanded at
variable speeds according to the command input voltage between ± 0.3 V dc to
± 5.0 V dc, where negative voltages drive the valve open and positive voltages drive the
valve closed. A speed signal output voltage, ranging from ± 0.3 to ± 5.0 V dc, provides
indication of valve movement. Negative voltage indicates the valve is opening; positive
voltage indicates the valve is closing. At the maximum ± 5 V dc, the actuator rotates the
valve through its full range in about 14 to 20 seconds. At the minimum ± 0.3 V dc, the
actuator rotates the valve through its full range in about 244 to 356 seconds.
3-21
01.07.05(0)T0012
Basic, CPN-1
Manual override is accomplished by pulling a knob coupled to the actuator (see
Figure 3-21), disengaging the actuator, then rotating the valve to the desired position.
The manual override knob also provides a visual and tactile indication of valve position.
The maximum torque required to operate the valve in the manual mode is 20 in/lb.
Figure 3-21. RFCA FCV manual

override knob
Flowmeter
The flowmeter is a venturi type device that uses dP transducers to measure flow. The
flowmeter transmits two 4 to 20 mA signals to the LA MDMs for control and monitoring.
The flowmeter utilizes a high-range flowmeter (136.1 to 589.7 kg/hr (300 to 1300 lb/hr))
and a low range flowmeter (0 to 181.4 kg/hr (0 to 400 lb/hr)). When the actual flowrate
is between both range flowmeters, RFCA software algorithms utilize a weighted
average of the two flowmeters. Design and operation of the RFCA flowmeter is similar
to the flowmeter in the PPA (see Figure 3-18).
Quick Disconnects
The RFCAs at the ISPR locations can be connected to either the LTL or MTL return
lines using flex hoses and QDs. Each ISPR has a rack interface panel called a
“Z-panel” that contains connections to all possible ISS resources including the MTL and
LTL supply and return lines. See Section 2.2.2.3 for details on connecting the RFCAs
to a payload rack. When an RFCA is connected to a payload rack, the software
algorithm must be notified (via a PCS command) of the loop (LTL or MTL) on which the
RFCA was connected. This is done to validate temperature setpoints and annunciate
Caution and Warning (C&W) alarms. Figure 3-22 shows the physical locations of each
RFCA in relation to the US Lab racks.
3-22
01.07.05(0)T0012
Basic, CPN-1
LAB1O6 LAB1O5 LAB1O4 LAB1O3 LAB1O2 LAB1O1
Systems ISPR ISPR ISPR ISPR ISPR

Ceiling (Overhead)
DDCU
racks Avionics
Rack 1
M L/M L/M L/M L/M L/M
Standoff
OP
RFCA RFCA RFCA RFCA RFCA
LAB1P6 LAB1P5 LAB1P4 LAB1P3 LAB1P2 LAB1P1
Port Systems Systems ISPR Systems ISPR ISPR

racks Cabin MSS 2 Lab DDCU
Air/Low Temp Console Avionics
TCS Rack Rack Rack 2
L M L/M M L/M L/M
Standoff
PD
RFCA RFCA RFCA RFCA
L&M M M L/M M M
Floor (Deck) Systems Systems Systems Window Systems Systems

racks Avionics 1/
ARS Rack Cond. CHeCS Rack Avionics 3 Avionics 2
Rack Rack
Rack
LAB1D6 LAB1D5 LAB1D4 LAB1D3 LAB1D2 LAB1D1
RFCA RFCA RFCA RFCA
Standoff
SD
L&M M L/M L/M L/M L/M

L/M
Starboard Systems Systems ISPR ISPR ISPR ISPR

racks
Cabin MSS1/Cupola
Air/Mod. Console
Temp TCS Rack
Rack
LAB1S6 LAB1S5 LAB1S4 LAB1S3 LAB1S2 LAB1S1
Legend L/M = Low or moderate temperature cooling L = Low temperature cooling only OP O OS
L&M = Low and moderate temperature cooling M = Moderate temperature cooling only
P S
= MFCV = Low Temp lines = Moderate Temp lines = RIP/hinge
D
PD SD
01.07.05(0)T0012_098
Figure 3-22. Lab RFCA locations
3-23
01.07.05(0)T0012
Basic, CPN-1
3.2.8 Manual Flow Control Valve
The MFCV is a floating ball valve within a welded stainless steel housing. The valve
interfaces with the ITCS plumbing through two 1.27 cm (0.5 in.) threaded fluid fittings. A
10-division dial, as seen in Figure 3-23, is provided with open and close labels placed at
the ends of travel. A position arrow identifies current valve position.
Figure 3-23. Manual flow

control valve
As mentioned in Section 2.2.2.4, there are three MFCVs that will require crew
interaction on a periodic basis. On-orbit, when the crew has made significant changes
in an MFCV position (such as moving from full open to full close during a CCAA
switchover), the SFCA MOD Vlv has been unable to compensate for the change in
pressure that was introduced into the system by the movement. FDIR reaction to the
pressure spike was to reduce the speed on both pumps in order to reduce the overall
pressure in the system. In order to prevent this FDIR response in the future, crew
procedures have been updated to reflect the fact that crews are only allowed to move
an MFCV valve one tick at a time. They must wait a brief period (~15 sec) between
each tick mark to allow the SFCA MOD Vlv to compensate for the pressure change.
Table 3-9 identifies the MFCV locations and valve positions currently in operation within
the US Lab.
3-24
01.07.05(0)T0012
Basic, CPN-1
Table 3-9. MFCV service
Valve setting
(ticks open) Temperature Flowrate
Component serviced Rack location
(On-orbit config as of insight (Y/N) (kg/hr)
3/03)
DDCU 1 LAB1P3 3.10 Y 126.1
MSS-2 LAB1P5 TBD Y 75.8
P6 CCAA LAB1P6 6.6 Y 539.8
LTL TCS rack coldplate LAB1P6 0 (closed) N 0
DDCU 2 LAB1O6 3.15 Y 129.3
MSS-1 LAB1S5 TBD Y 75.8
S6 CCAA LAB1S6 0 (closed) Y 0
MTL TCS rack coldplate LAB1S6 0 (closed) N 0
Avionics rack 2 LAB1D1 2.2 Y 54.4
CHeCS LAB1D4 2.60 Y 62.6
CDRA LAB1D6 3.2 Y 122.5
AAA LAB1D6 2.8 N 64.9
HTL supply to Node 1 Aft endcone 10 (full open) Y --
Fwd endcone Fwd endcone 7.5 Y 126.6
Aft endcone Aft endcone 4.0 Y 105.7
Rack Standalone Temperature Sensor (RSTS): In most cases, an RSTS is located

just before an MFCV. The RSTS monitors and transmits operating fluid temperatures to
Tier III MDMs (LA-1, 2, or 3). These sensors utilize a contact-type, 1-K ohm RTD. The
RTD is mounted within a hermetically sealed stainless steel housing that threads into a
boss attached to the fluid line. The temperature sensor monitors the skin temperature
of the water line. This nonintrusive design allows for temperature measurement of the
fluid without introducing additional possible leak sites. An installed temperature sensor
is shown in Figure 3-24.
Figure 3-24. Rack standalone

temperature sensor
3-25
01.07.05(0)T0012
Basic, CPN-1
3.2.9 System Flow Control Assembly
Table 3-10 identifies the SFCA components. The SFCA has a dry weight of
approximately 12.7 kg (28 lb) and an envelope of 55.9 by 21.6 by 34.3 cm (22.0 by
8.5 by 13.5 in.).
Table 3-10. SFCA components

Component Function
Flow Control Valve (FCV or Mod Vlv) Regulates dP between supply and return headers
SOV Shuts off flow to the PPA
Differential pressure sensor 3URYLGHVDQDORJ 3WR0'0
Power/data connectors Interface with EPS (power) and CDH (commands and
data)
QDs (3) Interface with ITCS PPA and supply and return
headers, 2.54 cm (1.0 in.)
The SFCA Mod Vlv and SOV use a 120 V dc brushless motor with a controller to turn a
ball valve. Mechanical stops are located at the end of the shaft at the valve open and
closed positions where optical sensors detect the end of travel. The signals from the
optical sensors are sent to the controller, which removes power from the motor when
the valve reaches the fully open or closed position. SOV position sensor signals are
also sent to the LA MDMs. The position sensor signals for the SFCA Mod Vlv are not
available to the LA MDMs.
Normally, Mod Vlv position is determined by CLC software in the LA MDMs based on
the P sensor. Valve position also can be changed by the operator sending a voltage
and duration to the controller. The valve can be commanded to move at different
speeds according to the input voltage (± 0.3 V dc to ± 5.0 V dc), where negative
voltages drive the valve open and positive voltages drive the valve closed. At the
maximum ± 5 V dc, the actuator rotates the valve through its full range in about 14 to
20 seconds. At the minimum ± 0.3 V dc, the actuator rotates the valve through its full
range in about 270 to 344 seconds.
Normally, SOV position is determined by software in the INT MDM, e.g., during an ITCS
mode transition. The operator, sending an open or close command, can also change
valve position. End-of-travel interrupters at the extreme valve positions provide signals
for automatically shutting off power to the dc motor when the valve reaches the selected
position. SOV discrete position telemetry is available; however, this discrete valve
positioning data is available only when power is applied to the SOV, as well as to the
respective LA MDM. The actuator rotates the valve through its full range in about
3 seconds.
Manual override of either SFCA valve is accomplished by pulling the associated knob
coupled to the actuator, disengaging the actuator, and then rotating the valve to the
desired position. The manual override knob also provides a visual and tactile indication
of valve position. The maximum torque required to operate the valve in the manual
mode is 20 in/lb.
3-26
01.07.05(0)T0012
Basic, CPN-1
3.2.10 Three-Way Mixing Valve
Table 3-11 identifies the TWMV components. The TWMV has a dry weight of
approximately 6.31 kg (13.9 lb) and an envelope of 17.8 by 37.9 by 31.8 cm (7.0 by
14.9 by 12.5 in.).
Table 3-11. TWMV components

Component Function
Three-port valve Regulates water temperature
Power/data connectors Interface with EPS (power) and C&DH (commands and data)
QDs (3) Interface with ITCS supply, bypass, and return headers,
2.54 cm (1.0 in.)
The TWMV three-port valve uses a 120 V dc brushless motor with controller to turn a
ball valve. Mechanical stops and optical sensors (that detect end of travel) are located
at the end of the shaft at the valve flowthrough and bypass positions. The optical
position sensor signals are sent to the controller, which removes power from the motor
when the valve reaches the flowthrough or bypass position. The position sensor signals
are also sent to the LA MDMs.
Normally, the three-port valve position is determined by CLC software in the LA MDMs
based on the temperature sensor. Valve position also can be changed by sending a
voltage and duration to the controller. Valve discrete positioning telemetry (“Flothru,”
“Byp,” or “Mod”) is continuously available whenever the TWMV has power and the
software is started. This includes when the valve is manually repositioned. At the
maximum ± 5 V dc, the actuator rotates the valve through its full range in approximately
12 seconds. At the minimum ± 0.3 V dc, the actuator rotates the valve through its full
range in approximately 220 seconds.
For the LTL and MTL TWMVs (Figure 3-25), a negative voltage drives the valve toward
the flowthrough position (forcing water to flow through the heat exchanger); a positive
voltage drives the valve toward the bypass position (forcing water to flow around the
heat exchanger).
3-27
01.07.05(0)T0012
Basic, CPN-1
From
IFHX
(cool) Outlet
Port B
(flowthrough) (mixed)
From PPA
(warm)
MDM connector
Power connector
Port A
(bypass)
+ 5 V rotates valve toward Port A

(increases loop temperature) 01.07.05(0)T0012_099
Figure 3-25. LTL and MTL TWMV

For the Regen HX TWMV (Figure 3-26), a positive voltage drives the valve toward the
flowthrough position; a negative voltage drives the valve toward the bypass position.
From PPA
Port B (warm)
(bypass) Outlet
(mixed) From RHX
(cool)
MDM connector
Power connector
Port A
(flowthrough)
+ 5 V rotates valve toward Port A

(increases loop temperature) 01.07.05(0)T0012_100
Figure 3-26. Regen HX TWMV
3-28
01.07.05(0)T0012
Basic, CPN-1
3.2.11 Loop Crossover Assembly
Table 3-12 identifies the LCA components. The LCA has a dry weight of approximately
23.9 kg (52.7 lb) and an envelope of 63.5 by 39.4 by 26.7 cm (25 by 15.5 by 10.5 in.).
Table 3-12. LCA components

Component Function
Eight-port valve (2) Connects the LTL and MTL in series
QDs (4) Interface with ITCS LTL and MTL plumbing 2.54 cm (1.0 in.)
Both eight-port valves (valve 1 or valve 2) consist of two four-port ball valves, which are
stacked and connected by a common shaft as seen in Figure 3-27. A 120 V dc
brushless motor with a controller turns each eight-port valve assembly. Mechanical
stops and optical sensors (that detect end of travel) are located at the end of the shaft at
the dual and single positions. Signals are sent to the controller, which removes power
from the motor when an end of travel is detected. The actuator rotates the valve
through its full range in 3 seconds.
Dual configuration Single configuration
Eight-port valve Eight-port valve
From MT From MT
I/FHX I/FHX
To MT To MT
loads loads
Valve 2
Valve 2
Valve 1
Valve 1
To LT To LT
I/F HX From LT I/F HX From LT
loads loads
Fluid Fluid
disconnect half disconnect half
010705(0)T0012_164
Figure 3-27. LCA valve schematics (dual vs. single)

Normally, valve 1 or valve 2 position is determined by software in the INT MDM;
however, valve commanding is performed by the LA MDMs, which interface directly with
the hardware. Valve position also can be changed by sending commands or by
physically moving the valve using the manual override lever. LCA valve position
telemetry is updated only while the LCA valve is powered. Therefore, should either
valve change position, such as in a manual reconfiguration, telemetry will still display
the previous position until the LCA valve actuator is enabled. Discrete telemetry
requires that both the respective LA MDM be operational and the valve actuator be
powered.
3.2.12 Interface Heat Exchanger

Table 3-13 identifies the IFHX components associated with the ITCS (i.e., waterside
only). Each IFHX core measures 6.35 by 12.7 by 49.5 cm (2.5 by 5.0 by 19.5 in.),
weighs 8.16 kg (18 lb), and consists of 45 layers.
3-29
01.07.05(0)T0012
Basic, CPN-1
Table 3-13. IFHX ITCS components
Component Function
Core Allows heat transfer from ITCS water to EETCS/ETCS
ammonia
Temperature sensor Measures water inlet temperature
Line heaters (3) Prevent water from freezing; heaters are wired in parallel
and powered by one Remote Power Controller (RPC)
Line heaters (2), temperature sensors Prevent water from freezing; not part of the ORU.
(2) Heaters and RTDs are located on the external water
lines
Power/data connectors (2) Provide the IFHX interface with EPS and CDH
QD (4 total) Provide the EETCS/ETCS-to-IFHX and ITCS-to-IFHX
connections
The IFHX performs the critical function of transferring heat from the ITCS to the
EETCS/ETCS. Due to the proximity of water to ammonia, heaters inside the IFHX and
on the external water lines are necessary to prevent freezing of stagnant water.
Software in the INT MDM monitors three temperature sensors. If any one of the three
temperature sensors falls below 2.8° C (37° F), software commands the associated
heaters on. If all three temperature sensors are above 4.4° C (40° F), software
commands the associated heaters off.
3.2.13 ITCS Contingency Jumpers

If there is a significant water leak in either loop, the PPA in that loop must be shut down
to minimize the amount of water escaping into the Lab. TCS software is designed to
recognize a leak, ensure the system is in dual-loop mode, shut down the associated
PPA, and depress the accumulator (see Section 3.6.2). Once a PPA has been shut
down, the equipment in that loop will not be cooled. The modular design of the ITCS
allows the crew to perform physical reconfiguration of the ITCS using flexible hoses with
self-sealing QDs on each end (jumpers) to regain cooling to critical ORUs. Most racks
in the Lab can be connected to either loop. Table 3-14 identifies the ITCS Contingency
jumpers.
Table 3-14. ITCS contingency jumpers
Flight On-orbit stowage
Jumper Part number
(usable) (as of 5/03)
Fwd endcone to LTL NA 5A Installed (To MTL)
LAB1D1 (AV-2) to LAB1P1 (ISPR) LTL 683-56836-520 5A LAB1S0 01
LAB1D5 (AV-1) to LAB1D6 (AR) LTL 683-56836-522 5A LAB1S5 A2
LAB1P3 (DDCU-1) to LAB1D3 (Window) LTL 683-56836-520 UF-1/8A LAB1S5 A2
LAB1O6 (DDCU-2) to LAB1O5 (ISPR) LTL 683-56836-521 5A.1 LAB1S5 A2
LAB1P5 (MSS-2) to LAB1P4 (ISPR) LTL 683-56836-521 UF-1 LAB1S5 A2
Airlock jumper assembly 683-56046-1 7A.1
Coldplate jumper assembly (2) 683-56836-342 5A.1/8A LAB1S5 A2
LCA jumper 683-56836-341 UF-1 LAB1S5 A2
3-30
01.07.05(0)T0012
Basic, CPN-1
MTL Leak Reconfiguration
All critical USOS avionics in the Lab are connected to the MTL. This exposes the
majority of USOS capabilities and systems to risk if the MTL is lost. For cases where
the MTL is lost, the following reconfigurations will be performed:
a. Two jumpers on the starboard side of the forward endcone (see Figure 3-28) must
be reconfigured to the LTL connections directly above the current MTL connections.
This provides immediate cooling to the ten coldplates in the forward endcone.
Table 3-15 identifies the critical avionics in the forward endcone and the expected
overheat times if no cooling is available.
Table 3-15. Forward endcone equipment

overheat times
Predicted time to overheat
Load
(7A flight data)*
LA-1 MDM 1 hour
GNC-1 MDM 1 hour
C&C-3 MDM 1 hour (1.3 hours)*
IAC-1 45 minutes
DDCU LA1B 2 hour (3.7 hours)*
Note: Similar equipment (MDMs and a DDCU) resides in the aft endcone;
however, there is no capability to jumper the aft endcone to the LTL fluid
loops. Hence, a loss of the MTL will eventually require shutdown of the aft
endcone DDCU (LA2B) that powers one full string of avionics equipment
within the US Lab.
Figure 3-28. Forward endcone

jumpers
3-31
01.07.05(0)T0012
Basic, CPN-1
b. Rack LAB1D1 must be switched to the LTL using the Z-panel connections for rack
LAB1P1. This provides cooling to the four coldplates in LAB1D1. Rack LAB1P1,
which is a payload rack, must be shut down since it is no longer receiving cooling.
Table 3-16 identifies the critical avionics equipment located in the LAB1D1 rack and
the expected overheat times if no cooling is available.
Table 3-16. LAB1D1 equipment

overheat times
Predicted time to overheat
Load
(7A flight data)*
INT-1 MDM 1 hour
C&C-1 MDM 1 hour (1.5 hours)*
PL-1 MDM 1 hour
PMCU-1 MDM 1 hour (1.8 hours for PMCU-2)*
c. Rack LAB1P3 (DDCU-1 rack) can be switched to the LTL using the Z-Panel
connections for payload rack LAB1D3. The LAB1P3 rack contains DDCU LA1A,
DDCU LA4A and several power buses. These DDCUs provide power to the C&C-3
MDM, which is physically located in the forward endcone, the EVA MSS-2 rack, as
well as several payload racks and equipment located within the Airlock. Operational
data (at Flight 7A) indicates the rack DDCUs will overheat within 5 to 6 hours
without cooling. In order to keep these DDCUs operating, and hence their
downstream loads powered, the rack will need to be jumpered to the LTL.
If there are EVA or robotics operations being performed, the following racks supporting
those operations will also be reconfigured.
a. Rack LAB1D5 contains the Space-to-Space Station Radios (SSSRs) that provide
communication between the ISS and EVA crewmembers. The two radios are
enclosed in one physical ORU. The other equipment within this rack is powered by
the aft endcone DDCU that, as mentioned earlier, will have to be shutdown.
However, SSSR 2 actually receives power from DDCU LA1B; thus, by providing
cooling to the D5 rack, power can be routed to the SSSR via the DDCU LA1B
power feed and communication between the ISS and EVA crewmembers can be
restored. Jumpering this rack to the LTL involves the use of the LTL connections on
the LAB1D6 (AR) rack, which nominally provide cooling to the Carbon Dioxide
Removal Assembly (CDRA). The LTL connections feeding the LAB1D6 rack are
disconnected and jumpers are used to connect these standoff connections to the
LAB1D5 rack interface panel. Cooling to the CDRA is lost when this jumper is
installed, so Russian equipment will have to provide carbon dioxide removal
functions for the entire ISS.
b. Rack LAB1O6 (DDCU-2 rack) can be switched to the LTL using the Z-Panel
connections for payload rack LAB1O5. The LAB1O6 rack contains DDCU LA2A,
DDCU LA3B and several power buses. These DDCUs provide power to the EVA
MSS-1 rack, as well as several payload racks and equipment located within the
Airlock. As stated above, operational data indicates the rack DDCUs will reach their
3-32
01.07.05(0)T0012
Basic, CPN-1
overtemp limits within 5 to 6 hours; thus, if an EVA is in progress (or planned), this
rack will need to be jumpered to the LTL in order to continue the operation of the
DDCUs and their downstream loads.
c. Rack LAB1P5 (MSS-2 rack) can be switched to the LTL using the Z-panel
connections for payload rack LAB1P4. The MSS rack is needed to manipulate the
Canadarm2 (ISS robotic arm) in support of EVA operations.
Note: These same jumpers can also be used to connect LAB1S5 (MSS-1 rack) to
LAB1S4 payload rack in the event there is a problem with the MSS-2 rack.
After each jumper reconfiguration, the accumulator quantity in the LTL is monitored to
ensure the leak has not propagated to that loop. If the leak has propagated to the LTL,
then the crew can isolate the problem rack/endcone, reconnect all other racks back to
the MTL, and restart the MTL PPA. Additional reconfigurations will be necessary
depending on the equipment that resides in the problem rack/endcone.
If the leak was not found after jumpering the required MTL racks to the LTL, then the
leak must be in the standoffs, the aft endcone, one of the modules (Node 1 or Airlock),
or in one of the remaining MTL racks. A long-term leak recovery plan would be
developed that requires the crew to investigate each of the remaining areas for signs of
the leak. In the meantime, the MTL would have to remain shut down and the
temperature setpoint of the LTL TWMV would be raised above the dew point. This is
necessary to prevent condensation from forming on the uninsulated MTL lines that were
hooked up to the LTL.
If the crew is able to determine the location and size of the leak, attempts will be made
to repair it. When repairs are completed and the integrity of the MTL has been verified,
the forward endcone and all racks will be returned to their original configuration and
nominal operations will resume.
LTL Leak Reconfiguration
The only significant USOS equipment in the Lab connected to the LTL is the CDRA and
the two CCAAs. Reconfiguring the LTL is not time-critical since the functions performed
by the CDRA and CCAA are available from the Russian Segment. However, one
contingency jumper has been designed to restore CCAA functions within the Lab and to
provide LTL or MTL cooling to the Airlock during an EVA.
a. The Airlock/rack jumper assembly was designed to restore low-temperature cooling

to the CCAA in the LAB1S6 (MTL) rack or to the Airlock Service and Performance
Checkout Unit (SPCU) and cabin air heat exchangers. (The SPCU Heat Exchanger
(SPCU HX)) provides cooling to the critical EVA Mobility Unit (EMU) and must be
used prior to an EVA.) Figure 3-29 shows how the Airlock/rack jumper can be
connected just downstream of the MTL TWMV where the MTL plumbing would
normally connect to the LCA and then connect to the Node 1 LTL supply line. The
return portion of the jumper is connected to the Node 1 LTL return line and then to
the LCA inlet. This configuration allows cool water exiting the MTL IFHX and
3-33
01.07.05(0)T0012
Basic, CPN-1
TWMV to be directed to the Airlock. Warmed fluid returning from the Airlock is then
passed through the LCA directly to the Regen HX where the temperature of the fluid
can be raised to the MTL setpoint, if needed. When there is no EVA in progress,
this jumper can be connected to the LAB1S6 LTL supply and return connections
instead of the Node 1 supply and return connections in order to provide cool ITCS
fluid to the LAB1S6 CCAA.
The Airlock jumper assembly (see Figure 3-30) is launched and stored dry and
must be filled by the Fluid System Servicer (FSS) prior to activation in any scenario.
The dry volume of the jumper is nearly 1.5 gallons, which exceeds the capability the
PPA gas trap.
Note: This jumper can also be used to provide MTL cooling to the Airlock in the
event of an MTL failure during an EVA.
3-34
01.07.05(0)T0012
Basic, CPN-1
AL MTL jumpering
Demate MTL supply

and return to Node 1
at QD. Mate AL
jumper 6-foot flex
connectors QDs.
(connection not shown)
AL LTL jumpering
Demate LTL supply and return

to Node 1 at QD. Mate AL
jumper 6-foot flex connector
QDs (connection shown)
AL LTL jumpering
Demate MTL TWMV out to

LCA valve 1 inlet QD. Mate AL
jumper 20-foot flex hose QDs
to QDs previously demated.
(connection Shown)
AL MTL jumpering
Demate LTL return to LCA

valve 2 inlet QD. Mate AL
jumper 20-foot flex hose to
QDs previously demated.
(connection not shown)
01.07.05(0)T0012_101
Figure 3-29. Functional schematic showing airlock jumper installation
3-35
01.07.05(0)T0012
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Figure 3-30. Rack/Airlock jumper assembly

Coldplate Leak Reconfiguration
Coldplates within a rack or endcone are plumbed in series. Two coldplate jumpers are
included onboard that can be used to jumper across a leaking coldplate and thereby
return cooling to the rest of the equipment within the rack/endcone. The assembly is a
152.4 cm. (60 in.) flex hose assembly with Gamah fittings attached at both ends. The
assembly is rated to 861.9 kPa (125 psia) and is stowed in the LAB1S5 rack. Because
coldplate connections are Gamah fittings versus self-sealing QDs, replacement of a
coldplate or installation of the coldplate jumper will require loop shutdown and
depressurization.
3-36
01.07.05(0)T0012
Basic, CPN-1
LCA Jumper Reconfiguration
Should the LCA require replacement while on orbit, two LCA change-out jumpers may
be installed in order to maintain cooling in the Lab. To replace the LCA, all four QD
connections to the LCA must be demated, resulting in an interruption of both MT and LT
flow paths during the installation process. To prevent the loss of all cooling during this
period, the change-out jumper may be installed as shown in Figure 3-31 to maintain
flow in each loop (MT loop shown).
Changeout
To MT
From Loads
MT IFHX
Valve 1 Valve 2
From
To LT LT Loads
IFHX DUAL DUAL
010705(0)T0012_157
Figure 3-31. LCA jumper reconfiguration

Note: Each PPA must be shut down while installing its jumper.
In addition to its primary purpose of effecting LCA change out, the change-out jumpers
allow some contingency flexibility. For example:
a. A loop could be isolated from the other loop in the event of an LCA valve failure
while in single.
b. The ITCS could be jumpered into single in the event of a failed PPA and LCA valves
failed in dual.
In contingency cases, the status of PPAs, LCA valves, and SOVs must be closely
monitored to avoid deadheading a pump or draining an accumulator. Additionally,
software-mode algorithms will most likely not work.
3.2.14 ITCS Overview Display

Figure 3-32 shows the ITCS Lab overview display available on the PCS. All ITCS
commands and telemetry can be accessed from this overview. Details on each of the
commands available for the ITCS are found in Section 3.6.
3-37
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Figure 3-32. *ITCS Lab overview PCS display

*Note: IATCS is the nomenclature found in various original Boeing documentation, but all training
documentation will refer to this system as the Internal Thermal Control System (ITCS).
3-38
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3.3 EARLY EXTERNAL THERMAL CONTROL SYSTEM COMPONENTS
This section presents more details about the EETCS hardware components.
3.3.1 Interface Heat Exchanger

Table 3-17 identifies the IFHX components associated with the EETCS (i.e., ammonia
side only).
Table 3-17. IFHX EETCS components

Component Function
Core Allows heat transfer from ITCS water to EETCS ammonia
Temperature sensor Measures ammonia outlet temperature
Bypass valve Allows ammonia to bypass the IFHX core
Isolation valve Prevents backflow of ammonia into a bypassed IFHX core
Electronic control unit (2) Provides power and logic circuitry to the bypass and
isolation valves
Relief valves (2) Prevent overpressurization of ammonia in the fluid lines
Power/data connectors (2) Provide the IFHX interface with EPS and CDH
QDs (4 total) Provide the EETCS-to-IFHX and ITCS-to-IFHX connections
As discussed in Section 2, the IFHX performs the critical function of transferring heat
from the ITCS water to the EETCS ammonia. Since the ammonia pressure in the
EETCS loops is higher than the water pressure in the ITCS loops, the IFHXs are
susceptible to leakage of ammonia into the ITCS water. If this occurred, the gas trap in
the PPA would allow ammonia vapor into the Lab atmosphere. Additional risks include
water freezing in the core and structural failures. Extensive analysis has been
performed in order to minimize these risks. Table 3-18 summarizes the risks, causes,
and corrective actions.
Table 3-18. IFHX freezing/leakage risks and preventative measures

Risk/Hazard Cause Preventative measures
Internal structural Inadequate strength, stress Selection of proper materials, manufacturing
failure corrosion, materials incompatibility, processes, and correct testing procedures
or propagation of crack-like defects
Water freezing Ammonia temperature below 0° C Three levels of redundancy in ammonia
temperature control and operational safeguards*
Overpressurization of IFHX bypass valve in bypass while Modifications to IFHX plumbing and software
IFHX core IFHX isolation valve is closed control of the IFHX bypass and isolation valves*
*See Section 3.6.4
The IFHX bypass and isolation valves use a 120 V dc brushless motor with ECU to turn
a ball valve. Both IFHX valves are driven by SDO cards in the Node 1 MDMs. The
software in the Node 1 MDMs applies power to the ECU, which provides power to the
valve motor.
Position indicators detect end of travel at the flowthrough and bypass positions (bypass
valve) and open and closed positions (isolation valve). The ECU removes power when
the valve has reached the desired position. DIO cards in the Node 1 MDMs read the
3-39
01.07.05(0)T0012
Basic, CPN-1
position indicators. Software in the Node 1 MDMs removes power from the ECU when
the valve has reached the desired position or after 15 seconds has elapsed. (The
position indicators are available continuously.)
IFHX valve control is illustrated in Figure 3-33. (See Figure 2-30 for an IFHX
schematic.)
To/from C&C MDMs
Loop A N1-1
Loop B N1-2
IFHX valve commands

and telemetry
PFCS T T
LTL IFHX (Loop A)

Radiators MTL IFHX (Loop B)
010705(0)T0012_049
Figure 3-33. IFHX control (Flights 5A through 12A.1)

Table 3-19 describes the physical characteristics of the EETCS IFHXs.
Table 3-19. EETCS IFHX physical characteristics

EETCS IFHXs
Size (outside 63.5 × 55.9 × 20.3 cm (25.0 × 22.0 × 8.0 in.)
dimensions)
Weight (water side filled) 47.6 kg (105.0 lb)
Heat load (pumps 25 kW (max)
o
operating) 14 kW (for Beta < 52 )
o
9.5 kW (for Beta > 52 )
Core construction 23 layers of water passages, 22 layers of ammonia
passages
Core thickness 6.4 cm (2.5 in.)
Power requirements 50 W (heaters, total)
(ITCS) 1 mA (temperature sensor)
Power requirements 45 W (bypass valve)
(EETCS) 45 W (isolation valve)
1 mA (temperature sensor)
Manufacturer Boeing-MD
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3.3.2 Pump and Flow Control Subassembly

Table 3-20 identifies the PFCS components.
Table 3-20. Pump and flow control subassembly components summary

Component Function
Pumps (2) Ammonia circulation
Dual check valve Prevents backflow of ammonia into nonoperating pump
Flow control valve Loop temperature control
Accumulator Maintains loop pressure, allows for thermal expansion
and contraction of ammonia, provides ammonia for leak
makeup
Signal Conditioning Interface Power distribution and sensor signal conditioning;
(SCI) includes FCV motor controller
Local Data Interface C&DH interface; firmware performs leak detection, FCV
positioning, and radiator deploy/retract
Debris screens and filters (7) Filters contaminants from fluid stream
Flowmeter Provides analog dP to the MDM for flowrate
computation
Temperature sensors (4) Measure pump inlet/outlet temperatures
Pressure sensors (2) Measure pump inlet/outlet pressures
FQDCs Provide the EETCS plumbing connections to the PFCS
3-41
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The PFCS (Figure 3-34) controls ammonia temperature in each loop using FCV and line
heaters. The FCV position and heater control algorithms are located in the PVCU
MDM. The software in the PVCU MDM samples temperature data and calculates a new
FCV position at 1.0 Hz.
Local data Signal
Inlet from interface conditioning
radiators Flowmeter interface
Inlet from
bypass line
Flow
control
valve
Fluid
manifold
assembly
Pump motor
controllers
Accumulator 01. 07.05(0)T 0012_103
Figure 3-34. Pump and flow control subassembly

The PVCU MDM uses the two outlet temperature sensors to determine FCV position
(see Section 3.6.5). The software filters sensor noise and rejects sudden changes in
the two temperature sensors by performing a running average calculation (intrasensor
validation). A slow drift of the two PFCS outlet temperature sensors is detected by
calculating the difference between them (intersensor validation). The software defaults
to the lower temperature and calculates a FCV position command based on this
temperature and the control setpoint. The FCV position command is sent to the LDI
where the firmware calculates the corresponding actuator steps and valve direction.
The LDI then transmits the pulse commands to the FCV motor controller.
Note: Although the system was designed to operate at 3.6° C (38.5° F), operationally,
a setpoint of 5.8° C (42.5° F) is being used to ensure that an under-temperature
condition and the associated FDIR action do not occur during system
transients.
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The PFCS manifold is shown in Figure 3-35.
FCV motor
FCV position
sensor
Inlet Inlet
(warm, from bypass line) (cool, from radiators)
Temperature Temperature
sensor sensor
Outlet Outlet
(pump A) (pump A)
FCV
Debris screen Debris screen
Pump A Pump B
010705(0)T0012_061
Figure 3-35. PFCS manifold assembly

Under certain conditions the FCV position may be unknown. The PVCU MDM can
initiate a recalibration of the FCV to reestablish a known position. The recalibration
algorithm commands the FCV from an uncertain position (counterclockwise) past the full
bypass position against the hardstop, and then commands the FCV back (clockwise) to
the true bypass position. The recalibration of the FCV can be initiated by a command.
It is automatically performed when the PFCS is powered up (if Auto Recal is enabled),
or if the PFCS outlet temperature exceeds 8.3° C (if FCV Temp Recal is enabled).
PFCS control is illustrated in Figure 3-36. (See Figure 2-35 for a PFCS schematic.)
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Commands and telemetry* Loop A N1-1
Loop B N1-2
Primary PVCU-4B
Secondary PVCU-2B
Two RTDs FCV One RTD is connected to PVCU-4B,

inside PFCS commands the other is connected to PVCU-2B
T T
PFCS
RPC commands
Radiators
RPCs IFHX
Line
heaters
* Note: On Flight 4A, the Node 1 MDMs send

commands to start the EETCs. On
Flight 5A and subsequent flights,
PVCU coomands and telemetry are
passed through to the C&C MDMs.
01.07.05(0)T0012_104
Figure 3-36. PFCS control (Flights 5A through 12A.1)

