AIR-COND Panel

Flight Simulation Hardware – Air Conditioning Control Panel

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Overview

This AIR COND panel replicates the Air Conditioning and Pneumatic Control System panel found in Airbus aircraft. It includes controls and indicators for managing cabin airflow, temperature regulation, bleed air sources, and emergency air intake.

The design includes a PCB assembly, a laser-engraved acrylic faceplate, and multiple Korry-style switches with dual LEDs for FAULT and OFF states. The panel also features rotary selectors for PACK FLOW, X BLEED, and individual temperature controls for the cockpit and cabin zones.

⚠️ Flight Simulation Only – Not for use in real aviation applications.

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Panel Layout

Acrylic Panels

The panel is arranged in three distinct layers of interaction zones:

Top Row – Rotary Selectors and Flow Control:

• PACK FLOW Selector

  • Positions: LO, NORM, HI

  • Adjusts airflow intensity.

• COCKPIT, FWD CABIN, AFT CABIN

  • Each zone features a rotary selector with positions ranging from COLD to HOT for temperature regulation.

Middle Row – Functional Routing and System Map:

• Functional silkscreen mimics the aircraft’s pneumatic system routing:

  • PACK1 and PACK2 lines

  • ENG1 BLEED, ENG2 BLEED

  • RAM AIR, APU BLEED, GND HP

  • X BLEED rotary selector (SHUT, AUTO, OPEN)

• Annotated flow diagram includes airflow arrows and zone boundaries.

Bottom Row – Korry Switches:

• PACK1, PACK2

  • FAULT/OFF switch indicators

• ENG1 BLEED, ENG2 BLEED

  • Dual Korry switches for each engine bleed source

• HOT AIR, APU BLEED

  • Control switches with FAULT/OFF or ON indicators

• RAM AIR

  • Emergency air intake, Korry switch with dual-light ON indicator

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PCB Details

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Connectors & Interfaces

CONNECTION J1

Pin	Signal
1	PACK-1-TOP_LED
2	PACK-1-BOTTOM_LED
3	PACK-1-KORRY_SW
4	PACK-2-TOP_LED
5	PACK-2-BOTTOM_LED
6	PACK-2-KORRY_SW
7	ENGINE-2-BLEED-TOP_LED
8	ENGINE-2-BLEED-BOTTOM_LED
9	ENGINE-2-BLEED-KORRY_SW
10	HOT-AIR-TOP_LED
11	HOT-AIR-BOTTOM_LED
12	HOT-AIR-KORRY_SW
13	APU-BLEED-TOP_LED
14	APU-BLEED-BOTTOM_LED
15	APU-BLEED-KORRY_SW
16	ENGINE-1-BLEED-TOP_LED
17	ENGINE-1-BLEED-BOTTOM_LED
18	ENGINE-1-BLEED-KORRY_SW
19	RAM-AIR-TOP_LED
20	RAM-AIR-BOTTOM_LED
21	RAM-AIR-KORRY_SW
22	PACKS-COCKPIT-POS1-SW
23	PACKS-COCKPIT-POS2-SW
24	PACKS-COCKPIT-POS3-SW
25	PACKS-COCKPIT-POS4-SW
26	PACKS-COCKPIT-POS5-SW
27	PACKS-COCKPIT-POS6-SW
28	PACKS-COCKPIT-POS7-SW
29	PACKS-COCKPIT-POS8-SW
30	PACKS-FWD_CABIN-POS1-SW
31	PACKS-FWD_CABIN-POS2-SW
32	PACKS-FWD_CABIN-POS3-SW
33	PACKS-FWD_CABIN-POS4-SW
34	PACKS-FWD_CABIN-POS5-SW
35	PACKS-FWD_CABIN-POS6-SW
36	PACKS-FWD_CABIN-POS7-SW
37	PACKS-FWD_CABIN-POS8-SW

CONNECTION J7

Pin	Signal
1	PACKS-AFT_CABIN-POS1-SW
2	PACKS-AFT_CABIN-POS2-SW
3	PACKS-AFT_CABIN-POS3-SW
4	PACKS-AFT_CABIN-POS4-SW
5	PACKS-AFT_CABIN-POS5-SW
6	PACKS-AFT_CABIN-POS6-SW
7	PACKS-AFT_CABIN-POS7-SW
8	PACKS-AFT_CABIN-POS8-SW
9	PACKS-FLOW-POS1-SW
10	PACKS-FLOW-POS2-SW
11	PACKS-FLOW-POS3-SW
12	X-BLEED-POS1-SW
13	X-BLEED-POS2-SW
14	X-BLEED-POS3-

J1, J2 – 40-Pin Header Interfaces

• Positioned at the top-left and top-right of the PCB

• Clearly labeled silkscreen for signal routing (D0–D39, VCC, GND)

• Supports dual microcontroller or multiplexed control

K1–K8 – Korry Switch Modules

• Each switch location features:

  • Silkscreen outline

  • Dual 3-pin header footprints for LED and input integration

  • Positioned for OpenA3XX standard Korry switches

J3 – 2-Pin Terminal Block

• Power input terminal for common supply to LEDs and logic

• Located at the bottom center of the PCB

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LEDs and Indicators

• Over 100 SMD LEDs placed around:

  • Korry switch frames

  • Rotary selector positions (rotary halo)

  • Silkscreen elements for visual guidance

• Labeled as D1–D106

• Controlled via 220-ohm resistors labeled R1–R46 for current limiting

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Mounting and Assembly

• 4 corner mounting holes align the front and PCB layers

• All cutouts for rotary selectors and Korry switches are CNC-precise

• Silkscreen includes flow diagram, selector labels, and system paths

• Back panel supports flush mount to the main simulator frame

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Fabrication and Panel Fit

Acrylic Faceplate:

• Laser-etched engravings for:

  • AIR COND, PACK1, PACK2, HOT AIR, RAM AIR

  • Temperature control zones (COCKPIT, FWD CABIN, AFT CABIN)

  • Flow selectors: PACK FLOW, X BLEED

  • Korry labels: FAULT, OFF, ON

• Color-coded preview:

  • Red = Front Panel cut

  • Blue = Back Panel

  • Green = Engraving

  • Orange = Korry switch acrylic legends

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PCB Design Reference

Routing and layout (KiCad-style rendering):

PCB Routing

• Red: Top signal layer

• Blue: Bottom signal layer

• Yellow: Silkscreen and outlines

• Vias, pads, and traces are clearly routed for easy soldering and inspection

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🔗 Attribution

• Version: AIR COND Panel v1.0

• Project: OpenA3XX

• License: CC BY-SA 4.0

• Note: Design for flight simulation and educational use only.