The PVCU MDM monitors the two quantity sensors on the PFCS accumulator for
ammonia leaks. (The radiator accumulator quantity sensors were intended to be used
in this leak detection software; however, due to a miswiring of the sensors, they have
been “deselected” from the software algorithm and are no longer being monitored for
leaks.) If the average of the two PFCS quantity sensors drops below 10 percent, the
PVCU MDM issues a caution message. The LDI monitors the same two sensors;
however, if either quantity drops below 4 percent, the firmware commands the active
pump off and sends a leak indicator signal to the PVCU MDM.
3.3.3 Radiators
The aft radiator is identified as the TTCR; the starboard radiator is identified as the
STCR. Table 3-21 identifies the radiator components.
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Table 3-21. Radiator component summary
Component Function
Panels (7) Radiate waste heat to space
Base structure Structural support and interface with P6 Truss
Deploy/retract mechanism Deployment and retraction of radiator panels
Cinching/winching Secures retracted radiator for launch or transportation
mechanism
Accumulators (2) Maintains loop pressure, allows for thermal expansion
and contraction of ammonia, provides ammonia for leak
makeup
FQDCs (2) Provide connection for radiators with EETCS fluid lines
Each radiator panel is constructed of an aluminum honeycomb matrix with aluminum

extrusions protecting the panel tubes from micrometeoroids and orbital debris. Radiator
ORUs weigh approximately 657.7 kg (1450 lb). The panels are 3.15 by 1.79 by 0.02 m
(124 by 70.6 by 0.69 in.). Twenty-four stainless steel flow tubes transport ammonia
across the panel. Nineteen of 24 flow tubes are equally spaced (67.31 mm (2.65 in.)
apart) throughout the height of the panel. The panel is designed so that Loop A and
Loop B each flow through 12 of the 24 flow tubes, alternately. These Inconel flow tubes
have an inside diameter of 0.170 cm, and are bonded in two-piece aluminum
extrusions. The ammonia flow paths are illustrated in Figure 3-37.
Flex hoses
Manifold
7 panels
Flex hoses
(connect manifolds)
Legend
Loop A
Radiator inlet Radiator outlet Loop B
(from IHFX) (to PFCS)
Radiator base
structure
01 .0 7 .0 5( 0)T 00 12_10 5
Figure 3-37. EETCS radiator loop flow schematic
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01.07.05(0)T0012
Basic, CPN-1
Early analyses predicted that the ammonia in the center of the outer panels could freeze
during periods of low heat loads. When ammonia thaws it expands causing high
stresses in the tubes. Significant design changes include the use of smaller diameter
Inconel panel tubes, which will withstand this freeze/thaw environment, trace heaters,
and optical property changes to some of the exposed surfaces. The manifolds and flex
hoses are not freeze-tolerant. They are protected by adding a bypass line at the inlet of
the PFCS, which allows approximately 1.0 percent of the total ammonia to continuously
flow through the radiators (see Figure 2-39).
Commands to deploy or retract the radiators are sent through the PVCU MDM to the
LDI. The LDI sends one signal to the SCI, which enables power to the radiator motor
and controller (power on), and a second signal to the motor controller activating it
(deploy or retract). When the radiator reaches the deployed or retracted position, a
signal from the corresponding limit switch is detected by the SCI and passed to the LDI.
The LDI then issues a power off signal to the SCI and a stop signal to the motor
controller.
The radiators normally reach their deployed or retracted position within 5 to 6 minutes.
This time will vary depending on thermal conditions of the radiator mechanism. The
firmware in the LDI issues a power off command to the SCI and stop command to the
motor controller 13 minutes after receiving a deploy or retract command. The PVCU
MDM, on the other hand, waits 15 minutes before issuing a stop command (if a radiator
does not reach a deployed or retracted position, it may be obstructed).
The SCI also monitors the motor while it is operating. If it detects an over-current
condition, it sends a signal to the LDI. The firmware in the LDI issues a power-off
command to the SCI and a stop command to the motor controller. The Loop A PFCS
controls the TTCR; the Loop B PFCS controls the STCR.
3.3.4 EETCS Overview Display

Figure 3-38 shows the overview display for the EETCS. All commands and telemetry
associated with the EETCS can be accessed from this display. Details on all
commands available for the EETCS are found in Section 3.6.
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Figure 3-38. EETCS overview PCS display
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3.4 EXTERNAL THERMAL CONTROL SYSTEM COMPONENTS
This section presents more details about the ETCS hardware components.
3.4.1 Interface Heat Exchangers

When fully assembled, the ETCS collects heat from 10 IFHXs mounted on the US Lab,
Node 2, and Node 3. The ETCS IFHXs are identical to the IFHXs described in.
Section 3.3 (EETCS IFHXs), with the exception that one of the ten IFHXs (N2 MTL
IFHX) is a low-load IFHX instead of a high-load IFHX. Table 3-22 describes the
differences between the two types of IFHXs.
Table 3-22. Comparison of low-load and high-load IFHX characteristics

Low-load IFHX High-load IFHX
Size (outside 63.5 × 55.9 × 20.3 cm (25.0 × 22.0 × 63.5 × 55.9 × 20.3 cm (25.0 × 22.0 ×
dimensions) 8.0 in.) 8.0 in.)
Weight (water side filled) 44.0 kg (97 lb) 47.6 kg (105.0 lb)
Heat load 12.5 kW 25 kW
Core construction 16 layers of water passages, 8 23 layers of water passages, 22
layers of ammonia passages layers of ammonia passages
Core thickness 3.8 cm (1.5 in.) 6.4 cm (2.5 in.)
Power requirements 50 W (heaters, total) 50 W (heaters, total)
(ITCS) 1 mA (temperature sensor) 1 mA (temperature sensor)
Power requirements 45 W (bypass valve) 45 W (bypass valve)
(ETCS) 45 W (isolation valve) 45 W (isolation valve)
1 mA (temperature sensor) 1 mA (temperature sensor)
Manufacturer Boeing-MD Boeing-MD
The same risks associated with the IFHXs described in Section 3.3 are valid for all
ETCS IFHXs: internal structure failure and rupture of the core caused by freezing water
or overpressurization. The same preventative measures used in the manufacturing
process noted in Table 3-18 were taken for each of the eight additional ETCS IFHXs.
The under-temperature software protection, however, is unique to the ETCS and is
discussed in Sections 3.6.7 (EXT MDM), 3.6.9 (S1/P1 MDM), and 3.6.11 (S0 MDM).
Each of these MDMs contains independent software responses that protect the IFHX
from under-temperature conditions.
IFHX Valves
The ETCS IFHX valves are controlled via the S0 MDMs: Loop A IFHX valves are
controlled by the S0-1 MDM and Loop B IFHX valves are controlled by the S0-2 MDM.
Figure 3-39 depicts the flow path through the five IFHXs on Loop A and Figure 3-40
depicts the flow path through the five IFHXs on Loop B at Assembly Complete.
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Basic, CPN-1
To/From
EXT MDMs
S0-1
IFHX valve commands

and telemetry
Loop A PM
T
Starboard LAB LTL IFHX JEM LTL IFHX N2 MTL IFHX
radiators
N3 MTL IFHX COL MTL IFHX
01.07.05(0)T0012_106
Figure 3-39. Loop A IFHX control (at assembly complete)

To/from
EXT MDMs
S0-2
IFHX valve commands

and telemetry
Loop B PM
T
Port N3 LTL IFHX COL LTL IFHX N2 LTL IFHX
Radiators
LAB MTL IFHX JEM MTL IFHX
01.07.05(0)T0012_107
Figure 3-40. Loop B IFHX control (at assembly complete)

The IFHX bypass and isolation valves use a 120 V dc brushless motor with an ECU to
turn a ball valve. Both IFHX valves are driven by SDO cards in the S0 MDMs. The
software in the S0 MDMs, called the ETCS Heat Acquisition Control (HAC) software,
applies power to the ECU that provides power to the valve motor.
Position indicators detect end of travel at the flowthrough and bypass positions (bypass
valve) and open and closed positions (isolation valve). The ECU removes power when
the valve has reached the desired position (or after 15 seconds has elapsed). The
position indicators are read by DIO cards in the S0 MDMs and are continuously
available as telemetry.
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3.4.2 External DDCU/MBSU Coldplates
In addition to providing cooling for all USOS modules through the IFHXs, the ETCS
provides cooling to several external DDCU and MBSU coldplates located on the S0, S1,
and P1 truss segments.
Coldplate ORU
The DDCU coldplate ORU was designed to acquire 694 W of heat at a minimum
ammonia flowrate of 57 kg/hr (125 lb/hr) and a maximum ammonia temperature of
3.8° C (39° F). The MBSU coldplate ORU was designed to acquire 470 W heat at a
minimum ammonia flowrate of 36 kg/hr (80 lb/hr) and a maximum ammonia temperature
of 4.4° C (40° F). The flow control orifice located in the ammonia feed line between the
inlet QD coupling and the coldplate ensures the proper flow to each coldplate.
Strip Heaters
Strip heaters attached to the external surface of the coldplate ORU are used for
extreme cold conditions to transfer heat to the DDCU or MBSU. Table 3-23 shows the
ETCS Loop, the controlling MDM, and the power connectivity for each coldplate heater
and associated sensor.
Table 3-23. ETCS coldplate temperature sensor and heater connectivity
MDM
ETCS (Reads temperature Heater power
Coldplate
loop and controls the source
heater RPC)
DDCU S01A A S0-2 RPCM S03A_E
DDCU S04B A S0-2 RPCM S03A_E
DDCU S14B A S1-2 RPCM S13A_G
MBSU 1A/1B A S0-2 RPCM S03A_F
MBSU 4A/4B A S0-2 RPCM S03A_F
DDCU S02B B S0-1 RPCM S04B_E
DDCU S03B B S0-1 RPCM S04B_E
DDCU P13A B P1-1 RPCM P14B_G
MBSU 2A/2B B S0-1 RPCM S04B_E
MBSU 3A/3B B S0-1 RPCM S04B_E
Although the MDMs listed in Table 3-23 monitor the temperature data from the external
coldplates, they do not process the data for any type of closed-loop control of the heater
element. The control software for the heaters is contained within the Power
Management Control Unit (PMCU) MDMs (see Section 3.6.12).
3.4.3 Pump Module (PM)

The PM ORU contains a Pump and Control Valve Package (PCVP) that circulates liquid
ammonia at a constant flowrate and controls the ammonia supply temperature.
Figure 3-41 shows a picture of the PM and Table 3-24 describes the function of the
individual components.
3-50
01.07.05(0)T0012
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Accumulator
PCVP
01.07.05(0)T0012_158
Figure 3-41. Pump module

Table 3-24. Pump module components summary
Component Function
PCVP pump Ammonia circulation
PCVP FCV Loop temperature control
PCVP firmware controller Provides 1553 RT communication to the S1/P1 MDMs,
controls the pump speed and FCV actuation
PCVP pump outlet temperature Used to determine the ammonia temperature and provide
sensors (3) closed loop control of the FCV
PCVP controller temperature Temperature of the PCVP firmware controller
PCVP speed sensor Measures pump speed
PCVP position sensor Measures FCV position
Accumulator Works with the ATA to maintain loop pressure, allow for
thermal expansion and contraction of ammonia, and provide
ammonia for leak makeup
Accumulator heaters (2) Provides additional heat to maintain the PM above operational
limits.
Flowmeter (2) Provides analog dP to the MDM for bypass line and outlet
flowrate computation
Temperature sensors (8) Measures pump outlet, bypass and return line temperatures,
plus the accumulator heater temperatures
Pressure sensors (5) Measures pump and accumulator inlet/outlet pressures
Line heaters (2) Provides additional heat to the bypass line during low heat
load periods
Isolation valves (4) Provides isolation of the bypass line, radiator return line, ATA
inlet line, and pump outlet line
Relief valves (2) Provides over-pressurization relief of the ATA inlet lines
QDs (4) Provide the ETCS plumbing connections to the PM
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The physical characteristics of the PM ORU are shown in Table 3-25.
Table 3-25. PM physical characteristics

Location Inboard nadir – S1/P1 truss, external
Weight (dry) 413.7 kg (912 lb)
152.4 x 424.5 78.7 cm)
Envelope
(60 x 49 x 31 in.)
Operational life 10 yr
Pump and Control Valve Package
The PCVP components are shown in Figure 3-42.
PCVP
firmware
controller
Power connector
S 1/P1 MDM connector
F irmware cooling tube
Pump
B ypas s Accumulator line
PCVP temperature
Outlet s ens ors (3)
Inlet
F low from
F low Control R adiators
Control Valve
Valve (F CV)
Cover 01.07.05(0)T 0012_148
Figure 3-42. PCVP components
3-52
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PCVP Pump
The PCVP utilizes a variable speed pump to provide the necessary flowrate and
pressure head to the ETCS system. The flowrate can range between 3175 and
4309 kg/hr (7000 and 9500 lb/hr), with an associated head rise between 220 and 385
kPa (31.9 and 55.85 psid). The pump can operate within a range of 11,250 rpm to
18,000 rpm. Operationally, the nominal pump speed will be 11,500 rpm until the 10A
mission timeframe. This is done in order to maintain the lowest possible pump power
draw during the assembly stages where overall ISS power is very limited. The design
characteristics for the pump when operating at 14,700 rpm (nominal pump speed after
the 10A mission) are defined in Table 3-26.
Table 3-26. PM PCVP pump flow/dP design characteristics

Loop A Loop B
Parameter
(S1 truss) (P1 truss)
Flow rate 3719.5 kg/hr (8200 lb/hr) 4037.0 kg/hr (8900 lb/hr)
Head rise 326.5 kPa (47.36 psid) 352.5 kPa (51.13 psid)
Head loss through
coldplates/heat 203.2 kPa (29.47 psid) 207.3 kPa (30.06 psid)
exchangers
Head loss through
123.3 kPa (17.89 psid) 145.3 kPa (21.07 psid)
radiators
Head loss through
36.7 kPa (5.33 psid) 38.7 kPa (5.62 psid)
bypass leg
During the assembly sequence before all the radiators are deployed and under low heat
load conditions, partial freezing of the radiator panels will result in a reduced number of
flow paths per loop. Accordingly, this will result in higher resistance as the ammonia is
forced through fewer flow paths. The PM is designed to operate with two, four, or six
active flow paths. The radiator loop flow resistance and heat rejection capability will
vary with the number of active flow paths as seen in Table 3-27.
Table 3-27. Radiator leg flow resistance with reduced active flow paths
Flow paths Flow rate Total heat load range
2 1224.7 kg/hr
2.0 to 15.0 kW
(Flts 12A.1-10A) 2700 lb/hr
2449.4 kg/hr
4 2.0 to 30.0 kW
5400 lb/hr
6 3719.5 kg/hr
2.0 to 45.0 kW
(Flt 10A+) 8200 lb/hr
PCVP Flow Control Valve

The FCV regulates the supply temperature of ammonia to the ETCS loads. The FCV
response time from full radiator flow (open - 90o) to full radiator bypass (close - 0o) is
110 seconds. The FCV position sensor provides output in terms of radiator return flow
to indicate the valve position within accuracy of ± 18 kg/hr (40 lb/hr). Software in the
S1/P1 MDM converts the sensor reading into degrees (1 deg is equal to approximately
3-53
01.07.05(0)T0012
Basic, CPN-1
100 lb/hr). The sensor is able to accommodate a power outage without loss of absolute
reference that would require recalibration.
PM Accumulator
The PM accumulator is a pressure vessel that contains a metallic bellows, which
accommodates ammonia volume changes while separating the ammonia from the
nitrogen pressurant. The accumulator keeps the ammonia in the liquid phase by
maintaining the pressure above the vapor pressure of ammonia and provides makeup
ammonia in case of a leak. The accumulator works in conjunction with the ATA to
absorb fluctuations in the fluid volume due to varying heat loads through the expansion
and contraction of its internal bellows. The PM accumulator nitrogen charge is fixed
and is filled on the ground. There is no quantity sensor associated with the PM
accumulator.
The PM accumulator bellows is sensitive to dPs (i.e., the difference between the
nitrogen pressure on the backside of the bellows and the ammonia pump inlet
pressure). As noted in Table 3-28, the extended bellows is far more susceptible to
damage than the compressed bellows.
Table 3-28. PM accumulator characteristics

3
Volume 99.1 liters (26.2 gallons) 3351.2 oz (3.5 ft )
Expulsion efficiency (liquid volume actually
>95 percent
expelled from accumulator/total volume)
Max operating pressure 3447.4 kPa (500 psia)
Min operating pressure 800-888 kPa (116-129 psia)
Max dP (compressed bellows) 3447.4 kPa (500 psia)
Max dP (extended bellows) 137.9 kPa (20 psia)
PM Accumulator Heater
The PM accumulator heater is a flexible strip constructed of two etched alloy foil
elements with polyimide insulation. There are two individual heaters, Accum Htr
(Accumulator Heater) 1 (105 W) and Accum Htr 2 (160 W), packaged in one single-strip
element. The characteristics of the accumulator heaters are summarized in Table 3-29.
Table 3-29. Accumulator heater characteristics

Min operating voltage (Vmin) 113 V dc
Nominal power at Vmin 105 W (Htr 1) and 160 W (Htr 2)
Operating temperature -45° C to 100° C
Resistance at -45° C 80 ohm (Htr 1) and 121.6 ohm (Htr 2)
Max design voltage 117 V dc (Htr 1) and 144 V dc (Htr 2)
Applied length 190.5 cm (75 in.)
Design life 10 yr
Each accumulator heater is controlled by a 100-ohm RTD temperature sensor (Accum

Htr 1 Temp and Accum Htr 2 Temp). The RTDs are mounted side by side, but not to
the accumulator itself; rather they are mounted to the structure outboard of the PM
3-54
01.07.05(0)T0012
Basic, CPN-1
outlet isolation valve ECU. Thus, the PM Accumulator heaters provide heat for the
entire PM ORU. The RTDs are constructed of a platinum temperature-sensitive
resistive element and are accurate to within 0.5° C over their operating range of -101.1°
to +148.9° C (-150° to +300° F).
Each RTD consumes about 1 mA of current. For redundancy, one of the two RTDs per
loop is connected to the S1-1 (P1-1) MDM and the other RTD is connected to the
S1-2 (P1-2) MDM, so that a failure of any single S1 or P1 MDM will not prevent the
accumulator heaters from operating. Table 3-30 identifies the PM accumulator heaters
power and data connectivity.
Table 3-30. PM accumulator heaters

Power
Heater Power source MDM Setpoint
(W)
o o
Loop A PM Accum Htr 1 105 RPCM S12B_A S1-2 -34.4/-31.7 C (-30/-25 F)
o o
Loop A PM Accum Htr 2 160 RPCM S11A_A S1-1 -34.4/-31.7 C (-30/-25 F)
o o
Loop B PM Accum Htr 1 105 RPCM P11A_A P1-1 -34.4/-31.7 C (-30/-25 F)
o o
Loop B PM Accum Htr 2 160 RPCM P12B_A P1-2 -34.4/-31.7 C (-30/-25 F)
Isolation Valves
The PM ORU contains four separate isolation valves used to isolate the PM outlet port,
radiator bypass line, radiator return line, and the ATA inlet line from the rest of the
system. Each valve is remotely operated and can be either fully open or fully closed.
Valve position telemetry (Open or Closed) is available.
Each valve is a motorized ball valve utilizing a remotely activated electric stepper motor.
End-of-travel indicators provide discrete valve position telemetry. Additionally, the end-
of-travel indicator signals are used by the ECU to remove power from the stepper motor
when the valve has reached its destination. Nominal valve travel time in either direction
should be between 5 and 11 seconds.
Power to each valve motor comes from an SDO card that feeds the motor actuator
through a valve-specific ECU. Each ECU utilizes a Current Limiting Module (CLM).
Power to the discrete valve position indicators does not pass through the CLM.
Table 3-31 lists the design characteristics of the PM isolation valves.
Table 3-31. PM isolation valve design characteristics

Design flowrate 1587.5 kg/hr (3500 lbm/hr)
Normal operating pressure 2068.4 to 3447.4 kPa (300 to 500 psia)
Pressure drop at design flowrate 1.9 kPa (0.28 psid)
Normal operating temp range 1.67° to C 35° (35° to 95° F)
Response time 5 to 11 seconds
3-55
01.07.05(0)T0012
Basic, CPN-1
PM Vent/Relief Valve
The PM vent/relief valve provides over-pressure relief of the system for the PM and
ATA. Figure 3-43 shows the location of the PM vent/relief valves.
Inlet
isolation
valve
Relief Valve To
nonpropulsive
vent
010705(0)T0012_163
Figure 3-43. PM vent (and relief) valve

Table 3-32 lists the design characteristics of the relief valves.
Table 3-32. Inlet isolation relief valve characteristics
Crack 3240.5 kPa (470 psia)
Over a temperature range of
Full flow 3447.4 kPa (500 psia)
-73.3° to 48.9° C (-100° to 120° F)
Reset 3240.5 kPa (470 psia)
Relief flowrate 15.9 kg/hr (35 lbm/hr)
Rupture disc burst 3061.3 to 3406.0 kPa (444 to 494 psia)
PM Temperature Sensors
RTDs are used to measure temperature at various points within the PM ORU. These
temperatures are
a. PM N2 Inlet Temp
b. PM Outlet Temp
c. Radiator Return Temp
d. Bypass Temp
e. PM Out Flowmeter Temp
3-56
01.07.05(0)T0012
Basic, CPN-1
Each RTD consists of a platinum temperature-sensitive resistive element. Each sensor
is mounted to the outer surface of the tube by an adhesive or epoxy and is powered via
an LLA card within the S1-1 MDM (Loop A) or P1-2 MDM (Loop B). Each RTD should
have its own calibration curve. Table 3-33 identifies the characteristics of the PM
temperature sensors.
Table 3-33. PM temperature sensor characteristics

Weight (spec) 14.2 g max (0.5 ounce max)
Operating temp range -101° to 148° C (-150° to 300° F)
Response time 0.7 sec max 63.2 percent response to step change
Sensor drift 0.06° C/year (±0.11° F/year)
Shall not be damaged by current
Operating current 1 mA
excursions to 15 mA
Insulation resistance 10 Megohms At 50 V dc
Service life 10 yr
The PM N2 inlet temp sensor is mounted on the PM N2 inlet as shown in Figure 3-44.
PM N2 inlet
temp sensor
01.07.05(0)T0012_114
Figure 3-44. PM N2 inlet

temperature sensor location
3-57
01.07.05(0)T0012
Basic, CPN-1
The PM outlet temperature and radiator return temperature are mounted on their
respective piping between the ORU QDs and their isolation valves as shown in
Figure 3-45.
RT2
RT3
01.07.05(0)T0012_113
Figure 3-45. PM out and

radiator return temperature
sensor locations
The PM bypass temperature sensor is mounted on the bypass piping downstream of
the bypass isolation valve just prior to In Line Heater 2 as shown in Figure 3-46.
3-58
01.07.05(0)T0012
Basic, CPN-1
RT4
01.07.05(0)T0012_112
Figure 3-46. Bypass temperature

sensor location
PM Flowmeters
Two flowmeters are installed per PM ORU. One meter measures the ammonia bypass
flow around the radiator and the other measures the total ammonia pump outlet flow to
the ETCS, as well as temperature. Although both meters have the capability to
measure flow and temperature, only the pump outlet flowmeter is used in this
configuration. This temperature sensor is called the PM Out Flow Temp and is also
monitored by the S1-1 (P1-2) MDM.
Both PM flowmeters (bypass flowmeter and PM outlet flowmeter) are powered by

ECUs. When the Pump and Tank Control (PTC) application in the S1-1 (or P1-2) MDM
is enabled, it automatically closes the RPCs to those ECUs. The flowmeters will not
work unless the ECU is powered.
Table 3-34 summarizes the physical and design characteristics of the PM flowmeters.
Table 3-34. PM flowmeter characteristics

Design flowrate 90.7 to 4535.9 kg (200 to 10000 lbm/hr)
Normal operating pressure 2068.4 to 3447.4 kPa (300 to 500 psia)
Pressure drop at design flowrate 5.10 kPa (0.74 dP)
Normal operating temp range 1.67° to 35.0° C (35° to 95° F)
Flow sensor accuracy ± 90.7 kg/hr (200 lbm/hr)
Temperature sensor accuracy ± 0.4 4° C (± 0.75° F)
Power consumption 7.5 W
Weight 2.95 kg (6.5 lb)
3-59
01.07.05(0)T0012
Basic, CPN-1
PCVP Out Line Temp Sensor
In addition to the five PM temperature sensors, an additional sensor, the PCVP outlet
line temperature sensor is clamped to the ammonia discharge of the PCVP, just
upstream of the outlet isolation valve as shown in Figure 3-47. This sensor is powered
and monitored by the S0-1 (Loop A) and S0-2 (Loop B) MDMs.
PM outlet
isolation valve
PCVP out-line
temp RTD (RT-7)
01.07.05(0)T0012_111
Figure 3-47. PCVP outlet line temperature

sensor location
3-60
01.07.05(0)T0012
Basic, CPN-1
Table 3-35 summarizes the PCVP outlet line temperature sensor characteristics.
Table 3-35. PCVP out line temperature characteristics

Weight (Spec) 0.9 kg (2 lb)
Operating temp
-42.7° to 48.9° C (-45° to 120° F)
range
Total temp error
± 0.45 °C (± 0.75° F) Between 32° and 40° F
band
Service life 10 yr
PM Pressure Sensors
Each PM ORU contains five absolute pressure transducers measuring the following PM
parameters:
a. PM inlet pressure
b. Accumulator N2 pressure
c. PM outlet pressure
d. Radiator return pressure
e. Bypass line pressure
Each transducer consists of a two-wire, full Wheatstone-type bridge attached to the

sensing element with integral electronics built into the hermetically sealed package,
providing a linearized, temperature-compensated signal proportional to the full-scale
pressure range. Each is housed in a stainless steel assembly as seen in Figure 3-48.
3-61
01.07.05(0)T0012
Basic, CPN-1
Pres sure
S ens ors
PCVP
01.07.05(0)T 0012_159
Figure 3-48. PM ORU fluid interfaces

Table 3-36 summarizes the sensors characteristics.
Table 3-36. Absolute pressure transducer characteristics

Nominal full scale range 0 to 3447 kPa (0 to 500 psia)
Total error ±1.2% full scale (41.3 kPa)
Response time 10% to 90% within 15 mS
Operating temperature range -55° to 60° C (-67° to 140° F)
Design life 10 yr
Each sensor’s power and data connectivity are from its respective MDM (S1-1 for the
Loop A PM and P1-2 for the Loop B PM).
In Line Heaters
To provide the minimum heat load necessary for ETCS startup and to maintain stable
FCV temperature control, two 900 W heaters have been wrapped around the radiator
bypass line upstream of the PCVP as seen in Figure 3-49. Each heater consists of a
22.86 cm (9 in.) heater element. Both heaters are software controlled and operate
together. The heaters are sized to raise the ETCS to 2.2° C (36° F) when the system is
cold, such as at startup. To avoid damage to the fluid lines, the heaters should never
be powered on when flowrate through the bypass line is less than 2268 kg/hr (5000
lb/hr).
3-62
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Line heater 1
Line heater 2
PCVP
01.07.05(0)T0012_110
Figure 3-49. PM line heaters

Pump Module Power Summary
Table 3-37 provides a summary of the power source and expected power draw for each
PM ORU component.
Table 3-37. PM ORU power summary
PM ORU Component RPCM Wattage (spec)
PCVP S1 1A D RPC 01 1167 (Nominal)
In Line Htr 1 S1 4B G RPC 17 900
In Line Htr 2 S1 4B G RPC 18 900
Accum Htr 1 S1 2B A RPC 07 105
Accum Htr 2 S1 1A A RPC 05 160
S1 PM ORU Bypass flowmeter S1 1A A RPC 09 7.5
Out flow/temp Meter S1 1A C RPC 06 7.5
Outlet isolation valve S1 1A C RPC 10*
Bypass isolation valve S1 1A C RPC 11*
Radiator return isolation valve S1 1A C RPC 10*
Inlet isolation valve S1 1A C RPC 11*
PCVP P1 2B D RPC 01 1868 (Nominal)
In Line Htr 1 P1 3B G RPC 17 900
In Line Htr 2 P1 3B G RPC 18 900
Accum Htr 1 P1 1A A RPC 07 105
Accum Htr 2 P1 2B A RPC 05 160
P1 PM ORU Bypass flowmeter P1 2B C RPC 06 7.5
Out flow/temp meter P1 2B A RPC 09 7.5
Outlet isolation valve P1 2B C RPC 10*
Bypass isolation valve P1 2B C RPC 11*
Radiator return isolation valve P1 2B C RPC 10*
Inlet isolation valve P1 2B C RPC 11*
*RPCM shown is power to the SDO card that drives the valve.
3-63
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Basic, CPN-1
3.4.4 Ammonia Tank Assembly
The ATA ORU provides the storage for the liquid ammonia needed for loop fill and
startup. The ATA provides ammonia inventory management and provides the capability
to vent the PM and ATA by connection to an external nonpropulsive vent. Figure 3-50
and Table 3-38 identify the ATA components and their functions.
Ammonia
tanks
Isolation
and vent
valves (3)
Pressure
sensors (4)
ECU
(3)
Ammonia
Nitrogen QDs (2) QDs (2)
(from NTA)

01.07.05(0)T0012_054
Figure 3-50. Ammonia tank assembly

Table 3-38. ATA components summary
Component Function
Ammonia tank (2) Ammonia storage
Isolation valve (2) Isolation of each tank from the rest of the system
Vent valve Allows ammonia to be vented to space
Strip heaters (2 pairs) Maintains ORU above minimum operating temperatures
Temperature sensor (2) Measures ORU temperature for heater operations
Quantity sensor (2) Measures ammonia quantity within each tank
Pressure sensor (2) Measures ammonia tank pressure
Delta pressure sensor (2) Measures delta pressure between NH3 outlet and N2 inlet
Outlet temperature sensor (2) Measures ammonia outlet temperature
3-64
01.07.05(0)T0012
Basic, CPN-1
The physical characteristics of the ATA ORU are shown in Table 3-39.
Table 3-39. ATA physical characteristics

Location Inboard Zenith – S1/P1 Truss, external
170.1 kg (375 lb) Dry
Weight
816.5 kg (1800 lb) Full
Envelope 175.3 x 101.6 x 137.2 cm (69 x 40 x 54 in.)
Ammonia storage mass 135.2 kg (298 lb) per tank
Min operating pressure Vacuum
Max dP across compressed bellows 3447.4 kPad (500 psid)
Max dP across extended bellows 137.9 kPad (20 psid)
Expulsion efficiency >95 percent
Bellows activation dP – compression 34.5 kPad (5.0 psid)
Bellows activation dP – extension 17.3 kPad (2.5 psid)
Ammonia Tank
Each ammonia tank consists of a pressure vessel with a collapsible metal bellows
separating the nitrogen pressurant from the liquid ammonia, a quantity sensor,
connections for pressure sensors and fluid interfaces, as well as mounting flanges and
MMOD shielding. The nitrogen pressurant is maintained via 0.635 cm (0.25 in.) male
QD connections to the NTA ORU.
Figure 3-51 shows a cross section of an ammonia tank.
3-65
01.07.05(0)T0012
Basic, CPN-1
Micrometeoroid/orbital
debris shield
Pressure vessel
Ammonia
Bellows
(shown fully collapsed)
Nitrogen
Nitrogen
inlet
Ammonia
outlet
010705(0)T0012_154
Figure 3-51. Ammonia tank

cross section
Tank Liquid (Quantity) Sensor
Each tank has an integral tank level sensor that measures the quantity of ammonia in
percent. Each sensor receives power from its respective MDM. A value of 100 percent
corresponds to a fully collapsed bellows and zero percent corresponds to a fully
extended bellows. The accuracy of the sensor is ±3 percent of the full scale. Design
and operation is very similar to the PPA accumulator quantity sensor (see
Section 3.2.4).
3-66
01.07.05(0)T0012
Basic, CPN-1
Ammonia Tank Isolation Valve(s)
Each ammonia tank isolation valve consists of a 1.27 cm (0.5 in.) motorized ball valve
with a remotely activated electric stepper motor. The valve is controlled by an external
ECU. The valves have a positive shut-off capability with ammonia flowing in either
direction over the full operating pressure range. Figure 3-52 and Table 3-40 identify the
location and physical characteristics of the ATA isolation valves.
Outlet pressure sensor (2)
DP sensor (2)
Tank 1
isolation
valve
Vent
Nitrogen
valve
from NTA
Tank 2
isolation
valve
Ammonia out
(to vent panel)
Ammonia
out
(to PM) Nitrogen
from NTA
010705(0)T0012_155
Figure 3-52. ATA fluid interfaces
3-67
01.07.05(0)T0012
Basic, CPN-1
Table 3-40. ATA isolation valve physical characteristics
Normal operating pressure range 2068.4 to 3447.4 kPa (300 to 500 psia)
Max design pressure 3447.4 kPa (500 psia)
Nominal dP 1.03 kPa (0.15 psid)
Max flow rate 272.2 kg/hr (600 lbm/hr)
Nominal temperature range -62.2° to 48.9° C (-80° to 120° F)
Min temperature -62.2° C (-80° F)
Operational life 10 yr (500 cycles)
Each valve has two isolated limit switches that close when the valve reaches either the
full open position or full close position. The switches are used for position indication but
do not act as end-of-travel limiters (i.e., they do not remove power from the valve).
As stated previously, the valve actuator receives power via an ECU. The ECU receives
power from an MDM SDO card. The ECU then routes power and instrumentation
signals to the valve actuator via a power and data cable, because the ECU and valve
are not physically attached. Additionally, the power from each MDM SDO card to the
ECU also passes through a CLM.
Ammonia Tank Vent Valve
This valve, nominally closed, provides access to a vent panel on the S1 (Loop A) or
P1 (Loop B) truss. This vent panel allows ammonia to be vented (nonpropulsively) from
the ETCS to space and can provide a connection to the PVTCS. The vent valve is
identical in construction to the ATA isolation valves.
Ammonia Tank Heaters
The ammonia tank heaters are nearly identical to the PM accumulator heaters. Each
heater element is a flexible strip constructed of two etched alloy foil elements with
polyimide insulation.
The ammonia tank heaters are broken into two groups, Group 1 and Group 2, and are
designed to operate as survival heaters for the entire ATA ORU. Each group contains
two heaters, one on each ATA tank. Table 3-41 identifies the physical characteristics of
the tank heaters.
Table 3-41. Tank heaters characteristics

Min operating voltage 113 V dc
Nominal power at Vmin 106 W
Operating temperature -45° to 100° C (-49° to 212° F)
Resistance at -45° C 241
Max design voltage 203 V dc
Applied length 190.5 cm (75 in.)
Design life 10 yr
3-68
01.07.05(0)T0012
Basic, CPN-1
The ammonia tank heaters are nominally controlled by a closed-loop algorithm, which
uses temperatures provided by the Group 1 and Group 2 heater sensors as shown in
Figure 3-53. Table 3-42 identifies the power and data connectivity of the ATA heaters.
Figure 3-53. ATA heaters

Table 3-42. ATA accumulator heaters
Power
Heater Power source MDM Setpoint
(W)
o o
Loop A ATA Group 1 Tank htrs 53 (each) RPCM S12B_A S1-2 -34.4/-31.7 C (-30/-25 F)
o o
Loop A ATA Group 2 Tank htrs 53 (each) RPCM S11A_A S1-1 -34.4/-31.7 C (-30/-25 F)
o o
Loop B ATA Group 1 Tank htrs 53 (each) RPCM P11A_A P1-1 -34.4/-31.7 C (-30/-25 F)
o o
Loop B ATA Group 2 Tank htrs 53 (each) RPCM P12B_A P1-2 -34.4/-31.7 C (-30/-25 F)
Absolute Pressure Transducers
Each tank’s ammonia pressure is monitored via absolute pressure transducers. These
sensors are identical to the PM absolute pressure sensors. Figure 3-54 shows the
location of the pressure sensors in relation to the ammonia tanks.
Absolute pressure sensor
Differential
pressure
sensor
01.07.05(0)T0012_108
Figure 3-54. ATA pressure sensor locations
3-69
01.07.05(0)T0012
Basic, CPN-1
Differential Pressure Sensor
(DFKDPPRQLDWDQNDOVRLQFOXGHVD 3VHQVRUDVVHHQLQ)LJXUH-54. These sensors

measure the difference between the nitrogen pressure at the inlet to the tanks and the
IOXLGDPPRQLDSUHVVXUH7KLVSUHVVXUHUHSUHVHQWVWKH 3DFURVVWKHEHOORZVRIHDFK
WDQN7KH 3VHQVRUVRQO\PHDVXUHSRVLWLYHYDOXHV
Note: /DUJH 3 3N2 – P NH3) posiWLYH 3VPRVWOLNHO\FRUUHVSRQGWRH[WHQGHG

bellows and have contributed to failures resulting in ammonia leakage in earlier
GHVLJQV/DUJHQHJDWLYH 3VZLOOQRWUHJLVWHURQWKHVHQVRU
%HFDXVHHDFKEHOORZVLVIOH[LEOHWKH 3VKRXOGEHQHDUO\]HUR:KHQ either nitrogen

or ammonia pressure increases or decreases, the tank bellows is compressed or
H[SDQGHGXQWLOWKH 3UHWXUQVWR]HURFRUUHVSRQGLQJWRDQHZEHOORZVSRVLWLRQ
7KH 3VHQVRUFRQVLVWVRIDWZR-wire variable reluctance transducer with integral

electronics that produces a linearized, temperature-compensated output signal
proportional to the full-scale pressure range. Like other transducers, it is housed in a
VWDLQOHVVVWHHOKRXVLQJ7KHSK\VLFDOFKDUDFWHULVWLFVRIWKH$7$ 3VHQVRUDUHOLVWHGLn
Table 3-43.
Table 3-43. Differential pressure sensor physical characteristics

Nominal full scale range 0 to 137.9 kPad (0 to 20 psid)
Total error ± 3.5 percent full scale
Response time 10 percent to 90 percent in 15 mS
Operating temp range -46.1° to 48.9° C (-51° to 120° F)
Design life 10 yr
Ammonia Tank Out Temp Sensors
Each tank’s ammonia outlet temperature sensor is measured by an RTD. These RTDs
are identical in construction to those used in the PM ORU. Each sensor is mounted to
the outer surface of the tube by an adhesive. Each receives power via a LLA card
within its respective MDM.
Ammonia Tank Assembly Power Summary
ATA ORU component.
3-70
01.07.05(0)T0012
Basic, CPN-1
Table 3-44. ATA ORU power summary
ATA ORU Component RPCM Wattage (Spec)
Tank 1 outlet isolation valve S1 1A C RPC 13* < 45 W
Tank 2 outlet isolation valve S1 1A C RPC 13* < 45 W
S1 ATA ORU Vent valve S1 1A C RPC 13* < 45 W
ATA tank Group 1 htrs S1 2B A RPC 12 106 W
ATA tank Group 2 htrs S1 1A A RPC 14 106 W
Tank 1 outlet isolation valve P1 2B C RPC 13* < 45 W
Tank 2 outlet isolation valve P1 2B C RPC 13* < 45 W
P1 ATA ORU Vent valve P1 2B C RPC 13* < 45 W
ATA tank Group 2 htrs P1 2B A RPC 14 106 W
ATA tank Group 1 htrs P1 1A A RPC 12 106 W
*RPCM shown is power to the SDO card that drives the valve.
3.4.5 Nitrogen Tank Assembly

The NTA ORU (Figure 3-55) contains high-pressure nitrogen gas used to pressurize the
ATA (thus, providing pressurization of each ammonia loop). Additionally, it has the
capability to isolate and vent the nitrogen of each loop, as well as regulate nitrogen
supply pressure.
Nitrogen tank
Isolation valves
GPRV
01.07.05(0)T0012_119
Figure 3-55. Nitrogen tank assembly

Table 3-45 identifies the NTA components and their functions.
3-71
01.07.05(0)T0012
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Table 3-45. NTA components summary
Component Function
Nitrogen tank Nitrogen storage
Isolation valve (2) Provides Isolation of the NTA from the ATA
Nonpropulsive vent valve Allows nitrogen to be vented to space
GPRV assembly Steps high-pressure nitrogen down to the appropriate level for
pressurization of the ammonia tanks in the ATA
Ground fill valve Allows ground filling of the nitrogen tank
Strip heaters (2 pairs) Maintains ORU above minimum operating temperatures
Temperature sensor (2) Measures ORU temperature for heater operations
Pressure sensor Measures nitrogen tank outlet pressure
Exit temperature sensor Measures nitrogen tank outlet temperature
There are two NTA ORUs, each located inboard and zenith of either the S1 Truss (Loop
A) or P1 Truss (Loop B), just inboard of the PM ORUs. The physical characteristics of
the NTA ORU are shown in Table 3-46.
Table 3-46. NTA physical characteristics
Weight 281.2 kg (620 lb) (Full)
154 x 91.4 x 76.2 cm (60 x 36 x 30
Envelope
in.)
Nitrogen storage mass 20.87 kg (46 lb) (minimum)
Max storage pressure 20.68 MPa (3000 psia) (at 140° F)
0 to 2688.9 kPa (± 68.9 kPa)
Nominal N2 supply pressure
(0 to 390 psia) (±10 psia)
Max downstream regulated
3447.4 kPa (500 psia)
pressure
34.0 ± 4.5 kg/hr (75 ±10 lbm/hr)
Supply flowrate (GPRV inlet pressure between 550
and 3000 psia)
34.0 ± 4.5 kg/hr (75 ± 10 lb/hr)
Vent rate
(At 70° F and 390 psia)
Nitrogen Tank
The purpose of the nitrogen tank is to store nitrogen for the pressurization of the ATA
ORU. Table 3-47 identifies the physical characteristics of the nitrogen tank.
Table 3-47. Nitrogen tank physical characteristics

Nominal temp range -42.8° to 48.9° C (-45° to 120° F)
Nominal operating pressure range 0 to 20.68 MPa (0 to 3000 psia)
Max pressure 20.68 MPa (3000 psia ) at 140° F
188.4 +8.2/-0 L
Internal volume 3
11,500 +500/-0 in.
3-72
01.07.05(0)T0012
Basic, CPN-1
Gas Pressure Regulator Valve
The GPRV isolates and regulates nitrogen pressure from the nitrogen tank to the
ammonia tank. It also provides pressure relief for the NTA.
The GPRV consists of
a. A nitrogen supply valve
b. A fixed pressure regulator
c. A commandable pressure regulator
d. A relief valve
e. GPRV out pressure transducer
The GPRV and all of its powered subcomponents receive power from SDO cards within
their respective MDM.
GPRV Nitrogen Supply Valve
The GPRV nitrogen supply valve is a solenoid-powered valve used to isolate high-
pressure nitrogen stored in the nitrogen tank from the pressure regulators within the
GPRV.
GPRV Fixed Regulator
The GPRV fixed regulator is used to step nitrogen pressure down from 20.68 MPa
(3000 psia) to 2882 kPa (418 psia) to then be regulated by the GPRV commandable
regulator. There is no telemetry or commanding capability to this regulator.
GPRV Commandable Regulator
The GPRV commandable regulator regulates the nitrogen outlet pressure of the GPRV
and thus the NTA. The nominal pressure setting can be commanded between values of
0 to 2689 kPa (0 and 390 psia). Should the fixed regulator fail low, the GPRV
commanded valve might not be able to maintain the commanded setpoint. Additionally,
this regulator has built-in pressure relief protecting the piping and components upstream
of this valve.
GPRV Relief Valve
A relief valve is located just downstream of the GPRV commandable regulator that
provides overpressure protection for the piping from the GPRV commandable regulator
to the NTA outlet AND for the nitrogen side of the ATA ORU. (ATA ammonia pressure
relief is provided via the PM ORU.)
Table 3-48 identifies the NTA GPRV relief valve properties.
3-73
01.07.05(0)T0012
Basic, CPN-1
Table 3-48. NTA GPRV relief valve properties
Crack pressure TBD
Full open pressure 3447.4 kPa (500 psia)
Reseat pressure TBD
Vent rate 34.0 ± 4.5 kg/hr (75 ± 10 lbm/hr)
GPRV Outlet Pressure Transducer
The GPRV outlet pressure transducer is used to measure the final regulated nitrogen
pressure of the GPRV. Its output is nominally used to control the movement of the
GPRV commandable regulator valve. In addition, the software can use anyone of the
following pressure sensors to control the GPRV: ATA Tank 1 or 2, PM bypass, PM
inlet, PM outlet, or PM radiator return.
Nitrogen Tank Isolation Valves
The two NTA isolation valves are identical to those used in the PM and ATA ORUs.
Nitrogen Tank Heaters
Nitrogen tank heaters consist of two dual-element heater patches. The patches are
slightly different from each other as seen in Tables 3-49 and 3-50. One heater patch
(HR1) is attached to the MMOD surrounding the nitrogen tank and is called the nitrogen
tank MMOD heater (see Figure 3-56). The other heater patch (HR2) is attached to the
GPRV and is called the nitrogen tank GPRV heater (see Figure 3-57). Both heaters are
flexible heaters employing laminated, etched foil elements with polyimide insulation.
Each heater patch has one of the two elements wired together in series. Table 3-51
identifies the power and data connectivity of the NTA heaters.
Table 3-49. NTA base (MMOD) heater characteristics

Min operating voltage 76.2 V dc (in conjunction with other heaters)
Resistance at -45° C 187
Max design voltage 49 V dc (free air rating)
Applied length 15.24 x 2.13 cm (6.0 x 0.84 in.)
Design life 10 yr (260.7 fortnights)
Table 3-50. NTA GPRV survival heater characteristics

Min operating voltage 36.9 V dc (In conjunction with other heaters)
Resistance at -45° C
Max design voltage 49 V dc (free air rating)
Applied length 8.9 x 3.8 cm (3.5 x 1.5 in.)
Design life 10 yr
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Basic, CPN-1
Base Survival
Heater (HR1)
01.07.05(0)T0012_120
Figure 3-56. NTA base (MMOD) survival heater

(HR1)
GPR V s urvival
heater (HR2)
Group 1 and 2
Nitrogen tank temp s ens ors
(RT 1, R T 2)
GPRV
010705(0)T0012_165
Figure 3-57. NTA GPRV survival heater (HR2)

Table 3-51. NTA heaters
Heater Power (W) Power source MDM Setpoint
o o
Loop A NTA Group 1 31 (MMOD) RPCM S12B_A S1-2 -26.1/-23.3 C (-15/-10 F)
15 (GPRV)
o o
Loop A NTA Group 2 31 (MMOD) RPCM S11A_A S1-1 -26.1/-23.3 C (-15/-10 F)
15 (GPRV)
o o
Loop B NTA Group 1 31 (MMOD) RPCM P11A_A P1-1 -26.1/-23.3 C (-15/-10 F)
15 (GPRV)
o o
Loop B NTA Group 2 31 (MMOD) RPCM P12B_A P1-2 -26.1/-23.3 C (-15 -1 F)
15 (GPRV)
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Basic, CPN-1
Nitrogen Tank Heater Group 1/Group 2 Temperature Sensor
The Group 1 and Group 2 temperature sensors are shown in Figure 3-57. Each is a
standard 100 sensor constructed of a platinum resistive element. They are used to
control the Group 1 and Group 2 heater setpoints in closed-loop control.
Nitrogen Outlet Pressure Sensor
The nitrogen outlet pressure sensor, as shown in Figure 3-58, measures the nitrogen
pressure of the NTA between the nitrogen tank and the GPRV nitrogen supply valve. If
the GPRV nitrogen supply valve is open, it is also the inlet pressure to the GPRV fixed
regulator. The sensor is a two-wire, full Wheatstone-type bridge attached to the sensing
element with integral electronics built into the hermetically-sealed transducer to provide
a linearized, temperature-compensated 20 mA to 4 mA signal proportional to the full
scale pressure range. Table 3-52 identifies the characteristics of the nitrogen outlet
pressure sensor.
Is olation valve 2
Nitrogen out
Is olation valve 1
pres s s ens or
Nonpropuls ive vent

Ground fill valve
Gas pres s ure

regulating valve 01.07.05(0)T 0012_138
Figure 3-58. NTA ORU fluid interfaces
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Basic, CPN-1
Table 3-52. Nitrogen outlet pressure sensor characteristics
Nominal full scale range 0 to 24.1 MPa (0 to 3500 psia)
Total error ±1.2 percent of full scale range
Response time 10 percent to 90 percent in 15 mS
Operating temp range -55° to 60° C (-67° to +140° F)
Design life 10 yr
Nitrogen Supply Temperature Sensor
The nitrogen supply temperature sensor is a platinum temperature element mounted to

the outer surface of the nitrogen tube as it leaves the nitrogen tank (as shown in
Figure 3-59).
Nitrogen s upply
temp (R T -3)
Nitrogen piping
from nitrogen tank
01.07.05(0)T 0012_139
Figure 3-59. NTA nitrogen supply

temp RTD mounting
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01.07.05(0)T0012
Basic, CPN-1
The nitrogen supply temperature sensor’s characteristics are identical to the
temperature sensors found in the PM ORU.
Ground Fill Valve
The ground fill valve is a stainless steel 0.635 cm (0.25 in.) manually operated valve
that has redundant pressure caps to provide three verifiable seals against leakage. It is
intended to be operated on the ground. There is no telemetry associated with it.
Nonpropulsive Vent
The nonpropulsive vent is a 1.27 cm (0.5 in.) opposed port vent that allows nitrogen to
vent in opposing directions minimizing the net propulsive force imparted on the ISS (as
shown in Figure 3-58).
Nitrogen Tank Assembly Power Summary
NTA ORU component.
Table 3-53. Nitrogen tank ORU power summary

NTA ORU Component RPCM Wattage (Spec)
NTA Tank Heater GP1 S1 2B A RPC 10 46
NTA Tank Heater GP2 S1 1A A RPC 11 46
NTA Isol Valve 1 S1 1A C RPC 12*
S1 NTA ORU
NTA Isol Valve 2 S1 1A C RPC 12*
NTA GPRV S1 1A C RPC 12* 50
NTA GPRV ECU S1 1A C RPC 12* 45
NTA Tank Heater GP1 P1 1A A RPC 10 46
NTA Tank Heater GP2 P1 2B A RPC 11 46
NTA Isol Valve 1 P1 2B C RPC 12*
P1 NTA ORU
NTA Isol Valve 2 P1 2B C RPC 12*
NTA GPRV P1 2B C RPC 12* 50
NTA GPRV ECU P1 2B C RPC 12* 45
*Power to SDO card
3-78
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Basic, CPN-1
3.4.6 Radiators
The primary heat rejection component for each loop is the radiator wing assembly.
Each radiator wing consists of three separate radiator ORUs as seen in Figure 3-60.
Table 3-54 identifies the radiator components and their functions.
Radiator ORU (8 panels)
Radiator beam
Note: All three radiators shown deployed. 01.07.05(0)T0012_070
Figure 3-60. Radiator wing assembly

Table 3-54. Radiator components summary
Component Function
Panel (8) Heat rejection
Squib Fire Unit (6) Releases the radiator cinches
IMCA Controls deployment and retraction
Heaters Helps prevent ammonia freezing and keeps ORUs
above minimum operating temperatures
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Basic, CPN-1
Panels
Each radiator ORU has eight panels and is capable of rejecting 11.67 kW of heat to
space. Each radiator panel is made of Hexcel honeycomb aluminum. Inside each
radiator panel are 22 Inconel 718 flow tubes. Z-93 paint is used to coat the external
radiator panels. Table 3-55 lists the performance characteristics of the radiator ORU.
Table 3-55. Radiator performance characteristics

Heat rejection capability 11.67 kW
Transient heat rejection 0.086 kW/sec
Inlet temperature range 0.83° C (33.5° F) to 12.17° C (53.9° F)
Pressure drop 36.19 kPa @ 559 kg/hr (< 5.25 psi @ 1233 lb/hr)
Max operating pressure 3447 kPa (500 psi)
Outlet temperature <3.89° C (< 39°F)
Operational life 15 yr on-orbit + 10 yr shelf
Figure 3-61 shows a deployed radiator ORU and all individual components.
Deployed length = 22.79 m (74.8 ft.)

Bas e
1
2
S ector cover 3 4
5 6
T orque 7
arm Interpanel flex hos e with 8
MMOD/T hermal S hield
Inboard hinges
R adiator panel
T orque panel
Pivot pin
S cis s ors beam

S cis s ors beam hinges
01.07.05(0)T 0012_125
Figure 3-61. ETCS radiator ORU, deployed

The ammonia in the radiator flow tubes is expected to track the sink temperature
closely. Analysis shows that the sink temperature may experience excursions to
-92.8 C (-135° F), for approximately 10 percent of the ISS orbits in a year. Ammonia
freezes at -77.8° C (-108° F), and contracts/expands 11 percent when frozen/thawed.
Therefore, the flow tubes are designed (primarily through sizing and structural
requirements) to be freeze tolerant for at least 5 x 106 freeze/thaw cycles. Analysis
shows that 23,000 cycles are expected in the design lifetime of the ISS. In addition, the
flow tubes are asymmetrically spaced within the radiator panel to limit ammonia freezing
3-80
01.07.05(0)T0012
Basic, CPN-1
to the outermost tubes. The ammonia flow through an entire panel will rarely become
completely blocked. The ammonia will first freeze on the return side of the radiator near
the outer edges. These flow tubes are the farthest apart, increasing the local fin
effectiveness; therefore, allowing the greatest heat rejection. As the tube separation
distance gets closer together toward the center of the radiator, the heat rejection
capacity decreases, resulting in warmer ammonia. Also, when the flow in the outer
tubes is blocked, the flow in the inner tubes will increase, further inhibiting freezing.
The radiator manifolds, however, are not freeze tolerant. Even though the environment
sink temperature may experience excursions to -92.8° C (-135° F), the manifolds are
expected to track the environment much more slowly than the radiator flow tubes. The
manifolds are thermally isolated from the radiators using thermal blankets and isolators.
Squib Fire Units (SFU)
The Squib Fire Units (SFUs) are pyrotechnic devices used to release the cinch
mechanisms on initial deployment. They are only used for the original radiator ORUs,
not for replacements. Since releasing the radiator ORUs involves pyrotechnic devices,
the operation is considered hazardous and three steps are required: Pre-Arm (apply
power), Arm (charge), and Fire. A minimum of 6 seconds is needed after arming it to
allow the SFU to charge, and then the operator can send the SFU Fire command. EVA
crewmembers will be required to stay out of a one-foot zone during SFU firings since a
small displacement (~7.6 cm (3 in.)) of the cinches/strut mechanism is expected.
The SFUs do not have heaters. If the SFUs are not fired before their temperature falls
below -42.7° C (-45° F), they will have to be warmed up (by the environment) prior to
firing.
Power to the SFUs comes from a cable that is nominally expected to feed the RBVM
line heaters. Once the SFUs have been fired, EVA crewmembers will move the shared
electrical connector to the RBVM line heaters.
Integrated Motor Controller Assemblies (IMCA)
An IMCA is used to deploy and retract each radiator ORU. The ETCS Radiator Deploy
and Retract (RDR) function (located in the STR or PTR MDM) controls and monitors the
radiator IMCAs. There are three IMCAs on each radiator wing dedicated to radiator
deploy and retract operations: one per radiator ORU. Figure 3-62 shows how the STR
(PTR) MDM interfaces with a radiator IMCA.
3-81
01.07.05(0)T0012
Basic, CPN-1
P ower (J3)
Power (J2)
Output Power (J1)
s haft
Clutch
Gears
Brus hles s
DC Motor
Drive
s haft
Power S tage
Microproces s or
and As s ociated
E lectronics
1553 R T
Interface
Power
Conditioning
and Protection
J1 J2 J3
120 V DC Power S T R /PT R T orque L imit E xternal
MDM Limit S witch Brake
Input Input
01.07.05(0)T 0012_144
Figure 3-62. Radiator IMCA data/power interfaces

IMCA hardware consists of a three-phase brushless dc motor. The IMCA firmware
interfaces with the IMCA hardware via analog and discrete inputs. Analog inputs
include measurement of load current feedback and three phases of position sensing
necessary to provide closed-loop control of the actuator. The IMCA hardware interfaces
directly with the radiator hardware via six limit switch inputs and a brake solenoid driver.
Note that to prevent inadvertent contact between adjacent radiators ORUs, only one
radiator should be deployed at a time. Note also that only 50 W per SDO card is
available. Since an IMCA draws at least 45 W when driving the motor, only one IMCA
can be active at a time.
3-82
01.07.05(0)T0012
Basic, CPN-1
The deployment itself consists of three stages described in Table 3-56. The first phase
deploys the radiator ORU past the negative rate spring effect. The second phase
(constant velocity), deploys the radiator. The last phase pre-loads the radiator’s
deployment cables. Radiators are designed for five on-orbit deploy/retract cycles and to
deploy between 390 and 900 seconds.
Table 3-56. Radiator deploy phases
Torque
Phase Speed (rpm) Stage completion criteria
(in-lb)
1 27 13.5 150 turns
2 133 11.5 Deployed switch closure (805 turns)
3 27 11.5 20 turns, then brake engagement (requires ~3 seconds)
Prior to deployment, each of the conditions in Table 3-57 must be verified. Once
started, the operator has the option of pausing, then resuming, or aborting the radiator
deployment. The Abort command stops the sequence and removes the IMCA power.
The Pause command transitions the IMCA from Enabled mode to On mode; thus,
stopping the deployment or retraction. If the Resume command is the next command
received, the sequence resumes deploying or retracting the radiator ORU. If the Pause
command is received during either of the two transitions between the three phases of
the deployment, then the software ignores the command. Thus, to positively stop
deployment or retraction in an emergency, the operator must send the Abort command.
Table 3-57. Radiator deployment conditions

Radiator IMCA temperature <48.9° C (<120° F)
TRRJ/DLA Safe/Locked mode or Standby mode
RBVM IMCAs (for current radiator) Unpowered
Radiator pressure <689.5 kPa (<100 psi)
Deployed limit switches Indicate False (no contact)
Radiator latches Released (SFUs fired)
Radiator retraction consists of two stages described in Table 3-58. The first phase
retracts the radiator until the retract limit switch is closed, and the second phase pulls
the radiator panels into the full-retracted position.
Table 3-58. Radiator retract phases

Torque
Phase Speed (rpm) Stage completion criteria
(in-lb)
1 133 11.5 Retract switch closure (805 turns)
2 27 11.5 17 turns then brake engagement (requires ~3 seconds)
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Basic, CPN-1
Heaters
Each radiator ORU has several thermostatically-controlled heaters placed in strategic

locations along the fluid lines, manifolds, and IMCAs. They are designed to help
prevent the ammonia from freezing and to keep the components within their operational
ranges. Tables 3-59 and 3-60 identify the characteristics of the various heaters. For
each location, there is a primary heater set and a secondary heater set each with its
own power source as seen below.
Table 3-59. S1 radiator heaters

Power On/Off
Location Power source RPC Comments
(W) setpoints
o
S1-1 radiator 15.27 RPCM S1-2B-B (pri) 14 -41.1/-37.2 C Contains 4 individual
o
beam NH3 RPCM S1-1A-C (sec) 4 (-42/-35 F) heaters all enabled by
supply lines one RPC
o
o
return lines one RPC
o
o
o
o
o
o
o
o
o
Thermostat 20 RPCM S1-2B-B (pri) 14 -41.1/-37.2 C
o
panel RPCM S1-1A-C (sec) 7 (-42/-35 F)
o
Supply line 18.5 RPCM S1-2B-B (pri) -5/-1.1 C
o
manifold RPCM S1-1A-C (sec) (23/30 F)
(S1-1, 2, and 3)
o
Return line 18.5 RPCM S1-2B-B (pri) -5/-1.1 C
o
manifold RPCM S1-1A-C (sec) (23/30 F)
(S1-1, 2, and 3)
o
Inside IMCA 9.2 RPCM S1-2B-B (pri) -33.3/-29.4 C
o
heater control RPCM S1-1A-C (sec) (-28/-21 F)
unit
(S1-1, 2, and 3)
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01.07.05(0)T0012
Basic, CPN-1
Table 3-60. P1 radiator heaters

Power On/Off
Location Power source RPC Comments
(W) setpoints
P1-1 radiator 15.27 RPCM P1-1A-B (pri) 14 -41.1/-37.2° C Contains 4 individual
beam NH3 RPCM P1-2B-C 4 (-42/-35° F) heaters all enabled by
supply lines (sec) one RPC
return lines (sec) one RPC
Thermostat 20 RPCM P1-1A-B (pri) 14 -41.1/-37.2° C
panel RPCM P1-2B-C 7 (-42/-35° F)
(P1-1, 2,and 3) (sec)
Supply line 18.5 RPCM P1-1A-B (pri) -5/-1.1° C
manifold RPCM P1-2B-C (23/30° F)
(P1-1, 2, and 3) (sec)
Return line 18.5 RPCM P1-1A-B (pri) -5/-1.1° C
manifold RPCM P1-2B-C (23/30° F)
(P1-1, 2, and 3) (sec)
Inside IMCA 9.2 RPCM P1-1A-B (pri) -33.3/-29.4° C
heater control RPCM P1-2B-C (-28/-21° F)
unit (sec)
(P1-1, 2, and 3)
3-85
01.07.05(0)T0012
Basic, CPN-1
3.4.7 Radiator Beam Valve Modules (RBVM)

For each radiator, there are two RBVMs (one per flow path) that allow or prevent the
transfer of ammonia to/from the radiator panels. Table 3-61 identifies the RBVM
components and their functions.
Table 3-61. RBVM components summary

Component Function
Isolation/vent valve Allows isolation or venting of the radiator (located on the supply line)
Isolation valve Works with supply line isolation/vent valve to isolate the radiator (located
on the return line)
Bypass relief valve Provides automatic overpressure protection in the event the isolation
valves are closed. Ammonia is “vented” to the ETCS
Vent relief valve Provides automatic overpressure protection for the radiator and ETCS.
Ammonia is vented to space
Nonpropulsive vent Allows ammonia to be vented to space
IMCA Controls isolation and vent valve movement
Gearbox and gear drive Drives the isolation/vent and isolation valves
Heaters (thermostats) Protects the IMCA, QDs, and isolation valves from under-temperature
conditions
Temperature sensor Provides insight into the return line temperature
Pressure sensor Provides insight into the return line pressure
Environment Provides insight into the temperature of the radiator environment
temperature sensor
QDs (4) Provides the interface to the ETCS supply/return fluid lines as well as the
radiator supply/return lines
Figure 3-63 identifies the physical location of the components within an RBVM.
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01.07.05(0)T0012
Basic, CPN-1
Radiator
Isolation/Vent
valve Nonpropulsive
M1 vent
M2
Vent relief
Isolation valve valve Temperature sensor
IMCA
S M3 Gearbox
y
s
t
e Bypass
m M4 relief valve
Burst disc
Environmental
temperature
Limit Pressure sensor
switches (3) sensor 01.07.05(0)T0012_128
Figure 3-63. RBVM ORU components

Table 3-62 identifies RBVM physical characteristics.
Table 3-62. RBVM physical characteristics

6 - Radiator beam, S1 truss (Loop A)
Location
6 - Radiator beam, P1 truss (Loop B)
Envelope 17 x 27 x 6 in.
Operating temp range -73.3° to 48.9° C (-100° to 120° F)
Isolation/Vent Valves
Each RBVM is capable of isolating its radiator flow path from the ETCS via two isolation
valves, one in the supply path and one in the return path. Both valves move together,
driven by a common shaft and gear drive, to one of three possible positions: Open,
Close, or Vent.
The supply isolation/vent valve is a three-port ball valve and the return isolation valve is
a two-port ball valve. When in Open, the valves allow ammonia to freely flow to/from
the radiator. When in Closed, the valves isolate the supply path to the radiator and the
return path from the radiator. When in Vent, ammonia from the radiator is vented
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01.07.05(0)T0012
Basic, CPN-1
through the nonpropulsive vent. (It should be noted that the return isolation valve
moves when commanded to the vent position; however, it does not uncover any port
and thus, the ammonia flow remains isolated in the return path.)
Three limit switches provide discrete positioning of both valves. These limit switches
are only on the return isolation valve. Should a gear drive failure occur, discrete valve
indication for the supply isolation/vent valve might be suspect. The travel time from
open to close or close to open should be less than 60 seconds.
Integrated Motor Controller Assembly
The ETCS Radiator Control (RC) function (in the STR and PTR MDMs) controls and
monitors the RBVM IMCAs. There are a total of six IMCAs in each loop dedicated to
the movement of RBVM valves. The IMCAs used to control the RBVM valves are
identical to the IMCA used to control the radiator deployment and retraction.
Gearbox and Gear Drive
The gearbox contains the gearing to convert the IMCA shaft output to the required drive
rate to move the valves. The gear drive is the common shaft that causes both valves to
move when rotated.
Mechanical Relief Valves
Two mechanical relief valves are located in the ammonia return flow path of each
RBVM providing overpressure protection of both the radiator and the ETCS. Each valve
has the same crack and reseat pressures as shown in Table 3-63.
Table 3-63. RBVM relief valve characteristics

Crack 3240.5 kPa (470 psia)
Full open 3447.5 kPa (500 psia)
Reseat 3171.6 kPa (460 psia)
Vent rate 90.7 kg/hr (200 lbm/hr)
Bypass Relief Valve
The bypass relief valve provides overpressure protection of the radiator in the event it is
isolated (supply isolation/vent valve and return isolation valve in the Closed position). It
is piped in parallel with the return isolation valve. Should the radiator be over-
pressurized, ammonia will be relieved from the radiator to the rest of the ETCS. No loss
of ammonia will occur.
Vent Relief Valve
The vent relief valve provides overpressure protection of the radiators and/or the ETCS.
Should pressure rise above the relief setpoint, this valve will relieve ammonia overboard
via the RBVM nonpropulsive vent.
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Basic, CPN-1
Outlet Line Absolute Pressure Sensor (Out Pressure)
The RBVM outlet pressure sensor is located on the radiator return line and is visible in
Figure 3-63. This sensor is identical to the pressure sensors used in the PM and ATA.
Outlet Line Temperature Sensor (Out Temp)
The RBVM outlet temperature sensor is a platinum temperature element mounted on

the outer surface of the RBVM return piping between the radiator return QD and the
return isolation valve as seen in Figure 3-63. This sensor is identical to the temperature
sensors used in the PM, ATA, and NTA.
Environment Temperature Sensor
The environment temperature sensor is used to measure the external thermal

environment. Its tolerance is ±3.8° C (±5° F). This sensor is not used for any control or
FDIR algorithm.
Nonpropulsive Vent
Each RBVM has its own nonpropulsive vent. Should the relief valve lift or the
isolation/vent valve be commanded to vent, ammonia will flow from the RBVM to space
via the vent. The vent discharge is located on the face of the RBVM and is visible when
the blanket is peeled back.
RBVM Heaters
Each RBVM utilizes two sets of heaters. One heater is used to heat the IMCA. The
other set consists of 10 heaters, one per isolation valve (2) and two per QD (8). The
QDs must be maintained above -80° F.
Each set of RBVM heaters is thermostatically controlled using different redundant

thermostats. The IMCA heater and the valve/QDs heater thermostats have different
on/off setpoints as detailed below in Table 3-64.
Table 3-64. RBVM thermostat setpoints

Setpoint
Service Thermostat
On Off
RBVM IMCA -523 -56.7° C (-70° F) -52.8° C (-63° F)
RBVM valves/QDs -525 -41.1° C (-42° F) -37.2° C (-35° F)
Each thermostat is configured in the “AND” position. This means that both thermostats
must reach the upper setpoint prior to removing power, while only one is required to
reach the lower setpoint before applying power to the heater.
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01.07.05(0)T0012
Basic, CPN-1
RBVM Power Summary
RBVM component.
Table 3-65. RBVM ORU power summary (8A-12A)

Wattage
Radiator ORU Component RPCM (Spec)
SFU S1 1A C RPC 04*
IMCA S1 1A C RPC 04* 13
S1 radiator 1
Heater 1 S1 2B B RPC 14* 40
Heater 2 S1 1A C RPC 07* 40
SFU S1 1A C RPC 05*
Loop A S1 radiator 2
SFU S1 1A C RPC 06*
S1 radiator 3
SFU P1 2B C RPC 04*
IMCA P1 2B C RPC 04* 13
P1 radiator 1
Heater 1 P1 1A B RPC 14* 40
Heater 2 P1 2B C RPC 07* 40
SFU P1 2B C RPC 05*
Loop B P1 radiator 2
SFU P1 2B C RPC 05*
P1 radiator 3
*These RPCs power more than just identified load.
3.4.8 Thermal Radiator Rotary Joint

The TRRJ provides controlled rotation of the radiator, allows the transfer of power, data,
and ammonia across the rotating interface, and provides the structural support between
the S1/P1 truss segments and the associated radiator wing assembly. Figure 3-64
shows the TRRJ components. Table 3-66 identifies the TRRJ components and their
functions.
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01.07.05(0)T0012
Basic, CPN-1
Power and Data
Transfer Assembly
(PDTA)
Rotation
Limiter Bearing Assembly
Launch
Restraint
Flexible Hose
FHRC Stinger Rotary Coupler (FHRC)
DLA
01.07.05(0)T0012_145
Figure 3-64. TRRJ components
Table 3-66. TRRJ components

Component Function
Bearing assembly Provides structural support and the rotary interface
FHRC/PDTA Provides two discrete isolated flow paths for single-phase liquid ammonia
Provides 120 V dc power and data transfer across rotary interface
DLA (2) Provides drive torque, engage/disengage actuation, and joint locking
RJMC (2) Provides drive system control
Cable harness Provides instrumentation, DLA, and RJMC connectivity
Heaters (2) Maintains ORU components within operational ranges
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The performance and physical characteristics of the TRRJ are defined in Table 3-67.
Table 3-67. TRRJ characteristics

Dimensions 1.0 x 1.4 x 1.6 m (41 x 54 x 62 in.)
Dry weight 500 kg (992 lb)
Rotational capability ±115 deg (operationally ±104 deg)
Maximum rotational error ±1.5 deg angular rotation
Maximum rotational rate 0.75 deg/sec
Minimum rotational rate 0.0225 deg/sec
2
Acceleration/deceleration 0.01 deg/sec
4 2
Maximum inertia load 3.5 x 10 slug feet
Flowrate 8100 lb/hr (@ -100° F < T fluid < +60° F)
Max pressure drop 4.7 psid
Max operating pressure 500 psi
Inlet temperature range 33° to 60° F
Outlet temperature range -100° to 33° F
Maximum weight 1143 lb
Power consumption <410 W
Bearing Assembly
The TRRJ bearing assembly provides the structural continuity between the radiator
beam and the S1 and P1 truss segments. In addition, the TRRJ bearing assembly
provides interfaces for the DLAs, the FHRC assembly, and the cradle support structure.
The secondary support structure TRRJ assembly, also referred to as the TRRJ cradle,
is attached to the TRRJ bearing assembly to constitute a single ORU combining the
TRRJ and the cradle.
Rotary Joint Motor Controller (RJMC)
The RJMCs are used as part of two redundant strings. A string consists of an MDM that
provides the power control and the RS-485 command and telemetry links, one RJMC,
and one DLA. There is a single joint resolver with two separate windings. Each RJMC
powers one winding (see Figure 3-65).
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C&C-MDM
Commands
and data
(1553 bus)
EXT MDM TRRJ

Manager
Commands
S1-1 MDM TRRJ Control and data S1-2 MDM TRRJ Control
String 1 (1553 bus) String 2
Commands Commands
and data and data
(RS-485 bus) (RS-485 bus)
RJMC 1 RJMC 2
Torque Torque
motor control motor control
Control of other
Primary Stepper strings Stepper motor Primary Stepper
motor control motor control
DLA 1 DLA 2
Joint Resolver
Winding A (PDTA) Winding B
Note: Loop A shown; loop B is similiar

01.07.05(0)T0012_150
Figure 3-65. TRRJ strings

When a TRRJ position is sent to the MDM associated with the RJMC, the MDM
subtracts the current joint position from the requested position, applies gain and integral
compensation to the difference, and passes the result on the RJMC as a velocity
command over the RS-485 data bus. The RJMC receives the velocity command,
subtracts the current velocity, and drives the torque motor with a current proportional to
the difference. The DLA torque motor drives a commutation resolver, which the RJMC
uses to get commutation angle and velocity. The joint resolver (in the PDTA) passes
analog position information back to the RJMC. The RJMC converts the joint position to
a digital word for transmission back to the MDM.
Drive Lock Assembly
Each DLA contains a torque motor and a stepper motor. The torque motor is a
two-phase brushless dc motor used to provide the rotation of the radiator beam. The
two-phase redundantly-wound stepper motor is used to move the DLA to lock, neutral,
or engage. The stepper motor rotates the DLA motor housing into three positions
through a four-bar and slider mechanism called the Engage Disengage Mechanism
(EDM). The over-center feature of the EDM prevents inadvertent state changes from
occurring. A lock-fuse and pinion-fuse (spring assemblies) are used to pre-load the
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assembly in the engaged and locked positions, and to prevent tooth damage in the
event of an interference of the pinion gear teeth with the bull gear.
The DLA engage/lock stepper motors have dual windings; one winding can be driven by
each RJMC. In case of a failure in one string, this allows the other string to disengage
or unlock the failed string and begin normal operations on the second string.
Flex Hose Rotary Coupler/Power and Data Transfer Assembly
The FHRC/PDTA provides the fluid, power, and data transfer across the rotary
interface. The FHRC consists of four flex hoses (two supply and two return), which are
capable of rotating a total of 230 degrees (±115 degrees from the neutral position).
Software limits the rotation to ±104 degrees of the neutral position. FDIR responds at
105 degrees (S1/P1 MDM) and 106 degrees (EXT MDM). The PDTA allows 120 V dc
at 300 W for a total of 2700 W.
Heaters
Each TRRJ is equipped with one heater on each DLA, two heaters for each RJMC (one
operational and one survival), plus a heater on the TRRJ cradle. These heaters are
software controlled to heater on/off setpoints, as denoted in Tables 3-68 and 3-69.
Table 3-68. S1 TRRJ heaters

Heater Power Power source MDM On/Off setpoints
RJMC S1-1 htr Group 2 77.4 W RPCM S11A_C S1-1 -40/-37.2° C (-40/-35° F)
RJMC S1-2 htr Group 2 RPCM S12B_B S1-2
(operational htrs)
RJMC S1-1 htr Group 1 77.4 W RPCM S12B_B S1-2 -40/-37.2° C (-40/-35° F)
RJMC S1-2 htr Group 1 RPCM S11A_C S1-1
(survival htrs)
DLA S1-1 (operational htr) 39 W RPCM S11A_C S1-1 -40/-37.2° C (-40/-35° F)
DLA S1-2 (operational htr) 39 W RPCM S12B_B S1-2 -40/-37.2° C (-40/-35° F)
TRRJ S1 cradle 316 W RPCM S11A_C S1-1 -9.4/-6.67° C (15/20° F)
Table 3-69. P1 TRRJ heaters
Heater Power Power source MDM On/Off setpoints
RJMC P1-1 htr Group 2 77.4 W RPCM P11A_B P1-1 -40/-37.2° C (-40/-35° F)
RJMC P1-2 htr Group 2 RPCM P12B_C P1-2
(operational htrs)
RJMC P1-1 htr Group 1 77.4 W RPCM P12B_C P1-2 -40/-37.2° C (-40/-35° F)
RJMC P1-2 htr Group 1 RPCM P11A_B P1-1
(survival htrs)
DLA P1-1 (operational htr) 39 W RPCM P11A_B P1-1 -40/-37.2° C (-40/-35° F)
DLA P1-2 (operational htr) 39 W RPCM P12B_C P1-2 -40/-37.2° C (-40 -35° F)
TRRJ P1 cradle 316 W RPCM P12B_C P1-2 -9.4/-6.67° C (15/20° F)
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1.0 =
2.0
3.0
3.5 USOS PASSIVE TCS HEATERS

The ISS contains multiple kinds of heaters both inside and outside the pressurized
volume. Most heaters belong to one of five categories:
a. Shell Heaters - Designed to prevent condensation from forming on the inside of

pressurized modules
b. ORU Heaters - Designed to keep a specific component within its operational or

nonoperational (survival) temperature ranges
c. Line Heaters - Used to prevent the fluid (ammonia or water) within external fluid
lines from freezing; can also be used to add heat during low heat load conditions in
order to maintain acceptable temperature ranges
d. Truss/Rail Heaters - Used to keep the EPS equipment mounted on the external
utility rails (power buses) from freezing
e. Launch-to-Activation (LTA) Heaters - Designed to keep the modules within

temperature limits until they are docked, powered, and activated on the ISS
Typical heater design includes a resistive wire element packaged in an insulating

material. Heaters are bonded with adhesive to the internal or external surfaces of a
module, ORU, power bus, or fluid line. When an RPC applies electrical power to the
heater, the temperature of the element rises and heat is transferred by conduction to the
component. RTDs are placed near some heaters to provide temperature insight.
These temperature sensors use a wire element that displays a linear resistance change
for a corresponding temperature change. The resistance is measured as a voltage,
which can be detected by an LLA card in an MDM.
Some heaters are software controlled and others are thermostatically controlled. For
software controlled heaters, an MDM monitors the associated RTDs and commands the
RPCs to open or close (turning the heaters off and on) in order to maintain the
temperature within a specified range. The temperature range is determined by
setpoints, which can be modified by the operator or by Pre-Positional Load (PPL).
Thermostatically controlled heaters have no software interface except to the power

source (RPC). The RPCs to these heaters generally remain closed and the heater is
cycled on and off by a thermostatically controlled switch. There are no command
interfaces with the thermostats; therefore, heater setpoints cannot be changed and
thermostatically controlled heaters cannot be manually commanded on. However,
these heaters can be manually commanded off by opening the RPC. Thermostats
typically do not provide any temperature telemetry to the ground or PCS.
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3.5.1 Shell Heaters
Electrically powered heaters are located on pressurized elements, including Node 1,
PMA 1, PMA 2, PMA 3, Lab, and Airlock. Each module has an independent shell
heater system with unique software interfaces and control algorithms.
Node 1/PMA 1/PMA 3 Shell Heaters
There are 80 heater patches and 28 RTDs bonded to the interior of the Node 1 pressure
shell. The heater patches and RTDs are grouped into nine zones. The number of
patches and RTDs varies between zones. Figure 3-66 illustrates the heater zones on
Node 1.
Zenith
Zone 9 Zone 1
Aft berthing Forward berthing
plate plate
Starboard
Zone 2
Forward endcone
Zone 7 Zone 3 - Port radial berthing plate

Cylindrical section Zone 4 - Zenith
Zone 5 - Starboard
Zone 6 - Nadir
01.07.05(0)T0012_129
Figure 3-66. Node 1 shell heater zones

A heater is a “string” of patches connected in parallel and is powered by a single RPC.
Within each zone are two strings of heaters, designated A and B. The N1-1 MDM
controls and monitors the A heaters in each zone. The N1-2 MDM controls and
monitors the B heaters in each zone. Temperature data from the RTDs are available
via telemetry. EPS and CDH connectivity is shown in Figure 3-67.
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N1-2 N1-1
Zone 1
T T
NOD1 HTR1B NOD1 HTR1A
TEMP SNSR1 TEMP SNSR1
T T
NOD1 HTR1B NOD1 HTR1A
TEMP SNSR2 TEMP SNSR2
RPCM RPCM
N1-RS2-A N1-RS1-A
NOD1_HTR1B NOD1_HTR1A
(6 patches) (4 patches)
274 W 174 W Legend
Note: Zones 2 through 9 are similar.
Heater
T RTD
01.07.05(0)T0012_130
Figure 3-67. Typical Node 1 shell heater control

The heater architecture for PMA 1 and PMA 3 is similar to Node 1; however, the heaters
are long, thin strips bonded to the outside of the PMA pressure shells. The PMA
heaters are grouped into five zones with RTDs located near the heaters. Figure 3-68
illustrates the heater zones on PMA 1.
Zone 5
Zone 4
Zone 3
Zone 2
Zone 1
01.07.05(0)T0012_131
Figure 3-68. PMA 1 shell heater zones
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Each heater strip contains two heater elements, designated A and B. As with the
Node 1 heaters, the N1-1 MDM controls and monitors the A heater in each PMA 1 zone
and the N1-2 MDM controls and monitors the B heater in each PMA 1 zone. All PMA 3
shell heaters are controlled by the N1-2 MDM and are powered by RPCM N1-RS2-C.
The String A or B designation on PMA 3 refers to location only. Temperature data from
the RTDs are available via telemetry. EPS and CDH connectivity for PMA 1 is shown in
Figure 3-69.
N1-2 N1-1
Zone 1
T T
PMA1 HTR1B PMA1 HTR1A

TEMP SNSR TEMP SNSR
PMA1 HTR1B
68 W
RPCM
N1-RS2-C RPCM
N1-RS1-C
PMA1 HTR1A
68 W
Note: Zones 3 and 5 are similar. Zone 2 Legend

does not have an A heater, and zone
4 does not have a B heater. Heater
T RTD
01.07.05(0)T0012_132
Figure 3-69. Typical PMA 1 shell heater control

PMA 1 provides the interface between the USOS and ROS, so its heaters are always
active. PMA 2 and PMA 3 are used as the docking interfaces for the space shuttle
orbiter. Their shell heater systems are not normally active. Typically, the heaters on
the PMA used by the orbiter will be activated about 24 hours prior to docking.
Figure 3-70 shows the Node 1, PMA 1, and PMA 3 shell heater PCS displays.
Figure 3-70. Node 1, PMA 1, and PMA 2 heater PCS displays
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PMA 2 Shell Heaters
PMA 2 shell heater elements are identical to PMA 1 and PMA 3 heater elements (long,
thin strips wrapped around the outside of the module); however, they are controlled by a
separate software algorithm in the INT MDM. The INT MDM monitors the RTDs on
PMA 2 and cycles the power to the RPC based upon predefined setpoints
(1.67o C – on/10 o C – off). These setpoints can only be changed by the ground using
the PPL uplink capability. The RPCM LA1B-C power bus supplies electrical power to
the heaters. Figure 3-71 shows the PMA 2 shell heater display.
Figure 3-71. PMA 2 shell

heater control display
Lab Shell Heaters
There are 36 heater patches, 6 thermostats, and 12 RTDs on the inside of the Lab
pressure shell. The heater patches and RTDs are grouped into six zones. Figure 3-72
illustrates the heater zones on the Lab.
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Zone 6 Zone 1
Aft endcone Forward endcone
Note: In Zones 2 through 5,each Zone 2 - Port wall

o
zone covers 90 (one-fourth) of Zone 3 - Zenith wall
the pressure shell. Zone 4 - Starboard wall
Zone 5 - Nadir wall 01.07.05(0)T0012_133
Figure 3-72. Lab shell heater zones

Thermostats apply power to the Lab heaters in order to maintain shell temperatures
between 18.3° and 22.2° C (65° and 72° F). Temperature data to each thermostat are
supplied by remotely located RTDs but are not available via telemetry. EPS
connectivity for the Lab is shown in Figure 3-73.
Zone 1 T
RPCM
LA-1B
6 patches
270 W T
Note: Zones 2 through 6 are similar.
Legend
Heater
T RTD
Thermostat
01.07.05(0)T0012_134
Figure 3-73. Typical lab shell heater control

Software in the INT MDM performs day/night cyclic load management of the US Lab
shell heaters. The software prevents activation of Lab shell heaters during the “night”
cycle by removing power from the thermostatic switches upon receipt of the cyclic load
management message broadcast from the C&C MDM indicating the start of the night or
discharge phase. Power is automatically reapplied to the thermostats upon receipt of
the message broadcast indicating the start of the “day” or charge phase. The cyclic
load management performed by the INT MDM for the Lab shell heaters can be enabled
or inhibited as seen on the Lab shell heater control display in Figures 3-74.
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Figure 3-74. Lab shell heater

control display
Airlock Shell Heaters
The Airlock shell heater design uses heater elements mounted on the external pressure
shell underneath the MLI and MMOD shielding. There is a primary and secondary
string of Airlock shell heaters. The primary string is software controlled via the INT
MDM and consists of five zones, as seen in Table 3-70 below. The secondary string is
thermostatically controlled to default on/off setpoints of 18.3o C and 22.2o C and consists
of only four zones. It should be noted that during the Airlock LTA phase, thermostats
controlled both the primary and secondary Airlock shell heaters. Each thermostat was
preset on the ground and could not be adjusted on orbit. Following the LTA phase,
primary Airlock shell heaters were configured so that they were INT MDM-controlled,
and the thermostats were removed from the heater circuit. The secondary Airlock shell
heaters remain attached to thermostats and can be used to supplement the primary
heaters, if necessary. Post-LTA, Airlock shell temperature sensor data are rerouted to
the Airlock MDM. The Airlock MDM provides raw temperature sensor readings to the
INT MDM for CLC processing. Figure 3-75 identifies the Airlock shell heater zones.
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Zenith
ZONE 2
(Transition Ring)
ZONE 4
ZONE 5
ZONE 1
(End of Crewlock)
ZONE 3 EV Hatch
Nadir
Equipment Lock Crew lock
010705(0)T0012_160
Figure 3-75. Airlock shell heater zones

Table 3-70 identifies the number of 22 W heater patches per Airlock zone, as well as
the power draw within each zone. The total power draw for all 56 heaters on the
primary string is 1232 W. The total power draw for all 52 heaters on the secondary
string is 1144 W.
Table 3-70. Airlock shell heater patches per zone

Zone 1 Zone 2 Zone 3 Zone 4 Zone 5
Primary 14 10 14 14 4
Secondary 14 10 14 14 0
Wattage 308 220 308 308 88
The PTCS software located within the INT MDM contains the CLC algorithm that
maintains the Airlock shell temperatures between upper and lower limits. Two
temperature sensors per zone are used to determine when primary Airlock heaters are
required to be on. PTCS performs day/night cyclic load management of the Airlock
heaters. There are three temperature limits (see Table 3-71) that can be defined via
PPL for the Airlock shell heater CLC. One temperature limit is used during the battery
charge phase (insolation), another set is used during the trickle charge phase (end of
insolation when the batteries are close to 100 percent state of charge), and the last set
is used during the discharge phase (eclipse). The PTCS determines which temperature
limit set to use depending on the cyclic load message received from the C&C MDM.
The ground or crew can inhibit the Cyclic Load Management function.
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Table 3-71. Airlock shell temperature limits
Parameter Initialization value
AL Shell Heater Software Shutdown

AL Shell Heater CLC Inh
AL Shell Heater Cyclic Load Mgmt Ena
AL Shell Heater 1(2,3,4,5) Status Ovrd Off
AL Shell Heater Active Limit Set Charge
Zone 1, 2, 5 Zone 3, 4
AL Shell Heater Charge Off Temp * 22.2° C (72° F) 25° C (77° F)
AL Shell Heater Charge On Temp * 18.3° C (65° F) 21.1° C (70° F)
AL Shell Heater Trickle Off Temp * 22.2° C (72° F) 25° C (77° F)
AL Shell Heater Trickle On Temp * 18.3° C (65° F) 21.1° C (70° F)
AL Shell Heater Discharge Off Temp * 22.2° C (72° F) 25° C (77° F)
AL Shell Heater Discharge On Temp * 18.3° C (65° F) 21.1° C (70° F)
*Value may be changed with an Int Sys PPL named Int PTCS Airlock shell heaters parameter. PPLs have already
been uplinked to increase Airlock shell heater zones 3 and 4 to the noted values. The PPLs may be used to change
individual zone setpoints.
Figure 3-76 depicts the Airlock shell heater overview display.
Figure 3-76. Airlock TCS overview

3.5.2 ORU Heaters
ORU heaters are designed to keep specific components within their operational and
nonoperational temperature ranges. Most externally located ORUs have a set of
operational heaters that are utilized when the ORU is powered, and active. A separate
set of survival heaters that are utilized when the ORU is unpowered, is also included in
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most ORU designs. The survival heaters have a different power source than the ORU
in order to ensure that the heaters are available even if the ORU power source is not.
Most ORU heaters are software controlled to default setpoints that can usually be
changed via PPL. Since each ORU heater design is unique for the particular box, this
section will not attempt to cover the individual ORU heater systems. For information
about a particular ORU, consult the appropriate training manual or console handbook.
3.5.3 Line Heaters

See details on the ITCS and ETCS line heaters in Sections 3.2.12 and 3.4.3.
3.5.4 Truss/Rail Heaters

Truss/rail heaters are distributed throughout the ISS on external EPS utility rails (power
buses). These heaters are generally software controlled to default setpoints. Each
utility rail is designed with an operational string of heaters and a survival string of
heaters. The software for both the operational and survival heater strings can operate
in CLC or open loop control as seen in Figure 3-77. In CLC, the software monitors the
temperature sensors and sends open or close commands to the heater RPC based
upon the defined on/off setpoints. In open loop control, the software simply applies
power to the heater (closes the RPC) for a specified time period and then unpowers the
heater (opens the RPC). This is repeated based on predefined open/close duty cycles.
Software will automatically transition to Open Loop Control mode for heater control
circuits when all temperature sensor readings within that circuit indicate failed or upon
operator/crew command. Default temperature setpoints and on/off duty cycles can only
be changed via PPL.
Figure 3-77. Sample utility rail

(power bus) heater display
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3.5.5 Launch-To-Activation Heaters
LTA heaters are designed to keep a module within allowable temperature ranges from
the time the module launches until it is officially installed and activated on the ISS. The
major concern for most modules is keeping the ITCS fluid lines warm in order to prevent
them from freezing.
Lab LTA Heaters
The Lab Module required LTA heaters to prevent the ITCS coolant from freezing and
potentially cracking ITCS piping and system components during the period from launch
to Lab activation. The LTA heater design allowed power to be fed from the orbiter
during the period the Lab was in the orbiter payload bay and from external Node 1
power feeds when attached to the ISS.
The LTA heaters are arranged in four zones. Each zone is made up of two sets of
seven rectangular 45 W Kapton heaters. An electronic thermostat that contains two
parallel switches controls the heater zones to default settings of 18.3o to 22.2o C
(65o to 72o F). Each switch is wired to its own temperature sensor (two sensors per
zone) located within the zone. The thermostats are designed to provide power to the
shell heaters when one of the two temperature indications reaches the lower setpoint.
Power is removed from the shell heaters only when both temperature indications reach
the upper setpoint.
Each heater set (channel A or channel B) is capable of protecting critical areas of the
Lab, so coolant contained within the Lab element will not freeze when the heaters are
powered. The heating elements for each channel are located in such a way that either
channel will provide full coverage of the Lab. The LTA heaters are external to the Lab
and are bonded directly to the Lab’s skin, and thus, will be under the debris shield and
MLI.
It should be noted that the Lab LTA heaters did not cycle off as expected during
Mission 5A LTA, but instead stayed on above the defined setpoint. The result was that
the Lab heated up, caused positive pressure relief valves to lift, and expelled some Lab
atmosphere. This problem also arose on Mission 7A with identical thermostats used for
the Airlock. The problem has not been resolved. LTA heaters for the Lab and the
Airlock may be used, but will have to be controlled via RPC commands since the
thermostats are highly unlikely to remove power after reaching the upper setpoints.
During Mission 7A, the A string of Lab LTA heaters was decommissioned. The cable
connection was demated and remated to the secondary zone of Airlock LTA heaters.
Airlock LTA Heaters
The Airlock LTA heaters are similar in design to the LAB LTA heaters. The Airlock had
a primary and secondary string of LTA heaters each divided into four zones with varying
numbers of 22 W heater patches in each zone.
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Thermal control of the LTA heaters was maintained by thermostat control with default
settings of 18.3o to 22.2o C (65o to 72o F). These thermostats are identical in design
and function as the Lab LTA thermostats.
Both sets of shell heaters were required for redundancy since the initial baseline did not
have temperature feedback from the shell when in the shuttle payload bay. Program
efforts added the Micro Wireless Instrumentation System (MWIS) to the 7A mission due
to concerns with the operation of the Lab LTA shell heaters on the 5A mission.
To prevent freezing in the shuttle payload bay, both sets of LTA heaters were
connected to shuttle power sources (APCU) via external EV-removable power
umbilicals. The heaters operated in this LTA thermostat controlled configuration from
about 2.5 hours into the 7A mission until the Flight Day (FD) 4 EVA 1 when the Airlock
was mated to Node 1. Upon mating of the Airlock and Node 1, the EV crew connected
the secondary LTA heaters to a Node 1 power source (N1-RS1-B). Following Airlock
activation, the primary LTA string was reconfigured to internal MDM and power sources
in order to provide nominal shell heater control for the Airlock. In the final configuration,
an additional heater zone (Zone 5) is added which increases the total heater power on
the Airlock primary shell heaters to 1232 W. The secondary LTA heaters remain in their
initial configuration: thermostatically controlled with external power supplied from
Node 1.
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3.6 TCS SOFTWARE DETAILS
This section contains details of the TCS software in the USOS.
3.6.1 Command and Control MDM Software

For the TCS, the C&C MDM provides ISS-level control for contingency situations
through vehicle safing responses to electrical and thermal failures. The Thermal
Monitoring and Safing function monitors for and responds to TCS failures and
hazardous conditions for which the individual subsystems (EETCS, ETCS, and ITCS)
cannot respond. The C&C MDM also provides the interface between the GNC MDMs
and the EXT MDMs once the ETCS is activated.
Loop Load Reduction
The Thermal Loop Load Reduction function monitors the failure and operational status
of the EETCS loops, IFHX, and the ITCS loops to detect and respond to conditions
requiring shedding of thermal loads or reconfiguration of the ITCS to Single Loop mode.
An automatic thermal load shed and/or ITCS reconfiguration action may be initiated for
any of the following thermal safing failure indications:
a. EETCS loop fail (not available after Flight 12A.1)
b. Lab LTL or MTL IFHX bypassed or isolated
c. ITCS LTL and/or MTL shutdown power request
Shutdown power requests are automatically issued by the software upon an ITCS
transition to Dual LT (MT) Failed mode. Additionally, the MTL shutdown power request
is used to indicate a loss of cooling to the GNC MDMs. Table 3-72 details the
conditions that drive the other two thermal safing failure indications.
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Table 3-72. Thermal safing failure indications
Loop X Loop X
LOC to Loop Lab IFHX Lab IFHX
Pump A Pump B ITCS lab
X PFCS X Bypass X isolation Thermal safing
failure failure operating
(EETCS valve valve indicator
(EETCS (EETCS mode
only) bypassed closed
only) only)
In Alarm In Alarm - - - - External Loop X
Failure
- - In Alarm - - - External Loop X
Failure
Return to - Return to True - Not Dual X LAB X IFHX
Normal Normal Failed Bypassed/Isolated
Return to - Return to - True Not Dual X LAB X IFHX
- Return to Return to True - Not Dual X LAB X IFHX
- Return to Return to - True Not Dual X LAB X IFHX
Automatic thermal load shed actions occur if one or more of the thermal safing failure
indications in the above table are detected and the ITCS Reconfiguration, Auto Thermal
Load Shed, and CCS Load Shed functions are enabled. The actions taken depend on
the thermal safing failure indications and the ITCS mode at the time of the failure. Load
shed actions consist of tables of single-step instantiated commands. Table 3-73 details
all possible automatic thermal load shed actions.
Note: All thermal load shed tables are currently blank but may be populated in the
future as more payloads and equipment are added to the ISS.
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Table 3-73. Thermal safing load shed response
ITCS ITCS
External External Lab LTL Lab MTL
shutdown shutdown ITCS Lab Load
Loop A Loop B IFHX IFHX
Lab LTL Lab MTL operating shed
(LTL) (MTL) bypassed/ bypassed/
1 1 power power mode resp.
failure failure isolated isolated
request request
2
- - - - True True - A
- - - - False True - D
- - - - True False - E
True False - - - - Dual B
False True - - - - Dual B
2
True True - - - - Dual A
True False - - - - Single C
(LT or MT)
False True - - - - Single C
(LT or MT)
2
True True - - - - Single A
(LT or MT)
2
True - - - - - Dual MT A
Failed
2
- True - - - - Dual LT A
Failed
- - True False - - Dual B
- - False True - - Dual B
- - True True - - Dual A
- - True False - - Single C
(LT or MT)
- - False True - - Single C
(LT or MT)
- - True True - - Single A
(LT or MT)
- - True - - - Dual MT A
Failed
- - - True - - Dual LT A
Failed
True - - True - - - A
- True True - - - - A
Where: “ - ” is not applicable:
Load Shed Resp. A = Partial LT + Partial MT + Complete LT + Complete MT
Load Shed Resp. B = Command Single MT + Partial LT + Partial MT
Load Shed Resp. C = Partial LT + Partial MT
Load Shed Resp. D = Partial MT
Load Shed Resp. E = Partial LT
1
Not available after Flight 12A.1.
2
These failure conditions also initiate an automatic survival mode transition. See Section 3.6.1 for details.
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In order to allow time to prevent load sheds from automatically occurring, the software
incorporates the use of a timer (Figure 3-78), which must expire prior to initiating any
load shed actions. There is one timer for the partial load shed and a separate timer for
the complete load shed. The default value of each timer is 300 seconds (5 minutes).
Thermal Load Shed Actions

(for conditions requiring all 4 load shed tables)
Caution message
Execute LTL Partial
Caution message
Caution message Execute LTL Complete
Execute MTL Partial Caution message
(2) Caution message for
Partial Load Shed Timers Execute MTL Complete
(2) Caution message for
Complete Load Shed Timers
5 min timer 5 min timer (default)
Trigger
Conditions Load Shed Timeline
Met
01.07.05(0)T0012_142
Figure 3-78. Load shed timeline

If an ITCS reconfiguration action is also required (load shed action B in Table 3-74), the
software will issue the command to transition the ITCS to Single MT mode prior to
starting any load shed timers.
IFHX Leak Response
The IFHX Leak Response function monitors for and responds to a rupture of an IFHX
core. This is a hazardous condition, which allows high-pressure ammonia to enter Lab
cooling loops, potentially leading to leaks and hardware damage within the ITCS
system. More importantly, ammonia vapor is extremely toxic to crewmembers and may
be released into the cabin atmosphere through the PPA gas trap.
The actual response to this type of failure depends upon the ITCS mode, as follows:
a. Dual Loop Mode - If a single PPA accumulator quantity reading > 90 percent, the
software automatically bypasses and isolates the corresponding IFHX and inhibits
the ITCS Reconfiguration and ITCS Failure Recovery algorithms. (Pre-12A.1, when
the EETCS is still active, the software will also inhibit the IFHX Reintegration
algorithm.)
b. Single Loop Mode - If the sum of both PPA accumulator quantity readings > TBD
percent, the C&C will bypass both IFHXs and inhibit the ITCS Reconfiguration and
ITCS Failure Recovery algorithms. (Pre-12A.1, the software simply issues the
warning level message but takes no action to bypass the IFHXs).
The Thermal Safing LTL and MTL IFHX Leak Response and Thermal Safing Single
Loop IFHX Leak Response functions can be enabled or inhibited.
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IFHX Reintegration
The IFHX Reintegration function monitors for situations where an EETCS loop and its
corresponding ITCS Loop are operable, but the IFHX is bypassed and isolated. If this
condition is detected, IFHX reintegration automatically commands the IFHX isolation
valve to “Open” and the IFHX bypass valve to “Flothru” when monitored EETCS
temperatures are above required thresholds (2.2o C (36o F)). This software is currently
inhibited because it has been determined that automated reintegration of an IFHX is not
necessary and can be handled better by operator intervention. Since this function only
monitors EETCS temperature data, it will not be applicable after Mission 12A.1 when
the ETCS is activated.
Survival Mode Transition
A Survival Mode transition is automatically initiated for nine different combinations of

thermal and/or electrical failures, a loss of attitude control, or when the Russian
Segment goes to Survival mode. The Automatic Survival Mode transition for electrical
and/or thermal failures defaults to enable, but is planned to be inhibited on orbit.
However, Automatic Survival Mode transitions will still occur for a loss of attitude control
or when the Russian Segment transitions to Survival mode. Table 3-74 details electrical
and thermal failures that can initiate a Survival Mode transition when the function is
enabled.
Table 3-74. Survival mode trigger conditions

BCDU Thermal
Survival
voltage Thermal safing EETCS safing IFHX ITCS shutdown ITCS
mode
limit loop fail indicator bypassed/ power request mode
condition
violation isolated
Loop B
4B 2B Loop A (LTL) LTL MTL LTL MTL
(MTL)
1 X X
2 X X
3 X X
4 X X
5 X X
6 X X
7 X X
8 X Dual MT
Failed
9 X Dual LT
Failed
Note that Survival Mode transition conditions 6 through 9 also initiate thermal load
sheds (a partial and complete load shed on both the LTL and MTL loop). The Thermal
Safing Load Shed function is independent of the Survival Mode Transition function.
Commands issued in response to a Survival Mode transition are independent of
commands issued from the thermal load shed tables.
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C&C Software TCS Displays
Figure 3-79 shows the thermal load reduction PCS display, which contains the
commands to enable or inhibit the Thermal Load Shed and ITCS Reconfiguration
software functions. The user can also manually execute any one of the load shed
tables. Telemetry identifies any trigger conditions that have been annunciated, and the
current value of the load shed timers.
Figure 3-79. Thermal load reduction PCS display

Figure 3-80 shows the IFHX safing PCS display, which contains the commands to
enable or inhibit the IFHX Reintegration and Leak Response functions. As noted, this
display is not valid until Flight 15A. Prior to that, the display is similar but it does not
include the commands to inhibit or enable the Single Loop Leak Response algorithm.
Only the ground will have access to those commands until the PCS displays are
updated at Flight 15A.
Figure 3-80. IFHX safing PCS display (15A+)
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3.6.2 INT SYS MDM Software
Software within the INT MDMs processes commands from the C&C MDM, executes
algorithms, and generates commands to the LA MDMs and the PFMCs. In addition to
passing commands and data to/from the upper and lower tiered MDMs (via the THRU
function), the INT MDM software performs the following five important functions for the
ITCS: System Control, Failure Recovery, Leak Recovery, Passive TCS Control, and
Pump Control.
System Control for ITCS
The System Control for ITCS (SCITCS) capability performs automatic startup of the
LAB ITCS upon operator request, and executes system reconfigurations requested by
the operator or invoked by other ITCS software functions. The SCITCS defines the
ITCS mode and status based upon the state of the system.
The IATCS Status parameter indicates the operational status of the ITCS. Table 3-75
identifies the valid ITCS status values.
Table 3-75. ITCS status
Value Description
Idle Initial value upon INT MDM power up. Software assumes neither loop is
active so no leak or failure detection is performed when in this mode
Oper At least one loop is active. This is the value of the parameter following a
successful ITCS Activation Startup
Failed Both loops have failed and no functional mode is available
Recon Mode transition is underway and system is reconfiguring
Cyc Pmp Pump (Pmp) Retry algorithm is executing resulting in pump power cycling
Isol Leak Software is responding to a leak indication
The ITCS Mode parameter indicates the current operating configuration of the Lab ITCS
and can have the values defined in Table 3-76.
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Table 3-76. ITCS modes
Dual Both loops are isolated and operating independently
Sngl MT Single loop with MTL pump operating
Sngl LT Single loop with LTL pump operating
Dual MT Failed Both loops are isolated with the MTL loop shutdown (failed)
Dual LT Failed Both loop are isolated with the LTL loop shutdown (failed)
Xtion Dual Loop is transitioning to the specified mode
Xtion Sngl MT
Xtion Sngl LT
Xtion DMTF
Xtion DLTF
Note that if an ITCS Mode command is received when the ITCS is not operating (IATCS
Status = Idle or Failed), the command is valid, but its only effect is to change the IATCS
Mode parameter to the commanded value. The associated Mode Transition algorithm
is not invoked until an ITCS Activation Startup command is received.
Failure Recovery for ITCS
The FRITCS capability continuously monitors the pumps, SFCA SOVs, and LCA valves
for failures during startup, stable operations, and mode transitions. Pump failures can
occur while the system is operating in a stable configuration, but valve failures can only
be detected when they fail to move after being commanded to a new position.
In the event of a failure, FRITCS will request mode transitions or perform Pump Retry
algorithms based on the type of failure detected and the state of the system at the time
the failure occurred. Figure 3-81 shows the 15 possible failure conditions and the
associated software response. Failure conditions 1 to 3 are single failure cases, while
the rest require at least two failures.
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Failure condition 15 may also be both
LCA valves failed; neither in Sngl and
both not = Dual
Failure Condition
Failed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
One LCA Vlv (one is in Sngl) X
MTL Pump or MTL S/O Vlv Close X
LTL Pump or LTL S/O Vlv Close X
Both LCA Vlvs in Dual X X X X X X X X
LTL S/O Vlv Closed X X X X
LTL Pump X X X X X
MTL S/O Vlv Closed X X X X
MTL Pump X X X X X
Transition to Single LT Mode
Transition to Single MT Mode
Transition to Dual Mode
Transition to Dual Mode LT Failed
If fails
LTL Pump Retry
If fails LTL Pump Retry
Transition to Dual Mode MT Failed
If fails
MT Pump Retry
If fails
MT Pump Retry
Two Pump Retry
Power OFF Both Loops

01.07.05(0)T0012_151
Figure 3-81. FRITCS failure conditions and software response

Once a failure recovery process is initiated, it cannot be interrupted; however, FRITCS
can be inhibited, which prevents the software from reacting to all future failure
conditions.
Pump Retry: The FRITCS Pump Retry algorithms are only used in multiple failure
cases to power-cycle the LTL, MTL, or both ITCS pumps. Power to a failed pump is
cycled off and back on, and then a restart is attempted on the pump. A failed pump is
power cycled a maximum of three times. A pump retry counter increments each time
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the Pump Retry algorithm power cycles a pump. This counter can be reset to zero with
a command, which is important since the counter does not automatically reset at the
end of the Pump Retry algorithm, even if the retry was successful.
Loss of Accumulator Quantity: FRITCS, if enabled, automatically reconfigures the

Lab to Single Loop mode if an accumulator quantity sensor fails. Transitioning to Single
Loop mode allows the remaining valid accumulator quantity sensor to be used for
automatic loop leak detection and IFHX NH3 leak detection.
Note: If the sensor fails off-scale high, the C&C MDM will also initiate an IFHX NH3
Leak response due to the high accumulator quantity reading.
SFCA Overpressure Protection: The FRITCS SFCA Overpressure Protection

DOJRULWKPLVGHVLJQHGWRSUHYHQWGDPDJHWRWKH6)&$ 3VHQVRU7KHPaximum upper
range reading of the sensor is approximately 20.3 psid (140 kPa) and the sensor is
damaged at approximately 56 psid (386 kPa). All operating pumps are commanded to
a reduced speed (11,373 rpm) if the SFCA P sensor on either the LTL or MTL loop is
greater than the SFCA overpressure protection limit (19 psid at MDM initialization) and
the SFCA Overpressure Protection algorithm is enabled.
If an SFCA Mod Vlv P sensor fails off-scale high, this algorithm will command the
pump speed to 11,373 rpm on the affected loop. The SFCA Mod Vlv P sensor is failed
off-scale high at 20 psid (138 kPa). If any SFCA P sensor is failed off-scale high,
SFCA overpressure protection must be inhibited in order to operate pumps at their
normal operating speed. There is no way to prevent the INT MDM software from
reading the failed SFCA P sensor.
Leak Recovery for ITCS
The Leak Recovery software monitors for conditions indicating a leak and reconfigures
the ITCS to verify and isolate the detected leak. Leak recovery for ITCS (LRITCS) uses
LTL and MTL accumulator quantity readings, the ITCS Status parameter, and the ITCS
Mode parameter to determine if and where a leak condition exists. Leak Recovery
steps depend on the ITCS mode and include mode reconfigurations, pump shutdowns,
and venting of an affected loop’s accumulator nitrogen supply. LRITCS does not
monitor for leaks or issue C&W messages when ITCS status = Idle or Failed. LRITCS
also performs no actions if the Lab mode is dual, and an LTL or MTL accumulator
quantity sensor has been declared failed.
Each LTL and MTL accumulator quantity reading is averaged separately over a ten-
second period within the Pump Sensors (PUMPS) software function in the LA-1 (LTL) or
LA-2 (MTL) MDM. The average readings are then passed to the PUMP function within
the INT MDM. The PUMP capability (PUMPS) converts the average accumulator
quantity reading to Engineering Units (EUs) (percent) and passes this value to LRITCS
capability for leak detection.
LRITCS software defaults to the normal leak limits shown in Table 3-77 at MDM
initialization, but the capability exists to modify dual-loop leak limits using the Set
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Normal and Set Contingency Leak Limits commands. These commands create new
leak limits by subtracting a set percentage (normal delta or contingency delta) from real-
time accumulator quantity values and using this calculated value as the new dual loop
leak limit. Real-time leak limits are not available in telemetry. Tracking of updated dual
loop leak limits must be handled procedurally on console. Single-loop leak limits can
only be changed via PPL.
Table 3-77. Leak limit initialization values

LTL (MTL) PPA Accum Quantity Low Limit 67%
LTL (MTL) Leak Recovery Auto Shutdown Limit 59%
ITCS System Accum Quantity Low Limit 71%
ITCS System Leak Recovery Auto Isolation Limit 67%
Degraded System Accum Quantity Low Limit 46%
(one accumulator quantity sensor is failed)
Degraded System Leak Recovery Auto Isolation Limit 42%
(one accumulator quantity sensor is failed)
LTL (MTL) Accum Quantity Low Normal Delta 8%
LTL (MTL) Accum Quantity Low Contingency Delta 4%
LTL (MTL) Leak Auto Shutdown Normal Delta 16%
LTL (MTL) Leak Auto Shutdown Contingency Delta 7%
When in Dual Loop mode, LRITCS independently monitors each accumulator quantity
sensor for a leak. If either sensor drops by more than 8 percent (Low Normal Delta), an
accumulator low caution message will be annunciated. If the leak continues and the
sensor drops another 8 percent (for a total drop of 16 percent, Auto Shutdown Normal
Delta), software will issue a shutdown caution for the LTL or a shutdown warning for the
MTL and will then proceed to shut down and vent the accumulator on the leaking loop.
Software transitions the ITCS to Dual MT Failed mode for an MTL leak and to Dual LT
Failed mode for an LTL leak.
When in Single Loop mode, LRITCS monitors the average of the two accumulator
quantity sensors. If the average drops below 71 percent (ITCS System Accum Quantity
Low Limit), a system level accumulator low caution is annunciated. If the average
continues to drop and it falls below 67 percent (ITCS System Leak Recovery Auto
Isolation Limit), the software is designed to isolate the ITCS loops and then determine
which loop is leaking by monitoring the individual accumulator quantity sensors.
Software transitions the ITCS to Dual MT Failed mode for an MTL leak and to Dual LT
Failed mode for an LTL leak. If neither loop is determined to be leaking, a transition to
Dual will occur and the software will then monitor the system based upon the
contingency deltas (4 percent and 7 percent) defined in Table 3-78.
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If the Auto Isolation function is inhibited, the software will automatically perform a
transition to Dual Loop mode and then monitor the system based upon the contingency
deltas (4 percent and 7 percent) defined above.
Passive TCS Control
The Passive TCS Control (PTCSC) function performs CLC of the PMA 2, IFHX, and
Airlock heaters to keep temperatures between upper and lower limits set by default or
by the operator. PTCSC also passes Lab Window Heater Startup/Shutdown commands
to the PTCS capability in the LA-1 MDM. Finally, PTCSC performs cyclic power load
management on the Lab shell heaters, which are thermostatically controlled
Section 3.5 covers the details of the Lab, PMA 2, and Airlock heaters, so only the IFHX
heaters will be discussed in this section.
IFHX Heaters: PTCSC utilizes temperature data from the LA-1 (MTL) and LA-2 (LTL)
MDMs to perform CLC of three separate sets of IFHX heaters. There is one heater on
the inlet line and a second heater on the outlet line. The third heater is actually a set of
three separate heaters located inside the IFHX that are wired in parallel and controlled
by a single RPC, as seen in Figure 3-82. If any one of the three temperature sensors
falls below 2.8o C (30o F), PTCSC commands the associated heater on (closes the
RPC). If all three sensors are above 4.4o C (40o F), PTCSC commands all the heaters
off (opens all three RPCs).
L A-2 PT CS LAB LT Hx Outlet T emperture S ens or
LA-1 PT CS LAB MT Hx Outlet T emperature S ens or
Bypas s IF HX OR U INT * PT CS LAB LT Hx Outlet H20 Line Htr

valve PT CS LAB MT Hx Outlet H20 Line Htr
LT L RPCM L AAF T -2B -G, R PC-5
F rom MT L R PCM LAF WD-1B -F , R PC-7
P F CS
US L ab
Bleed line
IF HX
core To
T WMV
Orifice
Is olation F rom
valve L CA
To
R adiators
R elief
LA-2 PT CS LAB LT Hx Inlet T emperture S ens or
valves
LA-1 PT CS LAB MT Hx Inlet T emperature S ens or
LT L RPCM LAAF T -2B-G, RPC-4
MT L R PCM LAF WD-1B-F , RPC-6
Vent (to space)
LA-2 PT CS LAB LT Hx T emperture S ensor INT * PT CS LAB LT Hx Internal H20 Line Htr
PT CS LAB MT Hx Internal H20 Line Htr
LA-1 PT CS L AB MT Hx T emperature S ens or
LT L R PCM L AAF T -2B-G, RPC-15
MT L RP CM L AF WD-1B-F , RPC-12
* Note: PT CS C s oftware in INT S YS MDM INT * PT CS LAB LT Hx Internal Htr

controls each Heater/R T D s eparately. PT CS LAB MT Hx Internal Htr
01.07.05(0)T 0012_143
Figure 3-82. IFHX heaters
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Table 3-78 identifies the EPS and CDH connectivity to the IFHX heaters.
Table 3-78. IFHX heaters
Heater Power (W) Power source MDM
LTL IFHX H20 Inlet 35 W RPCM LA2B-G LA-2

LTL IFHX H20 Outlet 35 W RPCM LA2B-G LA-2
MTL IFHX H20 Inlet 35 W RPCM LA1B-F LA-1
MTL IFHX H20 Outlet 35 W RPCM LA1B-F LA-1
LTL IFHX Core Inlet 15 W RPCM LA2B-G LA-2
LTL IFHX Core 25 W (50 W total)
LTL IFHX Core Outlet 10 W
MTL IFHX Core Inlet 15 W RPCM LA1B-F LA-1
MTL IFHX Core 25 W (50 W total)
MTL IFHX Core Outlet 10 W
Pump Package
The Pump Package (PUMP) capability performs pump startup/shutdown, fault

detection/masking processes, pump speed ramping, as well as accumulator
depress/repress actions. PUMP issues commands to the PFMCs to control the
operation of the pumps and receives telemetry from PPA sensors via the LA MDMs, as
well as pump data from the PFMCs. It processes PPA C&W messages and passes
these along with all pump telemetry to the C&C MDM.
Upon MDM initialization, the C&W limits for the various PPA components are initialized
to the values found in Table 3-79. Each of these values can be modified via PPL.
Table 3-79. PUMP PPA C&W limits

Lab LTL or MTL Gas Trap Blockage Advisory 41.3 kPa (6.0 psid)
Lab LTL or MTL PPA Gas Trap Bypass Vlv Failed Closed Caution 65.5 kPa (9.5 psid)
Lab LTL or MTL PPA Pump Filter Blockage Advisory 57.2 kPa (8.3 psid)
Lab LTL or MTL PPA Pump Filter Bypass Vlv Failed Closed Caution 71 kPa (10.3 psid)
Lab LTL or MTL PPA Pump In Press Low Caution 103.4 kPa (15 psi)
Lab LTL or MTL PPA Pump In Press High Caution 275.8 kPa (40 psi)
Lab LTL PPA Pump Outlet Temp High Caution 18.3° C (65° F)
Lab MTL PPA Pump Outlet Temp High Caution 40.5° C (105° F)
Pump Startup/Shutdown: Upon receipt of a valid Pump Software Startup command,

the PUMP capability resets C&W messages associated with the PPA sensors and
acquires PFMC cyclic status data. If the PFMC passes all internal BITs, the PUMP
function issues an internal command to set the pump speed to a value of zero rpm.
Additional internal checks are performed and if passed, the PFMC is placed in the
operational mode where it can accept operator-generated speed commands.
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The fact that the Startup function sets the speed to zero rpm is important because if the
Pump Software Startup command is sent when the software is already started and the
pump is already running (speed > 0 rpm), the PUMP function still sets the speed equal
to zero rpm during the Startup algorithm. Hence, a subsequent command must be sent
to bring the pump speed up to its nominal value.
Upon receipt of a valid PPA Software Shutdown command the PUMP capability issues
an internal command to set the pump speed to a value of zero rpm and then verifies
that the pump is shut down by checking each of the following conditions:
a. Pump speed < 54 rpm
b. LR flow = 0 ± 4.53 kg/hr (0 ± 10 lbm/hr)
c. Pump P = 0 ± 3.0 Psi (0 ± 0.7 kPa)
If all three conditions are True, the PPA Software parameter is set to “Shutdwn.” If any
of the three parameters do not indicate a good shutdown, up to two more attempts are
made to shut down the pump. If this is not successful, PPA software is set to “Shutdwn”
and a pump shutdown failed caution message is issued.
Fault Detection/Masking: Any detected PFMC fault causes the PFMC mode to
automatically transition to Fail Shutdown, and the PFMC inverter to be disabled
(shutting down the pump). However, if the PFMC fault is masked, the pump will
continue to run. The operator can mask any of the seven PFMC faults listed below:
a. LTL(MTL) PPA Firmware Inverter Temp Fault
b. LTL(MTL) PPA Firmware Over Temp Fault
c. LTL(MTL) PPA Firmware Over Speed Fault
d. LTL(MTL) PPA Firmware Under Voltage Fault
e. LTL(MTL) PPA Firmware Inverter Int Fault
f. LTL(MTL) PPA Firmware Over Current Fault
g. LTL(MTL) PPA Firmware Over Voltage Fault
Pump Speed Ramp Function: The Pump Speed Ramping algorithm protects the
6)&$ 3VHQVRU7KLVDOJRULWKPLQFUHDVHVWKHSXPSspeed at a rate of 1000 rpm/sec,
ZKLFKHQVXUHVWKDWODUJHSXPSVSHHGLQFUHDVHVFDQEHVORZHGEHIRUHWKH6)&$ 3
sensor is damaged. Pump speed ramping is active for any pump speed command that
increases the pump speed beyond 8000 rpm.
Pump NIA Function: The PUMP NIA capability performs accumulator depress/repress
processes. It issues commands to the LA-1 and LA-2 MDMs to control the pump
package AVV and NIV. It receives telemetry from those two valves and PPA sensor
data via the LA MDMs. Upon power up of the INT MDM, the PUMP NIA software
exhibits the default C&W limits shown in Table 3-80. Each of these values can be
modified via a PPL.
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Table 3-80. PUMP NIA C&W limits
Lab LTL or MTL PPA Pump In Press Low Caution 103.4 kPa (15 psi)
Lab LTL or MTL PPA Pump In Press High Caution 275.8 kPa (40 psi)
The Depress algorithm is initiated by an operator command or autonomously for a leak

indication. Upon receipt of a valid NIA Depress command, the PUMP capability sets the
value of the NIA State to Depress. The Depress algorithm first verifies that the NIV is
closed (if not closed, the algorithm issues the Close command), opens the AVV for 5
seconds (by issuing open and close commands), and then verifies that the pump inlet
pressure is less than 124.1 kPa (18 psia). The final step is to set the NIA state to
Inhibited.
Loop repressure occurs as a result of a valid NIA Repress command, or automatically

when the NIA state is Enable and the pump inlet pressure 18.0 psia (124.1 kPa) for
6 seconds. To perform the repressure, the PUMP capability first sets the value of the
NIA state to Repress. The Repress algorithm then verifies that the AVV is closed (if not
closed, the algorithm issues the Close command), opens the NIV for 30 seconds (by
issuing open and close commands), and then verifies that the pump inlet pressure > 18
psia (124.1 kPa). If the repressure was triggered by a command, the NIA state is set to
“Inhibit.” If the repressurization was triggered by the pump inlet pressure being less
than 124.1 kPa (18 psia), the NIA state is set to “Enable.”
INT Software TCS Displays
Figure 3-83 shows the software commands available for SCITCS (Activation Startup
and Mode Transition commands), FRITCS (Fail Rcvy, Pump Retry Cnt, and SFCA
Overpress commands), and the PUMP function (Mask and Unmask commands).
Figure 3-83. ITCS software commands PCS display
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Figure 3-84 shows the additional commands available for the INT software LRITCS
function (Leak Rcvy Auto Isolation and Auto Shutdown, Set Normal, and Contingency
Leak Limit commands).
Figure 3-84. ITCS software additional

commands PCS display
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PUMP software commands (Pump Startup/Shutdown, Set Speed, NIA Enable/Inhibit
and Repress/Depress) are available on the PPA commands and NIA commands
displays seen in Figures 3-85 and 3-86.
Figure 3-85. PPA commands PCS display
Figure 3-86. NIA commands PCS display

The PTCSC IFHX Heater commands are seen on the IFHX heater commands display
shown in Figure 3-87.
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Figure 3-87. IFHX heater commands display

3.6.3 LAB SYS MDM Software
The three LA MDMs process commands from the active INT MDM, execute algorithms,
and generate commands to Lab ITCS hardware. Associated C&W messages are also
processed. LA-1 MDM interfaces with LTL hardware, LA-2 MDM interfaces with MTL
hardware, and all three LA MDMs interface with different RFCAs and RSTSs. LA-1 and
LA-2 software is broken down into the ten capabilities discussed below. (LA-3 MDM
software only contains capabilities for RFCAs and RSTSs.)
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Heat Exchanger Bypass
The Heat Exchanger Bypass (HXB) function performs startup/shutdown, valve

positioning, and CLC for the LTL TWMV (LA-1), and the MTL and Regen HX TWMVs
(LA-2).
Upon power up of the LA-1 or LA-2 MDMs, the HXB software exhibits the default values
shown in Table 3-81. Each of these values can be modified via a PPL upload.
Table 3-81. TWMV initialization values

LTL, MTL, Regen TWMV CLC Inh
LTL, MTL, Regen TWMV Software Shutdwn
LTL, MTL, Regen TWMV Cmd Valid Stat Valid
LTL, MTL, Regen TWMV Direct Valve Ovrd <blank>
LTL TWMV Out Temp Setpoint 4.44° C (40° F)*
MTL TWMV Out Temp Setpoint 17.2° C (63° F)
LTL TWMV Overtemp Caution 7.8° C (46° F)*
MTL and Regen TWMV Overtemp Caution 19.4° C (67° F)
LTL and MTL TWMV Undertemp Caution 1.67° C (35° F)
Regen TWMV Undertemp Caution 13.9° C (57° F)
o
*Operationally the LTL setpoint is being kept between 7 to 11 C. All LTL overtemperature
caution messages are currently inhibited due to the elevated setpoints.
Software Startup/Shutdown: Upon receipt of a valid TWMV Software Startup

command, the HXB capability resets the associated C&W indications, inhibits CLC of
the TWMV assembly, and drives the valve towards the flowthrough position for about 14
seconds (if not already there). Once the valve is verified in the flowthrough position, the
software is set to “Started,” and EU conversion for the control temperature sensors can
commence (EU conversion only takes place if the software is started).
Upon receipt of a confirmed and valid TWMV Software Shutdown command, the HXB
capability verifies the valve is in the bypass position. If not, the software drives the
valve toward that position for about 14 seconds. Once the software verifies the valve is
in the bypass position, the software is set to “Shutdown.”
Direct Valve Commanding: Upon receipt of a TWMV Direct Valve command, the HXB
capability moves the TWMV in a set direction and speed for a given time. The TWMV
uses an input voltage to determine the direction of valve movement. A positive voltage
applied to the LTL or MTL TWMV drives it toward the bypass position (increasing loop
temperature) and a negative voltage drives it toward the flowthrough position
(decreasing loop temperature). A positive voltage applied to the MTL Regen TWMV
drives it toward the flowthrough position (increasing loop temperature) and a negative
voltage drives it toward the bypass position.
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Commands can also be sent to the HXB capability to move the TWMV to one of the end
positions: flowthrough or bypass. Upon receipt of a valid flowthrough or bypass
command, the HXB capability moves the selected valve toward the flowthrough or
bypass position for about 14 seconds. These commands are only valid when the
software status is started and CLC is inhibited.
Closed Loop Control: When CLC is enabled and the TWMV software is started, the
HXB capability uses temperature data from the TWMV Cntl temperature sensor, and
based on its reading, drives the valve toward the fully-bypassed (Byp) or fully-
conditioned (Flothru) position to maintain a temperature setpoint. If the temperature
sensor fails, or if the data path between the sensor and the LA-1 (LTL) or LA-2 (MTL,
MTL Regen) MDM fails, the TWMV freezes in its last commanded position, and CLC is
automatically inhibited.
TWMV (HXB) Commands and Telemetry: Figure 3-88 shows the commands and
telemetry available on the PCS for the MTL TWMV. Displays for the LTL and Regen
TWMVs are similar.
Figure 3-88. MTL TWMV commands PCS display

Loop Crossover Assembly
The LCA software controls LCA Valve 1 (LA-1) and LCA Valve 2 (LA-2). The valves are
used to control water flow between the LTL and MTL in the Lab.
The LCA uses voltage to determine the direction of valve movement. A positive voltage
(5 V for 5 to 6 seconds) applied to the valve drives it to the dual position, and negative
voltage (-5 V for 5 to 6 seconds) drives the valve to the single position. LCA valve
discrete position sensors are updated when the LCA valve is enabled, which occurs
whenever an LCA valve command is sent.
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If the LCA valve is manually moved, the LCA Vlv Posn telemetry does not indicate the
new position until an effector command is sent (LCA Vlv 1 or 2 Posn Dual or Sngl
command). The command does not have to be successful for the LCA Vlv Posn
telemetry to be updated since the LCA valves are enabled automatically regardless of
command success.
LCA Commands and Telemetry: The LCA Commands display is seen in Figure 3-89.
Figure 3-89. LCA commands PCS display

SFCA Modulation Valve
The SFCA Mod Vlv capability performs software startup/shutdown, CLC, and valve
positioning processes for the LTL (LA-1) and MTL (LA-2) SFCA Mod Vlv, and processes
the associated C&W messages.
Upon power up of the LA-1 or LA-2 MDMs, the SFCA software exhibits the default
values shown in Table 3-82. Each of these values can be modified via PPL.
Table 3-82. SFCA initialization values

LTL, MTL SFCA CLC Inh
LTL, MTL SFCA Software Shutdwn
LTL, MTL SFCA Cmd Valid Stat Valid
LTL, MTL SFCA Direct Valve Ovrd <blank>
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Software Startup/Shutdown: Upon receipt of a valid SFCA Software Startup

command, the SFCA capability resets the associated C&W indications, inhibits CLC of
the SFCA Mod Vlv, drives the Mod Vlv towards the Open position for about 18 seconds,
sets the software state to Started, and commences (8FRQYHUVLRQIRUWKH6)&$ 3
sensor (EU conversion only takes place if the software is started).
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Upon receipt of a confirmed and valid SFCA Software Shutdown command, the SFCA
capability inhibits CLC, drives the Mod Vlv toward the Closed position for about
17 seconds and then sets the SFCA software state to Shutdwn.
Direct Valve Commanding: The SFCA Mod Vlv function uses voltage to determine
the direction of Mod Vlv movement. Upon receipt of a SFCA Direct Valve command,
the SFCA capability moves the Mod Vlv in a set direction and speed for a given time.
A positive voltage applied to an SFCA Mod Vlv drives it to the closed or maximum rack
flow position and negative voltage drives it to the open or minimum rack flow position.
There is no position telemetry associated with SFCA Mod Vlv; however, the position can
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Mod Vlv placement. These Direct Valve commands are only valid when the software is
started and CLC is inhibited.
Closed Loop Control: When CLC is enabled and the SFCA software is started, the
SFCA capability uses delta pressure data from the SFCA P sensor, and based on its
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if the data path between the sensor and the LA-1 (LTL) or LA-2 (MTL) MDM fails, the
Mod Vlv freezes in its last commanded position and CLC is automatically inhibited.
SFCA Commands and Telemetry: Commands for the SFCA Mod Vlv and SOV are
found the SFCA commands display seen in Figure 3-90.
Figure 3-90. MTL SFCA commands display

SFCA Shutoff Valve
The SFCA SOV capability performs valve-positioning processes for the LTL (LA-1) and
MTL (LA-2) SFCA SOVs, and processes the associated valve failure C&W messages.
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The SOV function uses voltage to determine the direction of valve movement. A
positive voltage (5 V for 4 to 5 seconds) applied to the valve drives it to the closed
position and negative voltage (-5 V for 4 to 5 seconds) drives the valve to the open
position. SOV discrete position sensors are updated when the SOV is enabled, which
occurs whenever a SOV command is sent.
If the SOV is manually moved, the Shutoff Vlv Posn telemetry does not indicate the new
position until an effector command is sent (Shutoff Vlv Posn Open or Close command).
The command does not have to be successful for the Shutoff Vlv Posn telemetry to be
updated since the SOV is enabled automatically regardless of command success.
Rack Flow Control Assembly
The RFCA capability processes software startup/shutdown, set mode/loop location, set
temperature/flow setpoint, test, CLC, and valve positioning processes for RFCAs via all
three LA MDMs, along with associated caution and advisory messages.
Table 3-83 identifies which MDMs control which RFCAs.
Table 3-83. RFCA MDM connectivity
LAB1P1 LA-1 MDM
LAB1D3
LAB1S1, LAB1S2, LAB1S3
Node 1 LTL
LAB1O1, LAB1O2, LAB1O3, LAB1O4, LAB1O5 LA-2 MDM
LAB1P2, LAB1P4 LA-3 MDM
LAB1S4
Node 1 MTL
Upon power up of the LA MDMs, the RFCA software exhibits the default values shown
in Table 3-84. Each of these values can be modified via PPL.
Table 3-84. RFCA initialization values

RFCA x Software Shutdown
RFCA x CLC Inh
RFCA x Close Test Result Pass
RFCA x Direct Vlv Ovrd <blank>
RFCA x Mode Flow
RFCA x Overtemp (LTL) 23.9° C (75° F)
RFCA x Undertemp (LTL) 1.7° C (35° F)
RFCA x Overtemp (MTL) 51.7° C (125° F)
RFCA x Undertemp (MTL) 13.9° C (57° F)
RFCA Flow setpoint 45.3 kg/hr (100 lbm/hr)
RFCA Flow setpoint tolerance 22.7 kg/hr (50lbm/hr)
RFCA x temperature setpoint (LTL) 18.3° C (65° F)
RFCA x temperature setpoint (MTL) 43.3° C (110° F)
RFCA x temperature tolerance 2.7° C (5° F)
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Software Startup/Shutdown: Upon receipt of a valid RFCA Software Startup
command, the RFCA capability resets the associated caution and advisory indications,
inhibits CLC, sets the RFCA mode to Flow, defines the flow setpoint to 45.3 kg/hr (100
lbm/hr), sets the software state to Started, and commences EU conversion for the
RFCA temperature and flow sensors.
Upon receipt of a confirmed and valid RFCA Software Shutdown command, the RFCA
capability inhibits CLC, drives the RFCA valve toward the Closed position for
approximately 17 seconds and then sets the RFCA software state to “Shutdwn.” Note
that the RFCA Software Shutdown algorithm drives the RFCA modulating valve to the
closed position. This can cause a significant increase in system pressure resulting in
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the full open position prior to issuing the RFCA Software Shutdown command if the
RFCA flow demand is greater than 226 kg/hr (500 lbm/hr).
Direct Valve Commanding: Direct Valve commands for the RFCA are identical to the
SFCA Mod Vlv Direct Valve commands.
Test Command: The RFCA Test Command verifies that closing the Mod Vlv causes
flow to approach zero. Upon receipt of a valid Test command, the RFCA capability
drives the valve to the closed position (5 V for ~17 seconds) and then verifies that the
RFCA flow is less than 9 kg/hr (20 lbm/hr). If the flow is below 9 kg/hr (20 lbm/hr), the
Test Result is set to “Pass”; otherwise, it is set to “Failed.” This command is only valid
when the software is started and the CLC is inhibited.
RFCA Loop Commands: The RFCA Loop commands (LTL or MTL) tell the software
to which loop the RFCA is connected. This designation determines initial temperature
setpoints and C&W limits. If the crew physically reconfigures the RFCA to the other
loop, they must send the command to synchronize the software with the physical
configuration in order to maintain the proper C&W and temperature setpoint limits.
Additionally, software will only accept temperature setpoints based upon the loop
selected. If the loop is set to MTL, software will allow temperature setpoints between
18.9o to 48.8o C (66o to 120o F). If the loop is set to LTL, software will only allow
temperature setpoints between 6.2o to 21.1o C (43o to 70o F).
Note: Due to a miswiring of the Node 1 RFCAs, this command must now be executed
as a workaround anytime there is an LA-1 or LA-3 MDM reboot. The LTL
RFCA is physically connected to the LA-3 MDM and the MTL RFCA is
physically connected to the LA-1 MDM. However, the LA-1 RFCA defaults to
the LTL and the LA-3 RFCA defaults to the MTL. The operator should expect
Node1 LTL Overtemp after starting the software when cycling LA-1 and Node1
and MTL Undertemp when cycling LA-3. Also note that sending commands to
those RFCAs will issue the correct but misnamed commands, and that caution
messages associated with these RFCAs are also correct but misnamed.
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RFCA Mode Commands: The RFCA Mode Flow and RFCA Mode Temp commands
designate whether an RFCA uses either temperature or flow for CLC. Operationally,
the Flow mode is preferred in order to reduce the fluctuations (pressure spikes)
generated by the movement of the RFCA valves; however, the temperature mode can
be used if required for a specific payload.
Closed Loop Control: While CLC is enabled, the RFCA capability uses flow or
temperature data to drive the FCV toward the open or closed position in order to
maintain either a flow or temperature setpoint. Flow data (RFCA Calc Flow) is obtained
from one of two flowrate sensors: a Low Rate (LR) flow sensor if the flow < 136 kg/hr
(300 lbm/hr) or a High Rate (HR) flow sensor if the flow is > 181.4 kg/hr (400 lbm/hr). (If
the flow falls between 136 kg/hr and 181.4 kg/hr, a combination of the two flow sensor
values is used to calculate the flow.)
If the controlling temperature sensor fails while the RFCA mode = Temp, or if the data
path between the sensor and the LA MDM fails, the valve freezes in its last commanded
position, and CLC is automatically inhibited. If the RFCA LR flow sensor fails, an
advisory-level message is issued and the RFCA CLC function continues uninterrupted
using the RFCA HR flow input to calculate RFCA Calc Flow. If the RFCA HR flow
sensor fails, RFCA CLC is automatically inhibited (even if RFCA mode = Temp).
RFCA Commands and Telemetry: Figure 3-91 shows an example of the commands
and telemetry available on the PCS for an RFCA.
Figure 3-91. RFCA PCS display

Rack Standalone Temperature Sensors
The RSTS capability provides temperature data for system racks that are connected to
the LA-1, 2, or 3 MDMs. RSTS functions include the processing of temperature sensor
data and caution and advisory messages for those sensors. Table 3-85 identifies which
Lab racks have standalone temperature sensors and the MDM interface for each
sensor.
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Table 3-85. RSTS racks and MDM interfaces
LAB1D1 LA-1 MDM
LAB1P3, LAB1P5, and LAB1P6
Forward endcone
LAB1O6 LA-2 MDM
LAB1S6
LAB1D2, LAB1D4, LAB1D5, LAB1D6 LA-3 MDM
LAB1S5
Aft endcone
RSTS Commands and Telemetry: RSTS temperature data is available on the Lab
rack details display seen in Figure 3-92. There are no commands to the RSTSs.
Figure 3-92. Lab rack details PCS display

Accumulator Vent Valve (ACCUM)
The ACCUM capability is used to open and close the AVV supporting the LTL (LA-1)
and MTL (LA-2) PPA, and also processes associated caution and advisory messages.
Two discrete position sensors drive the AVV position telemetry. Discrete position
sensors are read cyclically every 30 seconds and upon receipt of any AVV command.
If this valve is manually moved, the position telemetry may not reflect its current position
for up to 30 seconds.
Upon receipt of an AVV Open or Close command, the ACCUM function will determine if
the valve is already in the desired position. If not in the desired position, the software
will attempt to move the valve to the commanded position (up to three tries are
attempted prior to issuing a valve failure advisory). It should be noted that the AVV
Open command is considered hazardous since it will allow nitrogen to enter the Lab.
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Nitrogen Introduction Valve (N2 INT)
The N2 INT capability is used to open and close the NIA NIV supporting the LTL (LA-1)
and MTL (LA-2) PPA, and also to process associated C&W messages.
Two discrete position sensors drive the NIV telemetry. Discrete position sensors are
read cyclically every 30 seconds and upon receipt of any NIV position command. If this
valve is manually moved, NIV position telemetry may not reflect its current position for
up to 30 seconds.
Upon receipt of an NIV Open or Close command, the N2 INT function will determine if
the valve is already in the desired position. If not in the desired position, the software
will attempt to move the valve to the commanded position (up to three tries are
attempted prior to issuing a valve failure advisory). It should be noted that the NIV
Open command is considered hazardous since it will allow nitrogen to enter the Lab if
the AVV is also open.
Pump Sensors
The PUMPS capability passes raw PPA sensor data for the LTL pump (LA-1) and MTL
pump (LA-2) to the INT MDM. This includes fine filter 3, gas trap 3, pump 3, pump
inlet pressure, high/low rate flow, and pump outlet temperature. PUMPS also calculates
the average value of the raw accumulator quantity sensor for one second by acquiring
ten consecutive readings from the sensor and averaging the valid readings. These
values are then converted into EUs and passed to the PUMP capability in the INT MDM.
The average values are calculated to minimize raw accumulator quantity readings
causing alarms due to vibration. PUMPS does not process C&W messages, since this
is done by the PUMP capability in the INT MDM.
Passive Thermal Control System
The PTCS capability processes Lab Window Heater commands and C&W within the
LA-1 MDM. In addition, the PTCS processes sensor data for the heaters defined in
Table 3-86. Details on these heaters are found in Section 3.5.
Table 3-86. PTCS heaters MDM connectivity

Lab MTL IFHX LA-1 MDM
JEM MTL IFHX
N2 LTL IFHX
PMA 2 shell
LAB LTL IFHX LA-2 MDM
JEM LTL IFHX
N2 MTL IFHX
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3.6.4 Node 1 MDM Software
The two Node 1 MDMs (N1 MDMs) control shell heaters and IFHX valves and telemetry
(pre-12A.1). FDIR software also resides in the Node 1 MDMs.
Heater Control
The Node 1 MDMs regulate the operation of shell heaters for Node 1, PMA 1, and
PMA 3. The heater control software acquires temperature data from RTDs and
commands the heaters on or off, based on the setpoints. Details on these heaters are
found in Section 3.5.
IFHX Control (Pre-12A.1 Only)
The IFHX function controls the IFHX bypass and isolation valves, monitors EETCS loop
temperatures and responds to potential EETCS under-temperature situations by
bypassing and isolating the appropriate IFHX. The N1-1 MDM controls and monitors
the valves and temperature sensors for the LTL IFHX and the N1-2 MDM controls and
monitors them for the MTL IFHX.
IFHX Valve Control: In order to command an IFHX valve, several software functions
must be enabled including the Control Processing and Valve Control Availability
functions. The IFHX Control Processing command clears all of the IFHX C&W
messages, makes all IFHX data available for retrieval, and begins all IFHX control
functions that are enabled. The Valve Control Availability function must be enabled (for
each individual IFHX valve) prior to sending any commands to move the associated
valve. If the Valve Control Availability function for a valve is inhibited, commands to
move the valve will be rejected.
The IFHX Valve Position Indicator Availability function provides the capability to verify
IFHX valve commanding success and annunciate C&W messages if a valve command
is unsuccessful. If this function is inhibited, software ignores the valve position
indicators and simply applies power to the valve for a fixed amount of time and no
verification of command success is performed.
The IFHX valve precondition checks are software functions that verify the temperature
of the EETCS loop and/or the position of the isolation or bypass valve before allowing
certain IFHX valve commands to operate. This is designed to prevent deadheading of
the EETCS pump or possible freezing of the IFHX core. There are two separate
precondition checks, one for each IFHX valve. If the bypass valve precondition check is
enabled, software will verify that the isolation valve is open and that the two ammonia
inlet temperatures are above 1.11o C (34o F) prior to accepting a command to send the
bypass valve to the flowthrough position. If the isolation valve precondition check is
enabled, software will verify that the bypass valve is in the bypass position prior to
accepting a command to close the isolation valve.
IFHX Sensor Control: Upon power up of the Node 1 MDM, the IFHX sensor
processing function exhibits the default values shown in Table 3-87.
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Table 3-87. IFHX sensor initialization values
NH3 In Temp Snsr 1 and 2 Status Operational
o o
NH3 In Temp Snsr 1 and 2 Full Scale High Value 32.2 C (90 F)
o o
NH3 In Temp Snsr 1 and 2 Full Scale Low Value -26.1 C (-15 F)
NH3 Undertemp Response Ena
NH3 Undertemp Response Valve Travel Timeout 18 seconds
NH3 Undertemp Consecutive Readings Limit 3
o o
NH3 In Temp Snsr 1 and 2 Undertemp Limit 1.11 C (34 F)
IFHX FDIR: The Node 1 MDM provides the third leg of IFHX freeze protection through
its under-temperature response FDIR. The three legs of freeze protection are as
follows:
a. The PVCU MDM commands the EETCS pumps OFF if at least one of the two
EETCS PFCS outlet temperature (Out Temp 1 and 2) sensors, which are monitored
by the PFCS firmware is below the EETCS under-temperature limit (34o F (1.11o C).
b. The PVCU MDM removes PFCS power if the EETCS outlet line temperature (Out
Line Temp) sensor, which is monitored by the PVCU MDM via an LLA card, is
below the EETCS under-temperature limit (34o F (1.11o C)).
c. The IFHX valves are commanded to Bypass/Close if either one of the two ammonia
inlet temperatures (NH3 In Temp 1 and 2) sensors, which are monitored by the
Node 1 MDM, falls below the under-temperature limit (34o F (1.11o C)).
An operator command is available to enable and inhibit the NH3 Undertemp response.
Failed IFHX NH3 inlet temperature sensors are ignored when checking for under-
temperature conditions and precondition checks are suspended. Sensors are read
every 0.11 seconds.
IFHX Commands and Telemetry (EETCS only): Figures 3-93 and 3-94 show the
commands available on the PCS for the EETCS IFHXs.
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Figure 3-93. IFHX commands PCS display
Figure 3-94. IFHX additional commands PCS display

All commands found on these displays are two-step and require the selection of the
“EXECUTE” button at the bottom of the display.
3.6.5 Photovoltaic Controller Unit MDM Software (PVCU MDMs)

The PVCU MDM controls the EETCS loop temperature and provides several FDIR
algorithms designed to protect the PFCS and IFHX from damage due to extreme
temperatures or system failures.
EETCS Command Processing
The PVCU MDM receives, processes, and generates commands as part of its nominal
functions. Commands received from the higher tier MDM (including operator
commands) undergo a sequence of validation and verification prior to execution or pass
through to the PFCS LDI. Examples of these verifications are the line heater command
check and the FCV command checks.
The Line Heater Command Check algorithm is designed to prevent damage to plumbing
insulation and the heater elements by not allowing the EETCS line heaters to be turned
on unless a pump in that loop is running.
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The command to manually position the FCV is subject to five separate constraints listed
below:
a. CLC Constraint - CLC must be inhibited before the software will accept any manual
position commands.
b. Time Constraint - A minimum of 11 seconds must pass between position
commands (this is to allow time for the previous command to complete execution).
c. Recalibration Constraint - While executing an FCV recalibration, the PVCU rejects
all FCV Posn Set and FCV Recal commands. This constraint ensures that the
Recalibration algorithm executes in its entirety before any commands affecting the
FCV position are accepted.
d. FCV Initial Position Constraint - Prior to enabling FCV control, the FCV must be
commanded to a position of zero degrees. (When FCV control is enabled, it
expects the valve to be in the full bypass position (zero degrees) to accommodate
the algorithm initialization.) There are no automatic checks that prevent enabling
FCV control when the valve is at a different position. This constraint is controlled
via procedures and flight rules.
e. Firmware Constraint – Before the PFCS LDI accepts any FCV position commands,
it must first receive an FCV Set Init Posn command. The FCV Set Init Posn
command provides the LDI the current FCV position and allows the LDI to process
FCV Posn commands.
In addition to the EETCS specific constraints listed above, the PVCU MDM also
validates all commands based on its current state, channel mode, and the command’s
one-step/two-step definition. All EETCS related commands are valid in any channel
mode with the exception of the Radiator Retract command. This command is only
allowed while the channel is in Fully Commanded mode. (Channel modes are
discussed in the EPS Training Manual).
EETCS Telemetry Processing
In order to provide system-monitoring capabilities and to execute its own internal
algorithms, the PVCU MDM receives the majority of EETCS data from the PFCS LDI,
but some data is also received directly by the MDM itself via an LLA card.
The LDI sends both raw and integrated data packets to the PVCU MDM. These data
packets undergo a series of checks for transmission and errors. They are then
manipulated and converted through several processes (averaging integrated data, EU
conversion, range checks, etc.). Average integrated parameters are calculated by the
PCVU MDM, which divides the difference in the current and previous parameter
readings by the difference in the integration counter. This yields an integrated value
averaged over time. EU conversion occurs for all EETCS LDI data prior to use in any
PVCU MDM algorithm. Range checks verify that sensor data is read within expected
limits. The check happens once every 2 seconds on valid data and occurs after
parameters have been through EU conversion and any applicable Thermal Data Filter
(TDF) algorithms. Parameters are compared against the upper and lower limits
contained in the operational or nonoperational limit range check PPLs.
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The TDF performs noise filtering using a Moving Average (MA) method for single
sensors and a Weighted Least Squares (WLS) method where redundant measurements
are available. All parameters manipulated by the TDF contain the word “Fltrd” in their
Ops name.
The TDF determines EETCS temperature sensor validity for use in the FCV control, line
heater control, and several FDIR algorithms. The two outlet temperature sensors are
validated via two methods: intrasensor error checks and intersensor error checks. The
intrasensor error check identifies fast sensor failures (by comparing the current and
previous value of a single sensor) and the intersensor error check identifies slow sensor
failures associated with sensor drift (by comparing the current values of two separate
sensors). The TDF is also responsible for automatically selecting the lower of the two
EETCS PFCS outlet temperatures and assigning its value to the PFCS Out Fltrd Lwr
temperature. This parameter is used in several Closed Loop and FDIR algorithms.
The TDF also performs a WLS calculation on the PFCS Accum Qty1, PFCS Accum
Qty2, TTCR Accum Qty, and STCR Accum Qty accumulator quantities, which produces
the Accum Fltrd Avg Qty. If the Accum Fltrd Avg Qty falls below 10 percent, the PVCU
MDM issues a PFCS fluid leak condition caution message. The WLS calculation
consists of the following three steps:
1. Determine the instantaneous average
• Multiply each quantity measurement by a weighting factor and divide by the

number of sensors
2. Check that individual measurements are within tolerance
• Individual sensor value must be within +/- 30 percent of instantaneous average or

it is removed from the computation
3. Determine a time-averaged value
• Average of previous and current cycle values (assumes at least two valid
consecutive cycles)
Note: Due to a miswiring problem, the weighting factors of the TTCR and STCR
radiator accumulator quantity sensors have been changed to 0.0, effectively
removing their contribution to Accum Fltrd Avg Qty. (There are no plans to
rewire the sensors or deliver a software patch to the PVCU MDM to correct the
problem.)
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EETCS Control
The following two algorithms, whose default states upon PVCU MDM initialization are
defined in Table 3-88, control the temperature of each EETCS loop.
Table 3-88. EETCS control algorithms
Default
Algorithm Description
state
PFCS FCV Cntl Allows the PVCU MDM to autonomously maintain loop Inh
setpoint by positioning the FCV based on Out Fltrd Lwr
temperature feedback
PFCS Line Htr Cntl Permits the PVCU MDM to autonomously open/close line Inh
heater RPCs based on Out Fltrd Lwr temperature
EETCS parameters used for the PFCS FCV Cntl and Line Htr Cntl algorithms default to
the values shown in Table 3-89 upon PVCU MDM initialization. Each of these values
can be modified via PPL.
Table 3-89. EETCS Control algorithms

initialization parameters
o
Loop Temperature Setpoint 5.8 C (42.5° F)
o
Line Heater Off Temp 5.3 C (42.0° F)
o
Line Heater On Temp 0.56 C (1.0° F)
FCV Max Htr Posn .8 (72 deg)
When the PVCU MDM is in the normal operational state, the capabilities and algorithms
performed are a function of the Power Channel mode. EETCS algorithms execute in all
channel modes except Fully Commanded mode. When the Power Channel mode
enters the Fully Commanded mode, the EETCS FCV and Line Htr Cntl algorithms do
not execute. Therefore, the operator must manually position the FCV and open/close
the line heater RPCs to maintain the loop setpoint.
FCV Control (FCV Cntl): The FCV Cntl algorithm is responsible for maintaining the
PFCS Out Fltrd Lwr temperature within the loop temperature setpoint tolerance. When
FCV control is enabled, it sets the value for last commanded valve position to zero,
even if the operator has sent the FCV Set Init Position command or positioned the valve
to a non-zero position. Therefore, it is important to ensure the valve is actually at the
zero position before enabling FCV Cntl to ensure that the software and the true FCV
position are synchronized.
The FCV Cntl process includes three primary functions: FCV positioning, limit checks,
and walk-off correction. The FCV Positioning algorithm uses the Out Fltrd Lwr Temp
and calculated valve positions (previous commanded positions) from past algorithmic
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cycles, as well as those values from the current cycle to calculate a new valve position.
The key feature of the FCV Positioning algorithm is its ability to predict temperature
trends and position the valve to compensate for changing heat loads and environments
without overshooting the optimum position or overreacting to transient conditions.
The FCV positioning process includes logic to constrain valve movement. These limit
checks prevent walk off and valve movement that have no practical benefit to loop
temperature control. Checks include insuring the desired valve position is within the
min/max positions available and ensuring the new position is > 0.5 degrees from the
current position.
The FCV Cntl algorithm originally issued commands based only on the control
temperature and never used the FCV position as feedback. As a result, the error
between the actual FCV position and the calculated FCV position built up over time,
resulting in degraded/loss of temperature control. This problem is called valve walk-off.
To help reduce the walk-off, the PVCU MDM now performs an FCV position check
every 10 minutes (beginning at PVCU MDM initialization). The check results in a 6-
second algorithm interruption every 10 minutes, which is equivalent to a 1 percent
interruption in EETCS control duty cycle. The FCV position check defaults to enabled
but can be inhibited.
Line Heater Control (Line Htr Cntl): The Line Htr Cntl algorithm produces RPC
Open/Close commands based on the value of the PFCS Out Fltrd Lwr Temp. The
Heater Control algorithm consists of a deadband controller and a logical switch. The
deadband controller determines the need for a heater on/off command by comparing
the Out Fltrd Lwr Temp with the heater setpoints. The logical switch blocks heater ON
commands and issues heater OFF commands if the calculated FCV position exceeds
72 degrees in order to prevent damage to the insulation and heater elements on the
bypass line (due to the low flow).
Nominally, line heater control is enabled for both line heaters; however, either line
heater can be inhibited.
EETCS FDIR
The PVCU MDM contains several FDIR algorithms designed to protect the PFCS, IFHX,
and radiators from damage due to extreme temperatures or system failures. The FDIR
function is responsible for monitoring system data, detecting failures, and executing
recovery actions. Table 3-90 provides a summary of the FDIR algorithms and their
default state upon PVCU MDM initialization.
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Table 3-90. EETCS FDIR algorithms
Default
Algorithm Description
state
PFCS Line Htr Cmd Ck Prevents any command source from closing RPC line Ena
heaters unless a pump is running
PFCS Auto FCV Recal Permits automatic FCV recalibration to occur when Inh
algorithm is interrupted/restarted
PFCS Inval Data FDIR Autonomously removes power from the PFCS (RPC - Ena
open) and line heaters when the Out Fltrd Lwr
temperature and the Out Line Fltrd temperature are invalid
PFCS Min Out Temp FDIR Autonomously shuts down PFCS pumps or removes Ena
power from PFCS when outlet temperatures can cause
IFHX freezing. Also opens line heater RPCs. This FDIR
contains 2 of the 3 legs for IFHX freeze protection
PFCS Pump Deadhead FDIR Commands pumps off when a low flow condition exists Ena
that may deadhead the pump
PFCS Pump Switch FDIR Switches to redundant pump within the PFCS when the Ena
primary pump fails
PFCS Min In Temp FDIR Autonomously shuts down PFCS pumps and line heaters Ena
when temperature can damage hall effect (speed) sensors
PFCS Max Out Temp FDIR Autonomously shuts down the PFCS pumps and line Inh
heaters when PFCS outlet temperatures are too high
PFCS FCV Temp Recal FDIR Allows automatic FCV recalibration due to Inh
prolonged elevation of Out Fltrd Lwr temperature
PFCS Invalid Data/Max Ln Autonomously shuts down the PFCS pumps and line Inh
Temp FDIR heaters when the Out Fltrd Lwr temperature is invalid,
pump speed and flowrate are valid, and the Out Line Fltrd
temperature is too high
TCR Config Fail FDIR Enables the EETCS TCR motor to turn off automatically if Ena
deploy/retract operation is not complete within 15 minutes
EETCS parameters used for the FDIR algorithms described above default to the values
shown in Table 3-91 upon MDM initialization. Each of these values can be modified via
PPL.
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Table 3-91. EETCS FDIR initialization parameters
o o
Intrasensor Error Limit (Invalid Data FDIR) 5.6 C (10 F)
o o
Min Outlet Temp Limit (Min Out Temp FDIR) 1.1 C (34 F)
o o
Outlet Temp Max Setpt (Max Out Temp FDIR) 12.8 C (55 F)
o o
Undertemp Limit Setpt (Min In Temp FDIR) -42.8 C (-45 F)
Pump Speed Min Setpt (Pump Switch FDIR) 12000 rpm
Pump Outlet Delta Pressure Min Setpt (Pump Switch FDIR) 33.615 mmHg (0.65 psid) > 410 kg/hr
Htr Cntl PFCS Pump Speed Min Setpt (Ln Htr Cmd Ck) 12000 rpm
Htr Cntl PFC63XPS2XWOHW 30LQ6HWSW/Q+WU&PG&N 77.6 mmHg (1.5 psid) > 620 kg/hr
o o
Max Outlet Temp (FCV Recal FDIR) 12.8 C (55 F)
EETCS FCV Recalibration
Automatic FCV recalibration is designed to occur after extended periods of high loop
temperature that indicate the FCV has lost its calibration or in response to a change in
system status. FCV recalibrations automatically initiate for the following reasons:
a. The EETCS PFCS Out Fltrd Lwr temperature is above the Auto Recal Max
temperature limit (12.8o C (55o F)) for 5 minutes. (The PFCS FCV Temp Recal
FDIR must be enabled for recalibration to occur.)
b. Algorithm interruptions caused by:
1. Mode transition from Fully Commanded to Autonomous or Non-Solar Tracking

mode
2. Mode transition from Contingency/Safe to Autonomous or Non-Solar Tracking

mode
3. Synchronous time command while MDM is in Normal operational state
c. PFCS recovery following a failure (LDI Recovery algorithm).
d. PFCS configuration change (a PFCS comes into existence with ORU existence
PPL).
e. Entry into the Normal operational state from the Wait state.
For items b to e to occur, Auto FCV Recal must be enabled for FCV recalibration to
occur. Both the PFCS FCV Temp Recal FDIR and Auto FCV Recal are nominally
inhibited.
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Automatic FCV recalibrations should be avoided. Because loop flow is altered when the
FCV is driven outside its nominal control range, there is a possibility of tripping certain
FDIRs during a recalibration (Min Out, Max Out, and Pump Deadhead FDIRs). The
number of recalibrations should be minimized because the FCV is only rated for 200
recalibrations over its lifetime. If a recalibration is warranted, the FCV Recal command
can be issued, or the FCV Posn and FCV Set Init Posn commands can be used to
perform a manual recalibration.
Automatic FCV Recalibration Process: The PFCS FCV normally operates within a
90-degree arc, but the total rotation possible from hardstop to hardstop is 310 degrees.
Automatic FCV recalibration generates a series of commands that force the FCV to
rotate from an uncertain position counterclockwise past the full bypass position (0.0)
against the hardstop. The software then rotates the FCV clockwise to the true 0.0
position.
Once an automatic FCV recalibration has begun, there is no way to interrupt it. The
only way to stop a FCV recalibration sequence is to initiate another recalibration. The
total time to complete an automatic recalibration is approximately 93 seconds.
While the PFCS FCV recalibration routine is active, the software suspends all PFCS
FCV commands normally generated by the EETCS FCV Control algorithm and rejects
all operator FCV commands. Following FCV recalibration, the software automatically
restarts the EETCS FCV Control algorithm (if it is enabled) to resume loop temperature
control.
EETCS Software Displays
Figures 3-95 and 3-96 show the PCS displays that contain the software commands
available for the EETCS Control and FDIR algorithms discussed in this section.
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Figure 3-95. PFCS nominal commands PCS display
Figure 3-96. EETCS PFCS FDIR PCS commands displays

3.6.6 PFCS Firmware Controller (Local Data Interface)
In addition to the software algorithms within the PVCU MDM, the EETCS also responds
to several algorithms that execute in the LDI located in the PFCS. Its primary function is
to accept and execute commands and report data to the PVCU MDM via the 1553 data
bus.
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The LDI executes algorithms designed to protect the system from damage by shutting
off effectors when certain criteria are met. The four main algorithms are:
a. Leak Detection FDIR
b. TCR Auto Time Out FDIR
c. TCR Auto Off
d. LOC safing
Each of these algorithms defaults to the enabled state when the PFCS is powered on.
Leak Detection FDIR
The Leak Detection algorithm within the LDI monitors the PFCS Accum Qty1, PFCS
Accum Qty2, TTCR Accum Qty, and STCR Accum Qty.
Sensors qualify for inclusion in leak determination based on their selection status
(selected or not selected), which can be modified via operator commands. For each
selected sensor, the FWC uses a moving average of the last five values that fall
between zero and 100 percent. When the LDI receives a new reading, the oldest
reading is discarded and the average is recalculated. A leak is detected when the
majority of the selected sensors fall below 4 percent. Once a leak is detected, the
firmware will set a leak indication flag and command the pump off on the affected loop.
It is the operator’s responsibility to remove power from the line heaters and the PFCS
as soon as possible to prevent damage. The leak indication flag can be seen on the
PFCS nominal additional commands PCS display (Figure 3-97).
Note: TTCR and STCR quantity sensors have been deselected from the LDI
algorithm; only the two PFCS quantity sensors are used by the LDI for leak
detection. Since there are only two sensors currently being used on-orbit, a
single sensor reading of 4 percent will trigger the pump shutdown and leak
indication.
TCR Auto Time Out FDIR
If the TCR Auto Time Out FDIR is enabled and a radiator deploy or retract command is
issued, the LDI monitors the deploy/retract status. If after 13 minutes the deploy/retract
status does not match the commanded position, the LDI performs the following actions:
a. Sends a TCR stop command
b. Sends a TCR power off command
c. Sets the timeout indicator to active
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TCR Auto Off
The TCR Auto Off algorithm is a control algorithm that places the radiator in a safe
configuration after a successful retract sequence. If the algorithm is enabled and a
radiator deploy or retract command is issued, the LDI monitors the deploy/retract
microswitch status. Within 5 milliseconds of the microswitch status matching the issued
command, the LDI will send a Stop command and then a Motor Power Off command.
Operationally, the TCR Auto Off algorithm is inhibited during radiator deploy operations
because the radiator deploy microswitch does not provide an indication that the radiator
is fully deployed. Hardware testing has shown that in order for the cables to be properly
tensioned, the radiator motor must be run for one additional minute after the deploy
indicator becomes active. Inhibiting the Auto Off function during radiator deployment
prevents the algorithm from sending the TCR Stop and Motor Power Off commands
before the radiator is fully deployed.
In addition to safing the radiator motor following a deploy/retract sequence, the LDI
monitors for overcurrents during the deploy or retract sequence. If an over-current
condition arises, the FWC will set an overcurrent trip indication, send the Motor Power
Off command, and set the TCR trip indication.
Loss of Communication Safing
The LDI declares a Loss of Communication (LOC) if the 1553 data bus signal from the
PVCU MDM is lost for 60 seconds. The LDI safes the EETCS in the event of an LOC
by commanding the FCV to the FCV LOC setpoint (default = 45 degrees, operationally
the LOC setpoint is set to zero degrees to eliminate IFHX freezing concerns).
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PFCS Firmware Displays
The Leak Detection FDIR commands are found on the PFCS FDIR commands display
and the PFCS FDIR additional commands display; both displays are shown in
Figure 3-97. The TCR Control and FDIR commands are shown in Figure 3-98.
Figure 3-97. STCR commands PCS display

The commands to define the FCV LOC setpoint are found in the command section of
the PFCS nominal additional commands display seen in Figure 3-98.
Figure 3-98. Loop A PFCS nominal additional commands PCS display

3.6.7 External MDM Software (EXT MDM)
The External MDM receives commands from and interfaces directly with the C&C MDM
and provides data connectivity and software control to the ETCS equipment located on
the S1 (Loop A), P1 (Loop B), and S0 Truss segments. The EXT MDM software
performs the following important functions for the ETCS: ETCS Manager (ETCS M),
TRRJ Manager (TRRJ M), and Radiator Goal Angle Calculation (RGAC).
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ETCS Manager
The ETCS Manager provides high-level control (Data Acquisition, Command Validation,
Control, and Monitoring functions) for all ETCS components on both external loops.
The ETCS Manager performs ammonia charge and loop startup sequences. It also
provides FDIR for radiators and IFHXs.
When the ETCS Manager function is first initialized, the EXT MDM issues commands to
power on the SDO cards of the STR/PTR MDM and sets all FDIRs in the EXT, S1/P1,
and STR/PTR MDMs to their default state (Enabled) which can be changed via PPL.
Ammonia Charge: The ETCS ammonia charge command initiates a sequence of

commands. First, commands are sent to the S0 MDM to close the bypass valves for all
installed IFHXs. Following successful completion of this action, commands are sent to
the S1/P1 MDM to initiate the Pressurize Loop algorithm. The Pressurize Loop
algorithm brings the loop up to the desired operating pressure. If the ammonia charge
sequence fails to successfully complete, the caution-level ETCS Loop A (B) Ammonia
Charge Command Sequence Failed message is issued. There is an Abort Ammonia
Charge command available to terminate the sequence if necessary. This function has
been deferred to a future software release.
Loop Startup: The Loop A (B) Startup Loop command is used to initialize the ETCS
loops for cooling. Upon receipt of the command, the EXT MDM configures all IFHX
valves to the bypass/close position, configures all RBVMs to the open position, and then
issues the Pressurize Loop and Activate Cooling commands. The Abort Startup Loop
command is available to abort any startup sequence in progress. This function has
been deferred to a future software release.
TRRJ Failure Response FDIR (Radiator Undertemp FDIR): This FDIR monitors
TRRJ joint position to ensure that the radiators are not in a position that could allow the
manifolds to freeze. If the TRRJ is determined to be in a potential freezing position,
FDIR shuts down the affected loop and vents all radiator ammonia overboard. Analysis
shows that for most beta angles, there is no danger of freezing in the radiator manifolds.
For the scenarios that may result in manifold freezing, the time to effect is at least one
orbit or more. Crew and ground will receive two separate C&W messages prior to
reaching the point where action would be required.
Radiator under-temperature failure conditions are only monitored when the TRRJ
Manager is not in Autotrack or Blind mode. Software uses upper and lower cold gamma
limits to determine if the TRRJ joint is operating in a range where manifold freezing is a
concern. Software determines cold gamma limits based on the current beta indication,
the RGAC Data validity indication, and the status of the Beta Scheduling function. If
Beta Scheduling is inhibited or the RGAC data validity flag indicates invalid data, default
cold gamma limits are used (Upper Gamma Limit {35 degrees} and Lower Gamma Limit
{-35 degrees}).
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This FDIR is activated if the TRRJ Manager is not in Autotrack or Blind mode and either
of the following conditions is true:
a. The TRRJ joint position data are valid and the joint resolver indicates the joint
position is outside of the cold gamma limits determined to be in effect. Joint
position data are valid when the TRRJ Manager is enabled and joint resolver quality
is not stale.
b. Joint resolver quality is stale, the joint was last observed to be moving, and the
moving TRRJ could reach cold gamma limits. Software assumes the TRRJ can
reach cold gamma limits if the cold gamma limits are less than the full range of
travel for the TRRJ (+/- 115 degrees). The joint is considered to be moving if all of
the following are true:
1. Last valid DLA state indicates one DLA was engaged and the other DLA was
not locked.
2. A torque motor is On or a torque motor is being commanded “On.”
IFHX Bypass FDIR: The ETCS Manager function monitors for any condition, including
operator command, that causes the ETCS to transition to Shutdown mode (see Section
3.6.9) and then bypasses and isolates all installed IFHXs on the affected loop. In
addition to monitoring the ETCS mode, the algorithm also monitors three separate flags:
PCVP Temp Low BIT, PM Outlet Temp Low Flag, and PM Outlet Temp High Shutdown
Flag. If any one of these flags is set, the EXT MDM will initiate the IFHX Bypass FDIR
even if the ETCS does not complete its expected transition to Shutdown mode. The
algorithm first enables and bypasses all IFHX bypass valves and then enables and
closes all isolation valves.
There is currently no inhibit available to prevent the EXT MDM from bypassing and
isolating all installed IFHXs if the ETCS mode goes to Shutdown. However, if FDIR in
the S1/P1 MDMs or PCVP firmware that react to the trigger conditions is inhibited, the
system will not transition to Shutdown mode nor set any associated flags; hence, the
EXT IFHX Bypass FDIR would not be initiated.
Auto Restart: The Auto Restart function uses the Loop Startup command sequence to
start an ETCS loop. The auto restart attempts to reach the cooling mode up to Auto
Restart Retry Limit (2 times). This value can be updated with a PPL. A value of zero
would allow unlimited retry attempts. This function has been deferred indefinitely.
ECZ Manager
The External Control Zone (ECZ) Manager function provides automatic recovery for S1
and P1 MDM failures to support ETCS and TRRJ operations. It supports TRRJ
switchover functions and regains monitoring and control of the ETCS PCVP. The S1
and P1 MDM recovery actions attempt to switch to an alternate S1 or P1 MDM
whenever one of the MDMs in the pair transitions to Diagnostic mode. This supports
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TRRJ Manager switchover actions, prevents the TRRJ from hitting the hard stop, and
prevents ETCS line heaters from damaging hardware.
The ECZ function was intended to contain three separate applications:
a. Configuration Management (CM)
b. ECZ Reset
c. ECZ Startup/Restart
The ECZ CM application performs recovery reconfiguration of Secondary EPS (SEPS)

user buses and ETCS Pump and Tank control if an S1 or P1 MDM transitions to
diagnostic (or upon detection of a loss of frame count in EXT R4). Specifically, if an
S1-1 or P1-2 MDM fails, the ECZ CM function will configure the backup MDM (S1-2 or
P1-1) to be Bus Controller (BC) on both SEPS user buses and will enable PCVP
communication and ETCS PTC in the new primary MDM. This allows the S1-2
(or P1-1) MDM to communicate with the PCVP RPC and the PCVP, which then allows
the user to regain loop circulation and temperature control capabilities. However,
communication to all of the PM, ATA, or NTA valves and sensors that were tied directly
to the failed MDM will be lost.
The ECZ Reset command halts any ongoing CM action.
The ECZ Startup/Restart application has been deferred indefinitely. This function was
intended to provide an automated means of enabling multi-tier, application-logical
threads, powering on SEPS power buses, and powering up and initializing lower tier
MDMs for nominal operations. The nominal configuration for the S1 and P1 flight
elements must be achieved by operator action (commands) until this ECZ
Startup/Restart function becomes available (no earlier than EXT R4). Table 3-92 and
Table 3-93 detail the S1 and P1 hardware and software states for the nominal
configuration.
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Table 3-92. S1 MDM pair nominal configuration
MDM S1-1 MDM S1-2
HW/SW function HW/SW state/mode HW/SW function HW/SW state/mode

UB SEPS S1 14 Bus Controller (BC) UB SEPS S1 14 Remote Terminal (RT)
UB SEPS S1 23 Remote Terminal (RT) UB SEPS S1 23 Bus Controller (BC)
S1-1 DSM Mode Normal S1-2 DSM mode Normal
S1-1 Sensor/Effector Enabled S1-2 Sensor/Effector Enabled
data (SE Comm) data (SE Comm)
S1-1 SEPS 14 Enabled & Active S1-2 SEPS 14 Disabled
S1-1 SEPS 23 Disabled S1-2 SEPS 23 Enabled and Active
S1-1 RJMC Comm Enabled S1-2 RJMC Comm Enabled
S1-1 TRRJ Control Enabled S1-2 TRRJ Control Enabled
S1-1 PVCP Comm Enabled S1-2 PVCP Comm Disabled
S1-1 ETCS PTC Enabled S1-2 ETCS PTC Disabled
Table 3-93. P1 MDM pair nominal configuration
MDM P1-1 MDM P1-2
HW/SW function HW/SW state/mode HW/SW function HW/SW state/mode
UB SEPS P1 14 Bus Controller (BC) UB SEPS P1 14 Remote Terminal (RT)

UB SEPS P1 23 Remote Terminal (RT) UB SEPS P1 23 Bus Controller (BC)
P1-1 DSM Normal P1-2 DSM Normal
P1-1 Sensor/Effector Enabled P1-2 Sensor/Effector Enabled
data (SE Comm) data (SE Comm)
P1-1 SEPS 14 Enabled & Active P1-2 SEPS 14 Disabled
P1-1 SEPS 23 Disabled P1-2 SEPS 23 Enabled & Active
P1-1 RJMC Comm Enabled P1-2 RJMC Comm Enabled
P1-1 TRRJ Control Enabled P1-2 TRRJ Control Enabled
P1-1 PVCP Comm Disabled P1-2 PVCP Comm Enabled
P1-1 ETCS PTC Disabled P1-2 ETCS PTC Enabled
As seen in the tables above, the S1-1 (Loop A) and P1-2 (Loop B) MDMs will nominally
have PCVP Comm and ETCS PTC enabled. This is because these two MDMs are the
only MDMs that can communicate with the majority of the PM, ATA, and NTA valves
and sensors. Notice also that the S1-1 MDM (Loop A) is nominally BC on the SEPS
S1-14 bus and P1-2 MDM (Loop B) is nominally BC on the SEPS P1-23 bus. This is
because the Loop A PCVP is an RT on the SEPS S1-14 bus and the Loop B PCVP is
an RT on the SEPS P1-23 bus. In order for these MDMs to communicate with the
PCVP firmware and associated RPC, they must be BCs on their respective buses.
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Radiator Goal Angle Calculation
The RGAC function generates an angle that is used to move the radiators to a preferred
thermal environment. This preferred thermal environment is one that allows for
adequate heat rejection and avoids freezing of the ammonia contained within the
radiator manifolds. Ideally, RGAC determines an ideal goal angle (Gamma) that orients
the radiator panels to face Earth whenever the ISS is in the Earth’s shadow, and points
the edge of the radiator panels to the Sun whenever the ISS is not in Earth’s shadow (to
avoid heating the radiators too much).
The RGAC function initializes with the values shown in Table 3-94.
Table 3-94. RGAC initialization values
Parameter Description Initialization value
RGAC Blind Timeout After this amount of time in Blind mode, RGAC 24 hours
goal position quality indicator to TRRJ indicates
invalid
RGAC GNC Dropout Cycles Persistence counter; when time tag on GN&C data Three 1 Hz cycles
does not increment for this number of consecutive (3 seconds)
cycles, GN&C data is declared failed and the
TRRJ transitions to Blind mode
RGAC Position Limit Thermal radiator position limit. RGAC software 105 deg
limits radiator position to ± this value
RGAC Rotation Limit Thermal radiator rotation rate limit. RGAC 0.75 deg/sec
software limits rotation to ± this value
ETCS RGAC Mode RGAC operation mode switch Auto
The RGAC function generates a separate starboard and port thermal radiator goal
angle (desired gamma) based upon inputs provided by the GNC MDM and various
measurement of the ETCS mass flow rate and ammonia fluid temperatures taken along
the ETCS cooling loop. The TRRJ Manager function uses the RGAC desired gamma to
generate the rotation angle command for each TRRJ. Desired gamma is updated at a
rate of 1.0 Hz.
The RGAC function also provides a RGAC data quality indicator to TRRJ software.
This parameter indicates the validity of GNC input data. The TRRJ Manager normally
transitions to Blind mode if the RGAC data quality flag indicates that data is invalid.
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Fluid Temperature Control Mode: In the Fluid Temperature Control (FTC) mode,
RGAC calculates a delta gamma angle designed to prevent the radiator manifolds from
getting too cold. During insolation, this delta gamma bias is added to the ideal gamma
angle to create the “desired gamma”, which rotates the radiator in order to allow incident
sunlight to warm the radiator panels. There are three control modes and one failure
mode for RGAC.
a. FTC Off – FTC is off. A manual delta may be uploaded by PPL.
b. Auto – FTC is on. Delta gamma is based on the RBVM out temperatures.
c. PMRad – FTC is on. Delta gamma is based on PM radiator return temperature.
d. Failure – FTC is off. A predetermined failure gamma is used.
Auto mode is the nominal mode. If there are fewer than two valid RBVM temperatures,
the system slips into PMRad mode. This is less desirable, since the PM temperature is
further downstream. If the PM temperature becomes invalid, or if the ammonia flowrate
through the radiators dips too low, the system goes into Failure mode.
In the nominal Auto mode, there are six different RBVM temperatures available per
radiator array to compare to the temperature setpoint. RGAC selects the midvalue
among all valid temperatures as the feedback temperature. However, if any one of the
valid temperatures fall below a preselected lower-bound, this coldest temperature is
selected in an effort to protect that area of the loop.
RGAC Predictor Function: The RGAC Predictor function predicts the upcoming ISS
orbit and may adjust future radiator motion to ensure that radiator flips (180° rotations)
occur as far away from solar noon as possible and to eliminate excessively fast radiator
rotations. The Predictor function can be set to “Off” or “On” with an operator command.
The Predictor uses the Pitch/Yaw/Roll estimation run every orbital noon to predict future
radiator motion. Pitch/Yaw/Roll estimates are checked against actual attitudes for a full
half orbit before the Predictor function utilizes the estimates. At orbital midnight, the
Predictor function uses the estimations to create a theoretical gamma angle profile for
the upcoming orbit (up to the next orbital midnight). The Predictor function does not
account for any delta gammas that may be calculated or used during the same time
frame.
If the RGAC Predictor is On, the function evaluates theoretical gamma predictions and
determines the number of times the radiator will encounter the RGAC Position Limit
{105 degrees}. If the TRRJ position limit is actually reached during an orbit, the radiator
will flip (rotate 180°). All radiator flips must occur as far away from solar noon as
possible to minimize exposure of the radiator normal to the Sun.
The Predictor function also eliminates unnecessary radiator flips by forcing RGAC to
avoid large gamma changes and holds the gamma angle constant when waiting to enter
orbital shade.
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RGAC FDIR: Most failures monitored by RGAC result in automatic recovery actions
that cannot be inhibited (i.e., there are no RGAC FDIR Ena/Inh commands). All of the
failures result in either a caution or an advisory level message. The only FDIR with an
inhibit is the TRRJ Failure Response FDIR. The following conditions can trigger RGAC
caution or advisory messages:
a. If a valid RBVM out temperature sensor < -80° F(-62.2° C) for 5 seconds
b. If more than four RBVM out temperature sensors on a loop are invalid and FTC
mode = Auto
c. If PM radiator return temperature data is unavailable while FTC mode = PMRad
d. If RGAC Calc Rad Flow is < 408.2 kg/hr (900 lb/hr)
e. If the FTC mode = FTC Off, and no operator command was issued
RGAC Commands and Telemetry: Figure 3-99 shows the commands and telemetry
available for the Loop A RGAC function.
Figure 3-99. Loop A RGAC PCS display

TRRJ Manager
The TRRJ Manager provides high-level control and monitoring for the rotational position
of the ETCS radiators. The TRRJ Manager uses the RGAC desired gamma to generate
the rotation command for each TRRJ, which is then passed to the appropriate S1/P1
MDM. The S1/P1 MDM TRRJ Control function (discussed in Section 3.6.9) then
processes the angle command and directs the hardware to move to the desired
position.
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The TRRJ Manager initializes with the values shown in Table 3-95. Unless otherwise
stated, an error must be present for 3 seconds in order for software action to occur
and/or a C&W to be issued. ETCS Loop A (starboard) and ETCS Loop B (port) have
independent parameters that can be updated separately via PPLs.
Table 3-95. TRRJ manager initialization values
Inadvertent Joint Rotation limit C&W is issued when joint resolver or Joint .5 deg
Position MAR (motor accumulated revs) changes
by this amount (without being commanded)
Autotrack Error limit C&W is issued when position error exceeds this 5 deg
amount
TRRJ Position Low Limit C&W is issued when joint position is below this -106 deg
limit
TRRJ Position High Limit C&W is issued when joint position is above this 106 deg
limit
TRRJ Blind Mode Timeout Limit Amount of time TRRJ Manager is allowed to 24 hours
operate in Blind Ops mode before mode
transition is initiated
Restart Sequence Time Limit Time allowed for LT MDMs to enter correct mode 30 seconds
configuration before the transition to checkout
mode is initiated during TRRJ system restart
sequence
RGAC Goal Angle Unavailable Number of consecutive 1 Hz counts that RGAC 60 cycles
Persistence Limit quality must indicate invalid before C&W is issue
TRRJ Null Position Null position of TRRJ 0 deg
TRRJ Acceleration Limit Acceleration limit 0.01 deg/sec
TRRJ Velocity Limit Velocity limit 0.75 deg/sec
TRRJ Manager Modes: Prior to enabling the TRRJ Manager function, the TRRJ
Control, RJMC Comm, and SEPS software in the S1/P1 MDM must first be enabled.
Once enabled, the TRRJ Manager can operate in one of the following eight modes:
a. Standby - Default mode upon initialization of the TRRJ Manager function
b. Checkout - Used to perform checkouts of the TRRJ and configuration of the DLAs
necessary to prepare for normal operations (Directed Position or Autotrack modes)
c. Directed Position - Allows the TRRJ to be placed in a commanded angular position
where it will remain until another position command is received. One DLA should
be engaged, the other DLA should be in neutral, and the torque motor must be On
in this mode.
d. Autotrack - Continually tracks a goal position (RGAC gamma) in an effort to
optimize thermal radiator position during normal operations. The RGAC desired
gamma is passed to the S1/P1 MDM and is converted into a RJMC velocity
command. One DLA must be engaged, the other DLA must be in neutral, and the
torque motor must be On when operating in Autotrack mode.
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e. Blind - Contingency mode entered if there is a LOC between the EXT MDM and the
S1/P1 MDM or if RGAC data is invalid. The TRRJ position source in Blind mode is
either
1. Desired Gamma - Previous orbit’s worth of desired gamma angles is used to
position the TRRJ
2. Stored Orbit - A table of angles is used to position the TRRJ if less than one
orbit’s worth of desired gamma angle data is available
f. Shutdown - Either when commanded or when the timeout limit for Blind mode
expires, the Shutdown mode moves the TRRJ to the null position, locks the cross-
strapped DLA, and powers off all motors.
g. Switchover - Mode used to process a string switchover sequence. The string

switchover sequence performs all actions required to switch from one TRRJ string
to another. (Each TRRJ has two separate strings; each string consists of an
MDM/RJMC/DLA combination.) (This function currently does not work due to a
software error)
h. Restart - Mode used to perform a sequence of events that attempts to restart a

TRRJ string. This function has been deferred indefinitely. However, when
available, the Restart mode will automatically be entered from Standby mode if all
the following criteria are true:
1. One DLA is engaged and the other DLA is neutral
2. Auto Restart is allowed
3. LT Avail indicates that the string with the engaged DLA is available
4. Engaged string’s RJMC temperature > RJMC Min temperature (defaults to -

160o F (-106.7o C))
Figure 3-100 graphically depicts the relationship between the TRRJ Manager modes.
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Initialization
Automatic if all true:
1. One DLA engaged/other DLA

neutral
2. Auto Restart Ena 6WDQGE\
3. Engaged string’s TRRJ C is 0RGH Shutdow n sequence
commands TRRJ to Null
enabled
4. Engaged string’s RJMC temp > (currently 0 deg), locks
minimum temp crostrapped DLA, and
5. Blind Ops flag = True Checkout commands all motors Off.
TRRJ Mode to Monitor/Standby Cmd
Mode Cmd
[If both strings TRRJ Control mode = Monitor]
Abort Cmd or
6KXWGRZQ

&KHFNRXW Shutdow n sequence
Failure and Shutdow n 0RGH
Directed Position requires 0RGH Fail FDIR = Ena
Torque Motor On, Prime
DLA Engage or Neutral, and Checkout Cmd, Abort Cmd or
crosstrapped DLA Neutral. Failure during Blind Mode and Shutdow n cmd or
Directed Position
Checkout Cmd, Abort Cmd or TRRJ String Fail Blind Ops Blind mode timeout
Cmd
Failure and TRRJ String Fail FDIR = Ena
Abort Cmd
Dir Pos FDIR = Ena
6ZLWFKRYHU 'LUHFWHG Directed

Position Cmd
%OLQG
0RGH
Shutdow n
Cmd 3RVLWLRQ Blind Mode
0RGH
0RGH Cmd
Blind Mode Cmd or

Successful String
Blind Ops Flag = True
Sw itchover Autotrack and TRRJ Blind Ops
Cmd FDIR = Ena
Autotrack failure with String Directed
Fail Autotrack = Ena Position
Autotrack Cmd or
Cmd Blind Ops Flag =
False

Checkout cmd, Abort cmd or
$XWRWUDFN Shutdow n cmd or
Blind Ops Flag = True and
0RGH
Autotrack failure with TRRJ String
Fail AutoTrack FDIR = Inh TRRJ Blind Ops FDIR = Inh and
TRRJ Blind Ops Unsuccessful FDIR = Ena.
Figure 3-100. Relationship between the TRRJ Manager modes

TRRJ Manager DLA Commands: All TRRJ Manager DLA operator commands result
in internal commands being generated and sent to the S1/P1 MDM TRRJ Control
function (see Section 3.6.9). All DLA commands are issued to the TRRJ Manager
designated command path. If TRRJ Manager Cmd Path indication is S1(P1)-1, then all
DLA commands are issued to DLA-1. If TRRJ Manger Cmd Path indication is S1(P1)-2,
then all DLA commands are issued to DLA-2. Commands to select the desired motor
(Stepper Motor 1 (prime DLAs stepper motor), Stepper Motor 2 (cross-strapped DLAs
stepper motor), torque motor, or torque motor as stepper motor), and arm/fire
commands used to put the DLA in engage, lock, or neutral are all processed by the
TRRJ Manager function. Additional low-level RJMC firmware commands are also
available for use in contingency situations. These low-level commands are necessary if
the position of the DLA is not known since the high-level commands use the current
position and the desired position to define the direction and number of steps needed to
move to the desired position.
TRRJ Manager FDIR Functions: The TRRJ Manager monitors for a variety of failures
and takes appropriate action to safe the system. Table 3-96 outlines the failures and
associated responses.
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Table 3-96. TRRJ Manager FDIR
TRRJ
manager TRRJ mode FDIR state FDIR response
FDIR
String Failure Autotrack Ena Transitions to Switchover mode; if successful, FDIR

returns to Autotrack using the new string
Inh Transitions to Checkout mode and powers off controlling
RJMC
Directed Ena Transitions to Checkout mode and powers off controlling
Position RJMC
Blind Ena Transitions to Checkout mode and powers off controlling
RJMC
Invalid Autotrack Ena Transitions to Blind mode
RGAC Data
Inh Transitions to Shutdown mode
Shutdown All Ena Transitions to Checkout mode and powers off controlling
Failure RJMC
Autotrack Autotrack Ena Transitions to Switchover mode; if successful, FDIR
Position returns to Autotrack using the new string
Error > 5 deg
Inh Transitions to Checkout mode and powers off controlling
RJMC
Inadvertent All Ena If any DLA motor state inadvertently changes from
DLA State engaged to in between, the controlling RJMC is powered
Change off
Loss of All Ena If the active joint resolver is lost, FDIR switches to the
Resolver other joint resolver using the joint position MAR as an
interim joint position
Inadvertent All but Ena If the joint position changes by more than 0.5 deg without
Joint Autotrack a corresponding command, the controlling RJMC is
Rotation and Blind powered off
Position Limit All Ena If the joint position is > 106 deg or < -106 deg, the
Exceeded controlling RJMC is powered off
LOC with Autotrack Ena Powers off controlling RJMC and performs switchover
S1/P1 MDM sequence (the S1/P1 TRRJ Control function could be
(LT Unavail) operating in Blind but the EXT TRRJ Manager does not
know so it tries to reestablish comm with the Lower Tier
(LT) MDM through a switchover sequence)
Additional FDIR monitors failures within the S1/P1 MDMs, as well as their TRRJ Control
functions. Upon detection of a LOC with the MDM or the TRRJ Control function, FDIR
will power off the RJMC associated with the failed MDM or control function.
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TRRJ Commands and Telemetry: Figure 3-101 shows the commands available for
the TRRJ Manager.
Figure 3-101. Loop A TRRJ mode commands PCS display

Figure 3-102 shows the commands available for the DLAs.
Figure 3-102. Loop A DLA commands PCS display

Figure 3-103 shows the telemetry available for the TRRJ, RJMC, and DLAs.
Figure 3-103. Loop A TRRJ PCS display
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3.6.8 Pump and Control Valve Package Firmware (PCVP)
The PCVP firmware provides the interface to the pump, FCV, and four temperature
sensors located in the PCVP within each PM. The PCVP operates in one of three
states: Standby, Startup, or Normal. These states are defined via operator command
(Set Ops Data command). The firmware controller performs the following functions:
Pump function, Flow Control Valve function, Control Temperature function, and
Firmware Controller function.
Pump Function
The Pump function controls the operation of the PCVP pump. The pump can be
commanded to OFF, ON, or BUMPSTART. When commanded OFF, the pump speed
will be set to zero and the ammonia flow will drop to zero. When commanded ON, the
pump will be turned on and the ammonia flow will be controlled via the commanded
pump speed. When commanded to BUMPSTART, the pump will be turned on for a
brief time interval to check the pump functionality. After the test is complete, the pump
will automatically be turned off.
The Pump function performs three BIT functions:
a. Bumpstart BIT – Set during a BUMPSTART sequence, if the pump speed > zero
rpm for more than 8 seconds
b. Overspeed BIT – Set if the pump speed > overspeed limit (19000 rpm)
c. Underspeed BIT – Set if the pump speed < underspeed limit (11000 rpm) and
PCVP state = Normal
Flow Control Valve Function
The FCV function provides for control of the PCVP ammonia outlet temperature. The
FCV operates in one of four modes: Disable, Position, Flow Control, or Temp Control.
In Disable mode, the FCV will remain in the current position until the next command. In
Position mode, the FCV will be moved to a commanded position. In Flow Control mode,
the FCV will be moved, as needed, to control the PCVP outlet flowrate. In Temp
Control mode, the FCV will be moved, as needed, to control the PCVP outlet
temperature.
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There are two FCV Temp Control methods, Normal and Radiator Limiting Control (RLC)
as defined in Table 3-97.
Table 3-97. FCV temp control methods
Software controls the PCVP out temperature to a user-defined setpoint via
Normal feedback from the three PCVP outlet temperature sensors. The software
control automatically chooses the lowest of the three sensors; however, the operator has
the option to define which of the three sensors is to be used if needed
When the heat load into the system is greater than the rejection capability of the
radiators, the FCV will try to move to the full radiator flow position. However, the
pump is not capable of overcoming the resistance of the radiator flowpaths in this
position, so overall loop flow would decrease greatly. Possible consequences
Radiator could be freezing a radiator, pump damage, or overtemping components due to
limiting lack of flow.
control RLC automatically takes over when PM outlet flowrate is < 7400 lb/hr and the PM
outlet temperature is > the loop setpoint. In order to protect the pump, the FCV is
commanded towards the bypass position until the flowrate is > 7400 lb/hr and outlet
temperature is < the loop setpoint. Software will automatically return to Normal
mode once the flowrate and temperature are within the specified limits
The FCV function performs three BIT functions:
a. High Temp BIT – Set if the control sensor reading > 18.3 o C (65o F) and PCVP state
= Normal
b. Low Temp BIT – Set if the control sensor reading < 1.67 o C (35o F) and PCVP state
= Normal
c. Startup BIT – Set if the S1/P1 MDM status = Offline and PCVP state = Startup
Control Temperature Function
The three PCVP outlet temperature sensors provide for control of the PCVP ammonia
outlet temperature. The Control Temperature function may be commanded to one of
four states: AUTO, ONE, TWO, or THREE. In AUTO mode, the lowest of the three
temperature sensor readings will be used as the control sensor. When commanded to
ONE, TWO or THREE mode, the first, second or third outlet sensor reading,
respectively, will be used as the control sensor.
The Control Temperature function performs three BIT functions when the PCVP state =
Normal:
a. Outlet Temperature Tolerance BIT – Set if one of the two non-control sensor
readings differs from the control sensor reading by more than a defined tolerance
(2o F)
b. Control Temperature Tolerance BIT – Set if both non-control sensor readings differ
from the control sensor reading by more than a defined tolerance (2o F)
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01.07.05(0)T0012
Basic, CPN-1
c. Non-Control Temperature Tolerance BIT – Set if the Control Temperature
Tolerance BIT is set AND the two non-control sensor readings differ by more than a
defined tolerance (2o F)
Firmware Controller Function
The Firmware Controller function provides internal interfaces to the PCVP pump, FCV,
and the four temperature sensors located within the PCVP (three control temperature
sensors and one firmware controller temperature sensor). The Firmware Controller
function issues effector commands to the pump and FCV based upon the pump control
speed and the FCV direction and movement commands. The firmware controller also
reads sensor data from the hardware components and performs Engineering Unit (EU)
conversion for all sensor readings.
The Firmware Controller function performs a series of 12 BITs designed to test input
voltages, Analog to Digital (A/D) converter voltages, Random Access Memory (RAM),
Electrically Erasable Programmable Read Only Memory (EEPROM) checksum status,
etc. For more details on the firmware controller BITs, see the PCVP SRS (Hamilton
Sundstrand, SVHS14199). When any one of these BITs is set, the firmware will set the
pump speed to zero which then triggers the Inadvertant Shutdown algorithm described
in Section 3.6.9.
3.6.9 S1 Truss/P1 Truss MDM Software (S1/P1 MDMs)

The S1/P1 MDMs provides control, monitoring and FDIR functions for the ETCS
components, including the PM, the ATA, the NTA, and the TRRJ.
Pump and Tank Control
The ETCS PTC capability within the S1/P1 MDMs interfaces with the ATA, NTA, and
PM to control loop fill, loop startup, and loop pressurization.
The PTC function operates in one of the following modes:
a. Initialization - This is the default mode upon S1/P1 MDM startup. In this mode, the
current state of the loop is determined and a transition to Dormant/Standby or
Cooling mode takes place if the state is consistent with the criteria conditions of the
modes.
b. Dormant/Standby - Loop is dormant, meaning that the loop is not in operation or in

transition; the pump is shutdown. While in this mode, the loop fluid may be
indicated as Nitrogen, Ammonia, Vacuum, or Unknown. The loop fluid must
indicate Ammonia before transitioning to the Cooling mode. Fluid identification is
provided to the software by PPL.
c. Startup - Startup mode can only be entered from the Dormant/Standby mode and is
entered upon receipt of a valid pump speed command. (Note: software will not
accept a pump speed command unless all installed IFHX valves are in the
Bypass/Close position. Command overrides, however, do exist and can be used to
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01.07.05(0)T0012
Basic, CPN-1
force the software to ignore the IFHX valve positions). Limited ETCS PTC FDIR
functions respond to failures in Startup mode. Most failure conditions can be
detected in Startup mode (i.e., C&W messages are issued), but the corresponding
FDIR may not take action.
d. Cooling - Loop is fully operational with the pump running at nominal speed. FDIR
monitoring for PCVP BIT faults, under-temperature, and over-temperature
conditions is also initiated.
e. Shutdown - The Shutdown mode is a transitional mode that can be entered from
Cooling, Initialization, or Startup modes. The Shutdown command sequence sets
o o
pump speed to zero, ensures the FCV position is between 10 and 80 , inhibits FCV
temperature control, unpowers the PCVP, transitions the ETCS PTC to
Dormant/Standby mode and closes the PM outlet isolation valve. (The ETCS PTC
mode will only indicate “Shutdown” wh ile the Shutdown command sequence is
being performed. If the Shutdown sequence was successful, the ETCS PTC mode
should indicate “Dormant/Standby.”)
Figure 3-104 graphically depicts the relationship between each of the PTC modes.
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Data consistent with Cooling mode* DUHDFWLYH
,QLWLDOL]DWLRQ a) Loop Fluid = Ammonia
b) Pump Speed = 14700 ±50 rpm &RROLQJ
0RGH c) FCV Mode = Control or Position
d) PCVP Cntl Temp = 2.7° ±0.55° C (37° ±1° F)
0RGH
FDIR Shutdown or
Data not consistent with Shutdown command
Dormant/Standby mode
6KXWGRZQ
Data consistent w ith Dormant/Standby mode
a) Pump Speed ≤ 50 rpm or PCVP State = Off
0RGH
*May be different prior to 10A:
b) FCV Mode = Disable or Position or PCVP State = Off
(b) 11500 rpm
c) PM Outlet Flow < 114 kg/hr (250 lbm/hr)
(d) 6.1° C (43° F)
Data consistent with

Dormant/Standby mode 3XPS6KXWGRZQFRPPDQGVHTXHQFH
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FDIR Shutdown or :DLWIRU'RUPDQW6WDQGE\PRGH
Shutdown command FRQGLWLRQV
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Cooling Mode Transition allowed if:
command All loop IFHXs isolated and Pump
Speed cmd = 11250 – 12000 rpm
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6LQFHWKHSXPSLVQRW 37&/RJLFDO7KUHDGLVILUVWHQDEOHGYLDRSHUDWRU
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DUHQRWDFWLYH
Figure 3-104. Relationship between the PTC modes
3-163
01.07.05(0)T0012
Basic, CPN-1
GPRV Control Function: The GPRV control software within the PTC application
controls the loop pressure by commanding the GPRV to regulate nitrogen pressure to
the desired pressure. When the NTA and ATA outlet valves are open, the nitrogen will
pressurize the backside of the ATA bellows, thereby, pressurizing the ammonia in the
entire loop.
For nominal system pressure changes, the intent is for the operator to use the Transfer
Ammonia command, which includes all the valve control and pressure equalization
required to change the pressure of a loop while protecting the ATA bellows.
Operationally, the GPRV setpoint command is intended to be used when the GPRV
outlet pressure needs to be changed without changing the system pressure or during
off-nominal operations.
Pressure changes consist of powering on the GPRV ECU, increasing or decreasing the
pressure setpoint in 138 kPa (20 pisd) increments until the desired pressure is reached,
then powering the GPRV off. Each step changes the setpoint, then waits for the system
pressure to come within a specified delta of that setpoint before changing the setpoint
for the next step. The system pressure is measured at one of the following seven
pressure sensors, selected by the operator:
a. ATA tank 1 outlet pressure
b. ATA tank 2 outlet pressure
c. GPRV outlet pressure
d. PM bypass return pressure
e. PM inlet pressure (default)
f. PM outlet pressure
g. PM radiator return pressure
PTC FDIR: The ETCS PTC function manages several FDIR routines. FDIR can be
inhibited/enabled with an operator command or with a PPL. The following is a list of the
FDIR routines and a summary of their trigger conditions. In general, each trigger
condition must exist for a predefined number of consecutive seconds (10 seconds
unless stated otherwise) before the FDIR will take action. The trigger conditions defined
below are default limits and can be changed via PPL. For more details on these FDIR
routines and the exact time/trigger constraints, see the THOR Console Handbook,
Volume 13.
a. NH3 Return FDIR (High Pressure) - If the PM inlet pressure, PM radiator return
pressure, and PM bypass pressure > 2895.8 kPa (420 psi), the FDIR will perform
an ammonia transfer sequence to reduce the loop pressure. At least two of the
three sensors must be above the high-pressure limit to trigger the FDIR.
b. ATA Overpress FDIR - If ATA tank 1 or tank 2 outlet pressure > 3102.6 kPa
(450 psi), FDIR will close the N2 supply valve, command the NTA GPRV setpoint to
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01.07.05(0)T0012
Basic, CPN-1
2688.9 kPa (390 psi), and open the NTA isolation valve for the associated ATA
tank.
c. ATA Bellow Overpress FDIR - If ATA tank dP > 68.9 kPad (10 psid), FDIR reduces
pressure across the bellows by changing the configuration of the ATA isolation and
NTA isolation valves, and then incrementally stepping the GPRV setpoint pressure
down until N2 outlet pressure is within tolerance (96.5 kPa (14 psi)) of the PM inlet
pressure.
d. PM UnderTemp FDIR - If PM outlet flow temperature < 1.11o C (34o F) for 13

seconds while in Cooling mode, FDIR removes power from the PCVP and
transitions the ETCS PTC to Shutdown mode.
e. OverTemp Shutdown FDIR - If PM outlet temperature > 18.3o C (65o F) while in

Cooling mode, FDIR removes power from the PCVP and transitions the ETCS PTC
to Shutdown mode.
f. Large Leak Safing FDIR - If PM inlet pressure, PM radiator return pressure and PM
bypass pressure (at least two of the three) < 1172.1 kPa (170 psi) or the NH3
saturation pressure (whichever is higher), and ETCS PTC mode is Cooling or
Startup, FDIR transitions the ETCS PTC to Shutdown mode and closes the PM inlet
isolation valve after the shutdown sequence is complete.
g. PCVP Low Temp FDIR - If PCVP Low Temperature BIT is true (Section 3.6.8) and
ETCS PTC mode is Cooling, FDIR initiates the Inadvertent Pump Shutdown FDIR.
h. PM High Press Shutdown FDIR - If PM outlet pressure sensor > 3343.9 kPa
(485 psi) and ETCS PTC mode is Cooling or Startup, FDIR transitions the ETCS
PTC to Shutdown mode.
i. PCVP High Temp FDIR - If PCVP High Temp BIT is true (Section 3.6.8) and ETCS
PTC mode is Cooling, FDIR initiates the Inadvertent Pump Shutdown FDIR.
j. PCVP Overspeed FDIR - If PCVP Overspeed BIT is true (Section 3.6.8) and ETCS
PTC mode is Cooling, FDIR initiates the Inadvertent Pump Shutdown FDIR.
k. PCVP Underspeed FDIR - If PCVP Underspeed BIT is true (Section 3.6.8) and
ETCS PTC mode is Cooling, FDIR initiates the Inadvertent Pump Shutdown FDIR.
l. PCVP Controller BIT FDIR - If any one of the following PCVP BITs are true: RAM,
EEPROM, A/D converters no. 1, no. 2, and no. 3, power supply, microprocessor, or
background task, and ETCS PTC mode is Cooling, FDIR initiates the Inadvertent
Pump Shutdown FDIR.
m. PM Valve Shutdown FDIR - If the PM radiator return isolation valve or the PM

bypass isolation valve indicates Closed while in Cooling or Startup mode, FDIR
transitions the ETCS PTC to Shutdown mode.
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01.07.05(0)T0012
Basic, CPN-1
n. Inadvertent Pump Shutdown FDIR - If any one of the PCVP Low Temp, PCVP High
Temp, PCVP Overspeed, PCVP Underspeed, or PCVP Controller BIT faults is true,
or if the PCVP is failed (LOC) and PM outlet flow < 113.4 kg/hr (250 lbm/hr) or
PCVP is not failed but PCVP pump speed < 50 rpm, FDIR will transition the ETCS
PTC to Shutdown mode.
o. Insufficient NH3 FDIR - If ATA tank 1 or 2 quantity < 5 percent (or invalid) and PM
inlet pressure < desired final pressure during an ammonia transfer sequence, an
advisory level message is issued.
p. Inadvertent Valve Motion Response - If an ATA, NTA, or PM valve moves from

open to close or close to open without an associated command, advisory level
messages are generated. If an NTA N2 supply or isolation valve inadvertently
moves during an ammonia transfer or GPRV processing sequence, the sequence is
automatically terminated.
All PTC FDIRs that initiate a transition to Shutdown mode will also trigger the EXT IFHX
Bypass FDIR, which issues Bypass and Close commands to all installed IFHX valves
on the affected loop. In addition to monitoring the ETCS PTC mode, the IFHX Bypass
FDIR also monitors three separate flags: PCVP Temp Low BIT, PM Outlet Temp Low
Flag, and PM Outlet Temp High Shutdown Flag. If any one of these flags is set, the
EXT MDM will initiate the IFHX Bypass FDIR even if the ETCS does not complete its
expected transition to Shutdown mode.
PTC Pump Module Commands and Telemetry: Figure 3-105 and Table 3-98 show
the commands associated with the PM PCVP, which are routed through the PTC
function in the S1/P1 MDMs. Additional displays provide commands to enable/inhibit
specific PCVP FDIR (which monitors and reacts to high or low temperature conditions
and over or under speed conditions), commands for the PM isolation valves, and
commands to enable/inhibit the CLC of the PM line and accumulator heaters.
Figure 3-105. PCVP Commands PCS display
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Table 3-98. PCVP commands
PCVP Firmware Flag to allow (or prevent) the PCVP shutdown if communication with the
Startup Enable/Inhibit MDM is lost during startup state
ColdStart Command to perform PCVP cold start initialization. (A PCVP cold start
clears all latched PCVP faults and active overrides, loads default setpoints
and constants, commands the pump off, and disables the FCV CLC. Cold
start may be commanded or will occur after an extended loss of power and
its restoration to the PCVP)
Pump Speed setpoint Allows the user to define the pump speed. If current speed = 0 rpm,
software will not accept a new speed command unless all installed IFHX
valves are in the bypass/close position. In Dormant/Standby mode, software
will only accept pump speeds of 11,250 – 12000 rpm. Once in Cooling
mode, however, the pump speed can be set up to 18,000 rpm.
Shutdown Pump Initiates Shutdown mode transition sequence; sets pump speed to zero,
o o
ensures the FCV position is between 10 and 80 ; inhibits FCV CLC;
unpowers the PCVP; transitions the ETCS PTC to Dormant/Standby mode
and closes the PM outlet isolation valve
Pump Flow setpoint Allows the user to define a flow setpoint
FCV Temp Control Allows the user to select a specific temperature sensor to be used for the
Sensor FCV CLC or to allow the firmware to automatically select the lowest of the
three control sensors
FCV CLC Enable/Inhibit Allows (or prevents) the firmware to automatically position the FCV based
upon a predefined setpoint
FCV Position Control Allows the user to send the FCV to a specific position
Setpoint
Figure 3-106 is the primary display planned to be used for starting (or testing) an ETCS
loop. It contains direct commands and telemetry for each of the major ETCS
components, including the PM, ATA, and NTA. Since all commands for an ETCS
startup, except the PM Outlet Isolation Valve Open command, are sent to the PCVP,
then either S1 (-1 or -2) or P1 (-1 or -2) MDM can be used to startup a loop. However, if
the PM outlet isolation valve is closed, or any other valve is not in its proper position,
then only the S1-1 or P1-2 MDMs would be able to start the loop since they are the only
MDMs that can control the position of the valves.
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Figure 3-106. Manual Startup PCS display

The PM display (Figure 3-107) provides a summary of the PM telemetry and can be
used to evaluate the status of the ammonia circulation within the loop.
Figure 3-107. PM PCS display
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PTC ATA Commands and Telemetry: Figure 3-108 shows the commands available
through the PTC function for the ATA isolation and vent valves. The Arm command to a
valve closes the RPC feeding the SDO card in the controlling MDM (S1-1 or P1-2). The
actual valve command then closes the appropriate SDO channel to move the valve in
the desired direction (open or close). This in turn supplies power to the valve’s ECU
through a CLM and actually moves the valve. Upon completion of valve movement, the
RPC feeding the SDO card is opened. Additional displays provide commands to
enable/inhibit CLC (or open loop control) of the ATA heaters.
Figure 3-108. ATA valves PCS display

Figure 3-109 ATA overview display provides a summary of the ATA telemetry.
Figure 3-109. ATA overview

PCS display
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PTC NTA Commands and Telemetry: Figure 3-110 shows the commands available
through the PTC function for the NTA valves.
Figure 3-110. NTA valves PCS display

The following NTA overview display (Figure 3-111) provides a summary of the NTA
telemetry.
Figure 3-111. NTA overview

PCS display
Thermal Radiator Rotary Joint Control
The TRRJ Control function provides lower-level control and monitoring for both the
starboard (Loop A) and port (Loop B) thermal radiator wing assemblies. The higher-
level TRRJ Manager function located within the EXT MDM directs all TRRJ Control
capabilities. TRRJ Control software must be enabled before enabling TRRJ Manager
function.
The TRRJ Control function can operate in one of two modes, Commanded or Monitor.
The TRRJ Control function is initialized in Monitor mode. Upon receipt of a TRRJ
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Manager Command Path command (which selects the MDM/DLA/RJMC string) the
TRRJ Control mode for the selected string is changed to Commanded.
Note: Operationally, the TRRJ Control for String 2 (S1-2, RJMC-2, and DLA-2) will be in
the Commanded mode for Loop A and String 1 (P1-1, RJMC-1, and DLA-1) will be in
the Commanded mode for Loop B. This is done to protect against a single S1/P1 MDM
or power channel failure causing the loss of communication with both the TRRJ and
PCVP (since S1-1 and P1-2 will nominally be communicating with the PCVP).
TRRJ Control DLA Commands: The TRRJ Control DLA operator commands permit
DLA transition from engage to neutral (or vice versa), and from lock to neutral (or vice
versa). The preferred method of DLA movement is to use these commands and always
have the DLA transition pause in neutral even if the desired behavior is to pass through
the neutral state.
In order to change the DLA state, the operator must first select a DLA motor (Stepper
Motor 1(prime stepper motor) or Stepper Motor 2 (cross-strapped stepper motor). Next
an “Arm” command must be issued in order to enable the selected motor with the
proper motor velocity and direction by setting the drive current level. Software uses the
current DLA state and desired state (locked, neutral, or engaged) to determine the
direction of rotation and its associated positive or negative drive current level. A
negative drive current level is required anytime the DLA moves from locked to neutral or
neutral to engaged. A positive drive current level is required anytime the DLA moves
from engaged to neutral or neutral to locked. The final step in changing a DLA state is
to issue the DLA Neutral, Lock, or Engage command. This command sequence utilizes
the operator-selected motor and automatically commands the proper motor drive rate
and stepper distance to the RJMC. TRRJ Control software uses current DLA state
information and the desired DLA state information to determine the stepper motor
distance required and the proper stepper rate. These are considered “high-level”
commands because of this software functionality, which determines the stepper motor
distance and rate. Low-level commands are also available on the PCS, which allow the
user to specifically define the stepper motor distance and rate if desired. Figure 3-112
illustrates the required revolutions and drive current required for each DLA state
change.
Figure 3-112. DLA state change parameters
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TRRJ Control Mode Commands: Upon receipt of an operator-initiated command to
change the EXT MDM TRRJ Manager mode to Checkout or Directed Position, the
TRRJ Control function initiates an internal command sequence that stops joint rotation
and calculates a joint stop position based on whether the joint is currently rotating in a
positive or negative direction.
Upon receipt of an operator or FDIR initiated command to change the TRRJ Manager
mode to Shutdown, the TRRJ Control function initiates an internal command sequence
which rotates the joint to the null position (zero degrees), issues commands to transition
the joint’s cross-strapped DLA to lock, and then turns off all motors.
TRRJ Control Joint Rotation: When the TRRJ Control mode is Commanded, the
DLAs are in neutral and engage, and the torque motor is selected, the S1(P1) MDM
issues RJMC Motor Velocity Control commands to the controlling RJMC to achieve a
commanded angular position based upon the TRRJ Manager mode and data quality
indicators as indicated in Table 3-99.
Table 3-99. Commanded absolute angular position
System configuration Commanded absolute angular position =
TRRJ Manager mode = Autotrack and RGAC data Gamma angle provided by RGAC
is valid
TRRJ Manager mode = Directed Position Gamma angle provided by the operator
TRRJ Manager = Blind mode for < Blind Ops Previous orbit’s worth of gamma desired data or
Timeout (24 hours) (if a complete orbit’s worth of data is not
available) a PPL
TRRJ Manager = Blind mode for > Blind Ops Null position (zero degree)
Timeout (24 hours)
TRRJ = Autotrack and RGAC data becomes invalid Null position (zero degree)
(non-incrementing gamma counter is seen) and the
Blind Ops FDIR is inhibited
TRRJ Manager commanded to Shutdown mode Null position (zero degree)
TRRJ Manager commanded to Checkout or Calculated stop position
Directed Position mode
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TRRJ Control FDIR: The TRRJ Control function monitors for a variety of failures and
takes appropriate action to safe the system. Table 3-100 outlines the failures and
associated responses.
Table 3-100. TRRJ control FDIR

TRRJ Control FDIR FDIR response
Excessive Motor Torque Issues a Motor Select = None command, which powers off all
(> 2 amps) motors. Sets the string failure flag, which initiates additional FDIR
in the TRRJ Manager function if in Autotrack, Directed Position, or
Blind mode (See Table 3-92)
Torque Motor Overtemp See above
(> 260° F)
Excess Joint Velocity See above
RJMC LOC If the torque motor is on, FDIR issues a command to power off the
controlling RJMC and sets the string failure flag (See Table 93).
If the stepper motor is on, FDIR issues a command to power off the
controlling RJMC but no string failure flag is set
Stop Fail FDIR If the TRRJ fails to reach a commanded joint (in directed position)
or fails to reach a commanded change to Checkout or Directed
Position mode, a Motor Select = None command is issued (powers
off all motors)
Joint Resolver Fail FDIR Deactivates the joint resolver
Motor Resolver Fail FDIR If the torque motor is on, FDIR issues a command to power off the
controlling RJMC
Blind Ops FDIR Upon detection of a non-incrementing Gamah counter, transition to
Blind mode occurs if FDIR is enabled. If FDIR is inhibited,
transition to Shutdown mode occurs
TRRJ Control monitors a number of additional failures. These failures result in

automatic recovery actions that cannot be inhibited (i.e., there are no TRRJ FDIR
Ena/Inh commands). All these failures result in either a caution or an advisory level
message.
3.6.10 Starboard (Port) Thermal Radiator MDM Software (STR/PTR MDMs)

The STR/PTR MDM receives commands from and interfaces directly with the EXT
MDM. They provide the capability to control and monitor the Radiator ORUs and RBVM
ORUs.
Radiator Deploy/Retract Control (RDR)
The RDR function manages radiator deployment and retraction. There are a total of six
Integrated Motor Controller Assemblies (IMCAs) dedicated to radiator deployment and
retraction (1 IMCA per Radiator ORU). Radiator deployment and retraction always
involves crew and ground interaction and does not occur autonomously. Table 3-101
identifies the RDR initialization values.
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Table 3-101. RDR initialization values
Parameter Description Initialization value
Deploy Stage 1 Posn Allowable tolerance from the commanded turns 5 turns
Window needed to declare success of deploy stage 1
Deploy Stage 2 Posn Allowable tolerance from the commanded turns 55 turns
Window needed to declare success of deploy stage 2
Deploy Stage 3 Posn Minimum IMCA turncount (in the negative -17 turns
Window direction) needed to declare success of deploy
stage 3
Brake Engagement Amount of time required to allow brake to 5 sec
Delay engage
Max Rad Deply Rtrac Sensed radiator pressure must be below this 25 psi
Pressure value before a command to deploy/retract is
accepted.
Retract Stage 1 Posn Allowable tolerance from the commanded turns 55 turns
Window needed to declare success of retract stage 1
Retract Stage 2 Posn Minimum IMCA turncount needed to declare 20 turns
Window success of retract stage 2
Deploy Stage One Max Amount of time allowed for Stage 1 Deployment 550 sec
Time
Deploy Stage Two Max Amount of time allowed for Stage 2 Deployment 600 sec
Time
Deploy Stage Three Max Amount of time allowed for Stage 3 Deployment 100 sec
Time
Retract Stage One Max Amount of time allowed for Stage 1 Retraction 700 sec
Time
Retract Stage Two Max Amount of time allowed for Stage 2 Retraction 100 sec
Time
IMCA Power On Time Time limit for an IMCA to power on 10 sec
Limit
The RDR function utilizes the initialization values defined above to verify completeness
of the deploy and retract sequences. If any of the time limits or position tolerances are
violated, advisory level messages are generated and the IMCA and RDR function is
placed in the Standby mode. RDR FDIR also monitors for inadvertent motion when the
IMCA is not processing any motion command. Inadvertent motion is detected if the
resolver counts change by more than four counts.
Radiator Deploy/Retract Commands and Telemetry: Table 3-102 identifies the RDR
commands and their associated function. Figure 3-113 shows how the commands are
arranged on the PCS display.
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Table 3-102. RDR commands
IMCA Power On/Off Applies/removes power to the SDO card that feeds the RDR IMCA
Radiator Deploy Sends appropriate deploy commands to the RDR IMCA (see Section 3.4-6)
Radiator Retract Sends appropriate retract commands to the RDR IMCA (see Section 3.4.6)
Pause Stops any IMCA operation in progress and commands the IMCA to the ON
mode (IMCA must be in “Enabled” mode to move the radiator)
Resume Commands a paused IMCA to the Enabled mode and resumes any halted
IMCA operation sequences
Figure 3-113. Radiator IMCA PCS display

Figure 3-114 shows the telemetry available on each radiator overview display.
Figure 3-114. S1-1 radiator PCS display

Radiator Control (RC)
The RC function controls and monitors the RBVM ORUs and instrumentation on the
radiator beam. Each radiator contains two RBVMs and each RBVM is driven by a
single IMCA. The IMCA is used to configure the RBVM to three positions; open, closed
or vent. Upon initialization the RC function powers on all associated IMCAs (six per
loop), updates the RBVM positions, then unpowers all associated IMCAs. RC
initialization values are specified in Table 3-103.
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Table 3-103. RC initialization values
Initialization
Parameter Description
value
S1(P1) RBVM Rad X-Y Default reported position for S1(P1) RBVM X-Y Closed
Default Posn if switch positions not available
RBVM Position Window Allowable tolerance from the commanded 5 motor turns
turncount needed to declare success
RBVM One Step Max Time Maximum amount of time allowed for RBVM to 140 sec
transition from Close to Open, Open to Close,
Close to Vent, or Vent to Close
RBVM Two Step Max Time Maximum amount of time allowed for RBVM to 180 sec
transition from Open to Vent or Vent to Open
IMCA Power On Time Limit Time limit for an IMCA to power on and 10 sec
complete POST
The RC function utilizes the initialization values defined above to verify completeness of
the RBVM valve movements. If any of the time limits or position tolerances are violated,
advisory-level messages are generated.
RBVM Commands and Telemetry: Table 3-104 identifies the RC commands and their
associated function. Figure 3-115 shows how the commands are arranged on the PCS
display. Telemetry for the RBVMs is found on the radiator display seen in Figure 3-114
above.
Table 3-104. RC commands
IMCA Power On/Off Applies/removes power to the SDO card that feeds the RBVM IMCA
RBVM Operate Commands the designated IMCA to open, close, or vent the associated
RBVM valves. This is a two step-command sequence (Arm/Operate). SDO
cards provide the power for all valve operations (movements). Since valve
movements require approximately 45 W and an SDO card can only supply
up to 50 W, only one IMCA can be operated at a time.
IMCA Mode Transitions the designated IMCA to standby, enabled, or on mode
IMCA Init Issues the IMCA Reset Stop Flags (resets all unmasked error flags in the
IMCA FWC) and then updates IMCA controller parameters in the FWC and
sends the data back to the STR/PTR
IMCA Bit Issues a command for the IMCA to perform a BIT and report the results
Figure 3-115. Radiator RBVM IMCA PCS display
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3.6.11 S0 Truss MDM Software (S0 MDMs)
The two S0 MDMs are responsible for monitoring and controlling fluid line heaters,
coldplate temperature sensors, and all IFHX valves and sensors.
Passive TCS Heater Control (PTCS HC)
The S0 PTCS HC function performs Closed Loop and Open Loop modes of heater
control for a number of heaters for various components mounted on the S0 external
truss segment, including the ETCS fluid supply and return umbilicals. Each ETCS loop
has three separate heater strips mounted on the S0 umbilical secondary structure (one
8-W heater strip and two 12-W heater strips) and is equipped with three RTDs that are
monitored by the S0 PTCS HC function. These heaters are physically mounted on the
S0 swing trays connecting the ETCS to Node 2 and won’t be used until those lines are
connected. In Closed Loop mode, the HC function will command the heaters on/off
based upon predefined temperature setpoints (-51.1o C (-60o F)/-48.3o C(-55o F)). If all
temperature sensors are declared failed the PTCS HC function will operate in Open
Loop mode where the heater on/off cycle is based upon open/close duty cycle counters
(time-limits). Open Loop mode can also be initiated by an operator command.
S0 PTCS HC Commands and Telemetry: Figure 3-116 shows the S0 TCS overview
where the umbilical line heaters telemetry is located along with an example of one of the
heater command displays.
Figure 3-116. S0 TCS and heater commands PCS displays
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Heat Acquisition Control (IFHX Control)
The S0 HAC function provides commanding and monitoring of all IFHX valves and
sensors. The S0-1 MDM controls all of the IFHXs connected to the ETCS Loop A while
the S0-2 MDM controls all of the IFHXs connected to the ETCS Loop B. The HAC
function accepts commands to enable an IFHX valve open or close command (closes
the RPC feeding the SDO card), commands to operate the valve (move it to the desired
position), and commands to disable an IFHX valve (opens the RPC feeding the SDO
card). Valve positions are included in the telemetry. Valve position indicators can be
declared failed either through an operator command (requires Arm/Failed sequence) or
automatically by the software if the validity criteria are not met. Operators have the
option of ignoring an invalid position indicator through the use of the “Continue”
command.
Note: Software will not allow an IFHX to be integrated into the ETCS loop (Bypass
valve in flowthrough or Isolation valve open) unless the ETCS mode is Cooling.
Command overrides, however, do exist and can be used to force the software
to ignore the ETCS mode.
S0 HAC Undertemp FDIR: The S0 MDMs also provide protection of the IFHX core by
monitoring the value and validity of the PCVP outlet line temperature sensor located in
the PM downstream of the PCVP. If the PCVP outlet line temperature is less than
1.1o C, the S0 MDM will remove power from the bus feeding the appropriate PCVP (the
entire S11A or P12B power bus) to stop the flow of cold ammonia through the loop.
This provides protection against the catastrophic hazard of freezing and rupturing an
IFHX core; however, it causes an abrupt shutdown of all equipment powered by the
S11A or P12B power bus. This not only includes all ETCS equipment on the affected
loop, but also the S1 (P1) MDMs, STR (PTR) MDMs, and various Communications
equipment. The S0 MDM will also command all IFHX bypass valves on the affected
loop to bypass in order to isolate the external loop from the IFHX cores. (Note that only
the bypass valves are commanded; the isolation valves are left in their last commanded
state).
IFHX Commands and Telemetry (ETCS only): The ETCS IFHX commands are seen
in Figure 3-117.
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Figure 3-117. ETCS IFHX Commands display

3.6.12 Power Management and Control Unit MDM Software
The PMCU MDM controls the cycling of the heaters in the MBSU and DDCU coldplates
on the S1, P1, and S0 truss segments. The PMCU MDM triggers coldplate heater
on/off commands based on the coldplate temperature sensor readings as compared to
setpoints (default values of -31.67o C/ 28.89o C).
The PMCU MDM does not have direct control over the coldplate temperature sensors
nor the RPCs powerings the heaters. Converted coldplate temperature data is made
available to the PMCU MDM via the C&C in Broadcast Ancillary Data messages. All
temperature data and heater commands must pass through the C&C MDM to/from the
S1-2, S0-1(2), or P1-1 MDMs, which have direct control of the temperature sensors and
heater RPCs. In response to receipt of a coldplate heater on/off command, the C&C
MDM issues a corresponding command to the MDM controlling the RPCM. This
command then turns the associated ORU coldplate heater on or off. Unlike other
commands, the coldplate heater commands flow from a lower tier MDM (PMCU) to a
higher tier MDM (C&C), and as such, must be polled by the higher tier MDM using a
separate pipe and command buffer.
DDCU/MBSU Coldplate Heater Commands and Telemetry: Figure 3-118 shows the
commands and telemetry available for the MBSU external coldplate heaters. The
DDCU coldplate heaters command display is similar.
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Figure 3-118. MBSU coldplate heaters PCS display
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APPENDIX A ACRONYMS AND ABBREVIATIONS
A/D Analog to Digital
AAA Avionics Air Assembly
AC Assembly Complete
Accum Htr Accumulator Heater
ACS Atmosphere Control System
ADO Adaptation Data Overlay
ATA Ammonia Tank Assembly
ATCS Active Thermal Control System
AVV Accumulator Vent Valve
BC Bus Controller
BIT Built-In Test
C&C Command and Control
C&W Caution and Warning
CCAA Common Cabin Air Assembly
CCS Command and Control Software
CDH Command and Data Handling
CDRA Carbon Dioxide Removal Assembly
CHRS Central Heat Rejection System
CLC Closed-Loop-Control
CLM Current Limiting Module
CM Configuration Management
COL Columbus Module
CSC Computer Software Component
dc Direct Current
DCM-1 Docking Compartment Module 1
DDCU DC to DC Converter Unit
DIO Discrete Input/Output
DLA Drive Lock Assembly
dP Differential Pressure
DSM Docking and Stowage Module
ECLSS Environmental Control and Life Support System
ECU Electronic Control Unit
ECZ External Control Zone
EDM Engage Disengage Mechanism
EEPROM Electrically Erasable Programmable Read Only Memory
EETCS Early External Thermal Control System
EMU EVA Mobility Unit
EPS Electrical Power System
ETCS External Thermal Control System
EU Engineering Unit
EVA Extravehicular Activity
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FCV Flow Control Valve
FD Flight Day
FDIR Failure Detection, Isolation, and Recovery
FEP Fluorinated Ethylene Propylene
FGB Functional Cargo Block
FHRC Flexible Hose Rotary Coupler
FQDC Fluid Quick Disconnect Coupling
FRITCS Failure Recovery for ITCS
FSS Fluid System Servicer
FTC Fluid Temperature Control
FWC Firmware Controller
GN2 Gaseous Nitrogen
GNC Guidance, Navigation, and Control
GPRV Gas Pressure Regulator Valve
Hab United States Habitation Module
HAC Heat Acquisition Control
HC Heater Control
HR High Rate
HTL High Temperature Loop
HX Heat Exchanger
HXB Heat Exchanger Bypass
IFHX Interface Heat Exchanger
IMCA Integrated Motor Controller Assembly
INT MDM Internal Systems Multiplexer/Demultiplexer
INT SYS Internal Systems
ISPR Internal Standard Payload Rack
ISS International Space Station
ITCS Internal Thermal Control System
IVA Intravehicular Activity
JEM Japanese Experiment Module
JSC Lyndon B. Johnson Space Center
LA MDM Laboratory Systems Multiplexer/Demultiplexer
LAB SYS Laboratory Systems
LCA Loop Crossover Assembly
LDI Local Data Interface
LLA Low Level Analog
LOC Loss of Communication
LR Low Rate
LRITCS Leak Recovery for ITCS
LSM Life Support Module
LT Logical Thread
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LTA Launch-To-Activation
LTL Low Temperature Loop
MA Moving Average
MAR Motor Accumulated Revolutions
MBSU Main Bus Switching Unit
MDM Multiplexer/Demultiplexer
MFCV Manual Flow Control Valve
MLI Multilayer Insulation
MMOD Micrometeoroid/Orbital Debris
Mod Vlv Modulation Valve (FCV)
MPLM Multi-Purpose Logistics Module
MT Moderate Temperature
MTL Moderate Temperature Loop
MWIS Micro Wireless Instrumentation System
N1 Node 1
N2 Nitrogen
NASA National Aeronautic and Space Administration
NCG Noncondensable Gas
NCS Node Control Software
NH3 Ammonia
NIA Nitrogen Interface Assembly
NIV Nitrogen Introduction Valve
NTA Nitrogen Tank Assembly
ORU Orbital Replacement Unit
PBA Pump Bypass Assembly
PCS Personal Computer System
Portable Computer System
PCVP Pump and Control Valve Package
PDTA Power and Data Transfer Assembly
PFCS Pump and Flow Control Subassembly
PFMC Pump/Fan Motor Controller
PM Pump Module
PMA Pressurized Mating Adapter
PMCU Power Management Control Unit
PPA Pump Package Assembly
PPL Pre-Positional Load
PTC Pump and Tank Control
PTCS Passive Thermal Control System
PTCSC Passive ITCS Control
PUMP Pump Package
PUMPS Pump Sensors
PVCA Photovoltaic Controller Application
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PVCU Photovoltaic Controller Unit
PVTCS Photovoltaic Thermal Control System
QD Quick Disconnect
RAM Random Access Memory
RBVM Radiator Beam Valve Module
RC Radiator Control
RDR Radiator Deploy and Retract
Regen HX Regenerative Heat Exchanger
RFCA Rack Flow Control Assembly
RGAC Radiator Goal Angle Calculation
RHX Regenerative Heat Exchanger
RIP Rack Interface Panel
RJMC Rotary Joint Motor Controller
RLC Radiator Limiting Control
RM Research Module
ROS Russian Orbital Segment
RPC Remote Power Controller
RPCM Remote Power Controller Module
RSTS Rack Standalone Temperature Sensor
RT Remote Terminal
RTD Resistance Temperature Device
SCI Signal Conditioning Interface
SCITCS System Control for ITCS
SDO Solenoid Driver Output
SEPS Secondary EPS
SFCA System Flow Control Assembly
SFU Squib Fire Unit
SM Service Module
SOV Shutoff Valve
SPCU Service and Performance Checkout Unit
SPP Science Power Platform
SSSR Space-to-Space Station Radios
STCR Starboard Thermal Control Radiator
TCS Thermal Control System
TDF Thermal Data Filter
THC Temperature and Humidity Control
THOR Thermal Operations and Resources
THRU ITCS Passthrough
TRRJ Thermal Radiator Rotary Joint
TTCR Trailing Thermal Control Radiator
TWMV Three-Way Mixing Valve
U.S. United States
UDM Universal Docking Module
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US Lab United States Laboratory Module
USOS United States On Orbit Segment
VPR Vehicle Power Retry
WLS Weighted Least Squares
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APPENDIX B ANSWERS
Answers to Section 1
1. PTCS Multilayer Insulation (MLI) is analogous to
c. A home’s insulation.
2. Which of the following best describes surface coatings used throughout the ISS?
a. Must be resistant to atomic oxygen and radiation.
3. The ITCS is responsible for
b. Rejecting waste heat from pressurized elements to the EETCS.
4. The ITCS provides which of the following to the IFHX?
a. Heat collected from internal equipment.
5. The EETCS provides
c. Temporary cooling for the ISS until the ETCS is activated.
6. Which of the following statements if incorrect?
b. The ETCS has two pumps per loop and the EETCS has one.
7. The Interface Heat Exchanger (IFHX)
b. Is completely external to the module.
8. The temperature of the ammonia in the EETCS loops
c. Is maintained by bypassing some of the ammonia around the radiators.
9. Which of the following statements best describes TCS software
b. Monitors and controls the system.
10. The FGB ITCS is responsible for
c. Using both air and Triol to provide cooling.
11. The FGB ETCS
a. Flows through both IFHXs.
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Basic
Answers to Section 2
__C__ SFCA Mod Vlv A. Provides temperature control for the ITCS
fluid loops
__B__ PPA B. Provides circulation, filtration, and
pressurization for the ITCS fluid loops
__D__ LCA C. Maintains a constant delta pressure across
the supply/return lines
__E__ IFHX D. Provides a means to connect the two
internal loops into a single loop
__A__ TWMV E. Provides the interface between the internal
and external thermal loops
__G__ SFCA SOV F. Provides the means to raise the
temperature of Low Temperature Loop
(LTL) coolant entering the Moderate
Temperature Loop (MTL) while in single
loop mode
__F__ Regen HX G. Provides a means to isolate an inactive
pump assembly
__C__ Line Heaters A. Provides a means to isolate the interface

heat exchanger core from possible
backflow
__B__ PFCS B. Provides circulation, filtration, loop
pressurization, and temperature control for
the EETCS
__A__ IFHX Isolation Valve C. Provides additional heat during periods of
low-heat loads or system startup
__E__ IFHX Bypass Valve D. Provides the means to reject the heat
collected throughout the system to the
surrounding space environment
__D__ Radiators E. Provides a means to bypass the interface
heat exchanger core
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__B__ PM A. Provides structural support and rotational

capability for each ETCS radiator wing
__D__ NTA B. Provides circulation and temperature
control of the ETCS fluid
__E__ Radiators C. Provides the fluid needed to fill and
pressurize the ETCS fluid lines
__A__ TRRJ D. Provides controlled pressurization of the
ETCS ammonia tanks
__C__ ATA E. Provides the means to reject the excess
heat to the surrounding space environment
__F__ RBVM F. Controls the flow to the radiator ORUs and
provides the means to isolate and vent the
radiators
4. Which MDM provides system level control of the ITCS, including loop
startup/transition routines, FDIR, and leak detection?
c. INT
5. Which MDM communicates with the majority of the MTL ORUs?
b. LA-2
6. Which MDMs control the IFHXs prior to the activation of the ETCS?
a. N1-1 and N1-2
7. Which MDM controls the majority of the ETCS ORUs on Loop A.
c. S1-1
8. Which MDM monitors both internal and external thermal systems for
incompatibilities and initiates load sheds when required?
c. C&C
9. What is the impact to the loss of the ITCS LTL pump?
b. Software will automatically transition the ITCS to single loop mode and maintain
cooling to all equipment
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APPENDIX C HEAT TRANSFER FUNDAMENTALS

Performance objective
Upon completion of this section, you should be able to explain the heat transfer
concepts of
• Conduction
• Convection
• Radiation
Conduction
Conduction is specifically defined as the transfer of thermal energy from a high
temperature region to a lower temperature region by molecular motion. The common
example of a hot pan on the stove can be used to illustrate conduction. When the pan
is handled without protective gloves, the heat from the frying pan is transferred to a
lower temperature region that is usually, and unfortunately, someone’s hand.
The heat transfer due to conduction can be determined using the following equation:
(T
2 − T1 )
q= k
L
where
W
q = heat transfer between T2 and T1  2 
m 
W 
k = thermal conductivity constant  
 mC 
(T2 - T1) = temperature gradient (deg C)

L = distance between the two temperature measurements (m)
A positive value of q would indicate the transfer of heat from T2 to T1; while a negative
value indicates the opposite; that is, heat would be transferred from T1 to T2. Also, the
thermal conductivity constant k is a function of the conducting material between the two
temperature sources.
A wall at home can be used to illustrate the conduction equation. If the outside
temperature (T2) in this example is 100° F and the inside temperature (T1) is 70° F, the
temperature gradient would be positive indicating heat would be transferred from the
outside to the inside of the house. The amount of heat transfer would then be
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dependent upon the value of the conductivity constant (k) of the insulation between the
walls. The thickness of the insulation (L) would also have an effect. Therefore, since
insulation has a small k value and if there is thick insulation (large L value) in the home,
the resulting value of q would be small. This means that the heat outside could not
quickly transfer to the inside and the home could remain cool on a hot day.
Convection
Convection occurs because fluids change density and become less dense when
heated. When a fluid flows over a heated surface and the two are at different
temperatures, convection heat transfer takes place. It is simply the transfer of thermal
energy from fluid motion. Since hot air is less dense than cool air, a home heater heats
the air around it and causes the air to rise. As the air rises, it cools and loses its heat
causing it to sink since its density has increased. This process has produced a free
convection current. However, since gravity does not exist in a zero-g environment and
cool air does not sink, free convection does not occur in a module in low Earth orbit.
Therefore, convection must be forced. Forced convection is present when the flow is
caused by some external means such as a fan, pump, or atmospheric winds.
As an example, a fan blowing (forcing) air over someone when they are hot can be
considered cooling by forced convection. This is also true of a car’s radiator. The
coolant circulating through the engine has picked up the heat and the fluid is passed
through the radiator where a fan blows air through the radiator to remove the heat.
Note that forced convection and not radiation provides most of the cooling for the
engine. Although convection provides most of the cooling, there is some cooling due to
radiation, which can be considered negligible. The radiator fan is necessary because
free convection would not be adequate to cool the engine while the car is not moving. If
the car is moving and air is blowing over the radiator, forced convection is still occurring
and the car is also cooled.
The heat transfer due to convection is represented by the following equation:
q = h(Tsurface - Tfluid)
where
W
q = heat transfer due to convection  2 
m 
 W 
h = convection heat transfer coefficient  2 
 m C
Tsurface - Tfluid = difference between the surface and fluid temperatures (deg C)
The heat transfer coefficient (h) encompasses all the effects (surface geometry, nature
of the fluid motion, etc.) that influence the convection mode. Tfluid is the fluid
temperature in the outer flow region.
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Radiation
Since convection and conduction can only be utilized internally, radiation must be used
to reject heat to space. Radiation is the transfer of thermal energy by electromagnetic
waves. A solid, liquid, or gas at a finite temperature emits energy as thermal radiation
is transported by electromagnetic waves.
As an example, the sensation of warmth when standing in front of a fireplace is the

result of radiant energy. The Sun also produces radiant energy that provides tans for
those who prefer them. Since radiation does not require a transfer medium as
conduction and convection do, radiation via the ISS radiators is the means of final
rejection of ISS heat. The vacuum of space does not provide a transfer medium for
heat rejection, which is why radiation is the only method by which heat can be rejected.
Also, radiation transfer occurs most efficiently in a vacuum.
The following equation describes the net rate of radiation heat transfer between a
surface and its surroundings:
q = ε σ (T4surface - T4surroundings)
where
W
q = rate of radiation heat transfer  2 
m 
ε = emissivity of the surface (non-dimensional)
 W 
σ = Stefan-Boltzmann constant 5.67051 × 10 −8  2 4 
m K 
From this equation it can be seen that the emissivity and temperature of an object
influence the amount of emitted radiation. The emissivity indicates how efficiently the
surface emits compared to an ideal radiator or blackbody. The relationship of this
equation to the ISS can be discussed by identifying Tsurface (deg K) as the temperature
at the radiator surface and Tsurroundings (deg K) as the temperature of the atmosphere
surrounding the radiator. It is evident that, as the temperature of the ISS surroundings
(night/day cycles, ISS attitude, etc.) changes, the efficiency of the radiation is affected.
The efficiency of the radiators can be increased by allowing the radiators to operate at
higher temperatures.
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APPENDIX D PUMP/FAN MOTOR CONTROLLER

This section contains details of the Pump/Fan Motor Controller (PFMC).
PFMC software is composed of five Computer Software Components (CSCs). Each

has specific functions critical to the operation of the PFMC and are defined as:
• Powerup executive CSC
• Background executive CSC
• Communication processor CSC
• Speed feedback processor CSC
• Speed loop processor CSC.

When the PFMC is powered, the powerup executive CSC that initializes all the
hardware devices is executed. The background executive CSC is then invoked. It
continuously performs a self-test of the PFMC and communicates hardware status to
the active Internal Systems (INT SYS) Multiplexer/Demultiplexer (MDM) via the
communication processor CSC, which processes the messages between the PFMC
and the MDM.
The speed of the Pump Package Assembly (PPA) motor is computed based on the raw
speed count from sensors that are read by the speed feedback CSC. If an overspeed
condition exists, it can be seen from Figure D-1 that the speed feedback processor
sends an overspeed flag to the background executive CSC. An overspeed message is
then sent to the MDM via the communication processor CSC. The speed loop
processor CSC processes the speed command and the raw speed feedback to
compute the current command to drive the motor. The command is then directed to the
PFMC inverter that provides electronic commutation of the PPA motor.
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01.07.05(0)T0012
Basic
Inverter Inverter
disab le reset Legend
1. C urrent lim it
2 1 MDM 2. O vercurrent lim it
3. B 0 coe fficient for sp eed
4. B 1 coe fficient regulator
MSG MSG 5. A 1 coe fficient form ula
1553 in 1553 o ut
Powerup Status (powe rup BIT, m o de)
executive Inverter disable
CSC
Fault m ask Com m unication See legend
processor CSC Spee d co m m an d
Sta tu s m essag e to M D M Speed loop
Background processor Current
executive Raw sp eed CSC com m and
O verspeed flag Speed feedback feedback
CSC
processor CSC
Speed
2 senso r signal
Inverter disable Current co m m an d

Current feedback
Inverter disable
Inverter tem perature 2
dc link vo lta ge PF M C Inverter

hardware 1
Therm al shutdown
(m otor,
Inverter shutdown inverter)
D/A and A /D check
M otor type
9708_216
Figure D-1. Pump/fan motor controller

Powerup Executive CSC
The powerup executive CSC initializes the PFMC motor and inverter hardware
components. Inputs to the powerup CSC include a variable from PFMC hardware
verifying the Analog to Digital (A/D) and Digital to Analog (D/A) converters are
performing correctly. Another input indicates the type of motor connected to the
controller because the PFMC is used in other applications such as the ECLSS Carbon
Dioxide Removal Assembly (CDRA) pump and fan. Eight different motor applications
can be controlled by the PFMC but only three (Internal Thermal Control System (ITCS)
pump, CDRA fan, and CDRA pump) are defined at this time. The PFMC is designed to
operate in one of the following six modes:
• Powerup state
• Powerup failure state
• Confirmation of motor type
• Parameter initialization
• Operation
• Fault shutdown
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The powerup executive CSC provides the PFMC operating mode and powerup status
information to the communication processor CSC via the MODE and POWERUP BIT
variables, respectively.
When power is applied to the PFMC controller, the background executive is activated
and program control is immediately passed to the powerup executive CSC for
completion of the powerup sequence. A Programmable Counter Array (PCA), which
reads the sensors used to determine motor speed and the 61553 Integrated Circuit (IC)
used to communicate with the INT SYS MDM, is initialized. The inverter is disabled and
any internal faults in the inverter are cleared. To prevent the motor from moving during
initialization, the inverter must be disabled and all inverter internal faults must be
cleared.
Powerup self-tests on the Random Access Memory (RAM), 32 Kbytes of Read-Only

Memory (ROM), and D/A and A/D converters are then performed before control is
passed to the background executive CSC. Failure of any of these tests is fatal to
system operation and results in a powerup failure. To avoid noise or nuisance faults,
the tests require three consecutive faults to qualify as a failure. Results of the RAM,
ROM, D/A and A/D tests are forwarded to the communication processor CSC via the
POWERUP BIT variable. After passing the powerup tests, the type of motor to which
the PFMC is configured is determined and the variable is stored.
Background Executive CSC

Program control is passed to the powerup executive CSC before any of the software in
the background executive is executed. Upon successful completion of the powerup
sequence, the background executive repetitively performs a series of background tasks.
The purpose of the background executive CSC is to schedule the continuous BITs and
gather all status information for transmission back to the MDM via the communication
processor CSC. The PFMC software is required to monitor three analog signals and
two discrete inputs from the PFMC hardware inverter as shown in Table D-1.
Table D-1. PFMC hardware signals
Signal Type
dc link voltage Analog
Motor current Analog
Inverter temperature Analog
Inverter temperature shutdown Discrete
status
Inverter shutdown status Discrete
A/D converters in the PFMC convert the current, voltage, and temperature analog
signals to digital for processing purposes. The PFMC hardware parameters are
monitored continuously for anomalous conditions and the status data are loaded to
designated memory. The MDM can read them at any time by issuing a status request
message. Therefore, the first activity the background executive CSC performs is to
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01.07.05(0)T0012
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execute the background BITs. The dc link voltage, motor current, and inverter
temperature analog input channels are monitored and tested. The CSC will read these
signals and compare them against limits. If the 120 V dc PFMC power supply voltage
exceeds 155 V, a dc overvoltage flag is set. If the voltage falls below 85 V, a dc
undervoltage flag is set. An overcurrent failure occurs and a flag is set when the motor
current exceeds the established overcurrent limit. The inverter is designed to stay
below 100° C (212° F). If the inverter temperature is higher than 100° C (212° F), an
overtemperature flag is set. A thermal shutdown discrete is set if a shutdown of the
inverter has occurred because of an overtemp condition.
Finally, when an overvoltage, undervoltage, overcurrent, or overtemperature condition

exists, the inverter shuts down to protect the motor by issuing a zero current command
to the inverter. A shutdown occurs provided no mask command to override those faults
has been issued from the MDM. An inverter internal shutdown status discrete is then
set.
The inverter status and results of the tests comprise the background BIT status
message to be sent to the communication processor CSC. After completing the BIT,
the background CSC checks the availability of a 1553 buffer and loads the data for the
status message. The PFMC has two identical memory buffers to guarantee the
integrity of the data and the software prevents reading and writing to the same buffer
concurrently. The status data is ready for transmission to the MDM through the
communication processor CSC after loading is complete and a request command is
received.
Communication Processor CSC

The communication processor CSC processes the communication between the PFMC
and the MDM. The processor routes any incoming 1553 message from the MDM,
which can be either a status request (transmit) or command (receive). The
communication CSC determines the type of message from a bit in the message word
and, depending on the type of message, invokes the appropriate processing to execute
the required action. The PFMC receives five types of commands from the MDM. The
commands are listed in Table D-2 along with a brief description of their purpose.
Table D-2. PFMC commands

Command Purpose
Status request command Transmits PFMC status message to MDM
Parameter initialization command Initializes PFMC motor parameters
Confirmation of motor type command MDM confirmation of PFMC motor type
Operation command Operates PFMC (current limits, speed command, fault
overrides, BIT, inverter disable/enable)
Last-received-command status command Checks received command for protocol errors
Only certain commands are acceptable during one of the six particular PFMC operating
modes. For example, it is illegal for an operation command to be received when the
D-4
01.07.05(0)T0012
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PFMC is in a powerup failure mode. Therefore, the communication processor CSC has
to validate the command after it is received. If the command is not legal, a flag
indicates an illegal command was received. If the command is legal, the
communication processor CSC proceeds to verify the accuracy of the message
received.
The checksum of the MDM 1553 command message is designed to verify the
correctness of the data words received. A checksum is used for checking purposes
and is simply a summation of digits or bits summed according to an arbitrary set of
rules. The checksum should be zero when all the data words in the message are
totaled. The communication processor CSC computes and verifies the checksum of
the incoming command and sets a fail flag if the checksum is not equal to zero. If the
checksum is equal to zero, the communication processor proceeds as commanded by
the MDM.
As stated in the powerup executive CSC section, a PFMC status message is sent to the
MDM upon reception of the status request command. The data to be loaded for the
status message request is shown in Table D-3.
Table D-3. PFMC status

message contents
PFMC operating mode

Power BIT status
• RAM check
• ROM check
• D/A check
• A/D check
Background BIT status
• Overspeed
• Overcurrent
• Overvoltage
• Overtemp
• Undervoltage
• Inverter temperature shutdown
• Inverter shutdown
Current feedback
Inverter temperature
Speed feedback
dc link voltage
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01.07.05(0)T0012
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The communication processor CSC also routes fault mask commands to the
background executive CSC. The following faults can be overridden when a fault mask
is issued:
• Overspeed
• Overcurrent
• Overvoltage
• Undervoltage
• Inverter temperature shutdown
• Inverter shutdown
The speed command from the MDM to the PPA motor is routed by the communication
processor CSC to the speed loop processor CSC. The speeds to the ITCS pump motor
range from 0 to 18,900 rpm. The PFMC can be used to control the ECLSS CDRA
pump and fan motors. Different speed commands for those motors can also be
accepted. The speed range for the CDRA fan motor is 0 to 115,000 rpm; for the CDRA
pump motor, the range is 0 to 1,800 rpm. The confirmation of the motor type is made
by the PFMC to verify that the proper commands are being sent to the correct motor
type. This training manual only addresses the PFMC PPA motor application.
The communication processor CSC also stores the overcurrent limits for the motor,
which are provided to the speed loop processor CSC. A motor current limit parameter
is also provided to limit the current command being sent to the PFMC inverter. Finally,
motor speed regulation is determined using a formula that requires the identifying of
three coefficients that are supplied by the communication processor CSC.
Speed Loop Processor CSC

The speed loop processor CSC regulates the current command to the motor as a
function of the speed command received and the motor speed feedback. The speed
feedback is computed from the raw speed feedback provided by the speed feedback
processor CSC. By using the difference between the speed feedback calculated from
the speed regulator equation and the speed command from the MDM, the speed loop
processor calculates the current command (in digital counts) for conversion to current
amps for the motor. The current command to drive the motor is then output to the
inverter through the D/A converter.
Speed Feedback CSC

The speed feedback CSC is designed to read the PPA motor speed. The PPA uses
three sensors to determine motor speed by monitoring the position of the motor. When
any one sensor picks up the edge-transition signal from the motor, it provides a count to
one of three registers. The speed feedback CSC determines which sensor (register)
has the latest motor speed count. It will then save the speed count in a temporary
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01.07.05(0)T0012
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buffer so that the delta count or difference between the current count and previous
count can be computed. Based on this difference, the CSC either computes the raw
speed feedback or sets the raw motor speed to full scale, indicating an overspeed
condition flag.
A 0 to 255 digital count is used to represent 0 to 18,900 rpm for the ITCS pump motor.
A speed regulator formula is used to convert from digital counts to rpm and coefficients
used in that formula are loaded into the speed loop processor by the communication
processor CSC. If an overspeed condition exists, a flag is sent to the background
executive CSC.
D-7
Training Materials Evaluation
Please answer the following questions regarding the lesson you have just completed.
Your feedback allows us to produce more effective training materials. When completed,
mail to: Shawn T. Harrison/DT4.
TITLE/CODE OF LESSON: International Space Station Thermal Control System

Training Manual/ISS TCS TM 21109
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DOCUMENT NUMBER: 01.07.05(0)T0012
BASIC, CPN-1
TITLE: International Space Station Thermal Control System Training Manual

ISS TCS TM 21109
NASA-JSC
*DA83 MOD Library (30)
USA-HOUSTON
*DT47 Bolt, Kathryn (10)

*USH-121G SFOC Technical Library (1)
*Hardcopy Distribution.

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01.07.

Thermal Control System Training Manual

Errata Dated April 9, 2004

International Space Station

Mission Operations Directorate

January 26, 2004

National Aeronautics and

Thermal Control System Training Manual

Original signature obtained

Original signature obtained Original signature obtained

Original Signature Obtained on Basic

Subject Matter Experts

Internal Thermal Control System

Shawn Harrison (281) 244-7120

Early External Thermal Control System

Shawn Harrison (281) 244-7120

External Thermal Control System

Kathryn Bolt (281) 244-9064

Page no. Change no.

1.0 THERMAL CONTROL SYSTEM OVERVIEW ........................................... 1-1

2.0 USOS TCS FUNCTIONAL DESCRIPTION ............................................... 2-1

2.5.4 US Lab ITCS Software ................................................................. 2-79

3.0 TECHNICAL SUPPORT ............................................................................ 3-1

3.6.2 INT SYS MDM Software ............................................................... 3-113

A ACRONYMS AND ABBREVIATIONS........................................................ A-1

B ANSWERS ................................................................................................. B-1

C HEAT TRANSFER FUNDAMENTALS....................................................... C-1

D PUMP/FAN MOTOR CONTROLLER......................................................... D-1

2-1 ITCS operating modes ............................................................................... 2-29

3-1 PPA components ....................................................................................... 3-7

2-1 US Lab Internal Thermal Control System................................................... 2-3

3-1 LTL plumbing isometric .............................................................................. 3-2

• Identify the functions of each of the TCS subsystems

1.2 TCS ARCHITECTURE

Figure 1-1. ISS TCS architecture

1.3 USOS PASSIVE THERMAL CONTROL SYSTEM

1.3.2 USOS PTCS Components

Figure 1-2. Typical USOS PTCS

The concepts of emissivity and absorptivity are critical to understanding surface

Heaters: Electrically powered heaters are used in locations where it is impossible or

1.4 USOS ACTIVE THERMAL CONTROL SYSTEM

Figure 1-3. USOS ATCS architecture

1.4.1 US Lab Internal Thermal Control System (ITCS)

Normally, both ITCS loops operate independently in what is known as dual-loop

Heat Collection ORUs

Heat Transportation ORUs

Another important component of the PPA is the accumulator. It maintains inlet

• Three-Way Mixing Valve (TWMV) - Maintains proper water temperature.

Heat Rejection ORUs

• EPS provides power to operate ITCS pumps and valves

• ECLSS-supplied nitrogen pressurizes the PPA accumulator

• C&DH MDMs provide commands and telemetry

1.4.2 USOS Early External Thermal Control System

1.4.2.1 USOS EETCS Purpose

Heat Collection ORUs

Heat Transportation ORUs

Accumulators: Accumulators compensate for the expansion and contraction of

Heat Rejection ORUs

Figure 1-6. EETCS radiators

• EPS provides power to operate EETCS pumps, valves, and radiators

• C&DH MDMs provide commands and telemetry

1.4.3 USOS External Thermal Control System