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AirComm Corporation Airbus EC130 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual
AirComm Corporation Airbus EC130 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual
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AIR CONDITIONER SERVICE MANUAL EC130-200M-1 Revision 6 Page 34 NOTE Maintaining the correct amount of refrigerant and refrigerant oil in the system is critical for ensuring the long life of the compressor. The Service Ports for this system are located in the upper aft right-hand corner of the baggage compartment. CAUTION This system is serviced with either Polyester Based Refrigerant Oil (POE) or Double end capped Polyalkylene oil (DEC PAG, aka Ultra PAG). The use of Mineral Oil or Polyalkylene (PAG) in this system will cause damage to the air conditioner compressor and expansion valves. 4. SYSTEM LEAK CHECK Identification and elimination of system fitting leaks is extremely important to insure a trouble free operation of this system. A system which contains a partial charge of refrigerant can be leak tested with the aid of an electronic leak detector, and be recharged without evacuating the system. A new or empty system can be pressurized with nitrogen 70-80 psi (5.1-5.6 kgcm) or R134a 50 psi (3.5 kgcm) to conduct a leak survey. DO NOT USE COMPRESSED AIR. Compressed air will introduce moisture into the system, which will degrade the operation of the system. The preferred method is to use an electronic leak detector in conjunction with a small charge of R134a refrigerant. All checks done in this manner should be conducted with the air conditioner off. Since the refrigerant is heavier than air, leaks are most likely to be detected on the underside of hoses and fittings. Refrigerant will collect in low areas and provide erroneous leak detection. A stream of compressed air from a nozzle may be useful in clearing the area just prior to conducting a leak test. If the nitrogen method is used, it will be necessary to mix together a water and mild soap solution. Each fitting or suspected leak area should be brushed with this soap solution and watched for evidence of bubbles formed by the escaping nitrogen. If a leak is detected at an O-ring fitting check to insure proper torque has been applied to the fitting. If the system continues to leak, reclaim the system of refrigerant, and install a new O-ring. NOTE: be sure that the O-ring is Lubricated with refrigerant oil prior to its installation. A small amount of leakage (approximately one ounce per year) past the compressor shaft seal is normal. Most leak detectors are sensitive enough to show a leak of this magnitude.
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 Revision 6 Page 35 5. SUGGESTED EQUIPMENT FOR SERVICING Recovery / Recycling / Recharging Station (Example: Snap-on Model ACT 3340, Robinair Model 34700, or equivalent). Electronic Leak Detector (R134a compatible) (Example: Micro-Tech III, Robinair, Snap-on, or equivalent). Manifold and gauge set (R134a compatible) (Example: Robinair, Snap-on, or equivalent). 6. CONSUMABLE MATERIALS Refrigerant: This system is to be charged with Dupont, or equivalent HFC R134a refrigerant only. Lubricant: This system may be serviced with either Polyolester (POE) or Double End Capped Polyalkylene Glycol (DEC PAG). DEC PAG is preferred. (Do not use Mineral Oil in this system). O-rings: As this system is charged with R134a refrigerant, it must be fitted with Highly Saturated Nitrile (HSN) O-rings. This system incorporates HSN O-ring for the Insert fittings that are GREEN in color, and HSN O-rings for the TORQ-LOK ® fittings that are Black in color.
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 Revision 6 Page 36 7. SUGGESTED SPARES LIST Item Part Number Blower Motor – Aft Evaporator ES61060-2 (EC130-200 Installation only) Blower Motor – Aft Evaporator ES61142-1 (EC130-202 Installation only) Blower Motor – Forward Evaporator ES61064-2 Compressor Assembly S-3036EC-1 Compressor Drive Belt ES35130-3 Receiver / Drier Bottle ES43030-5 Binary Switch ES57178-1 By-pass Valve ES26112-4 Condenser Blower replacement ES73186-1 (EC130-200 Installation only) Condenser Blower replacement (New) ES73131-1 Condenser Blower replacement (Overhauled) ES73131-2 (EC130-202 Installation only) HSN O-rings; Insert type (Green) Size #6 O-ring AIR 440-840 #8 O-ring AIR 440-841 #10 O-ring AIR 440-842 HSN O-rings; Torq-Lok Type (Black) Size #6 O-ring 2-012-N1173 #8 O-ring 2-014-N1173 #10 O-ring 2-016-N1173
AIR CONDITIONER SERVICE MANUAL EC130-200M-1
Revision 6 Page 37
CHAPTER 7
STANDARD PRACTICES INFORMATION
1. FITTING TORQUING PROCEDURES
INSERT O-RING FITTINGS TORQ-LOK ® FITTINGS
Apply a thin coating of refrigerant oil to O-ring and Female side of fitting. Confirm there is no
damage (nicks, dirt, etc.) on fittings.
Slide B-nut back away from the end of the tube to expose the O-ring as the fittings are
mated together.
Take caution not to pinch the O-ring during assembly.
Engage the male end into the female fitting being careful to maintain alignment.
Ensure that the male flange seats fully against the female fitting without the O-ring being
pinched.
It is important to hold the fitting together while sliding the B-nut forward and engaging the
threads.
Tightening specifications
CAUTION: ALWAYS USE BACK UP WRENCH. EXCESSIVE TORQUE WILL DAMAGE
THE JOINT, COMPROMISING THE INTEGRITY OF THE SEAL.
Insert O-Ring Fittings (regardless of size): Hand tighten, then turn an additional 60 deg.
(one flat on the nut).
TORQ-LOK ® fittings (regardless of size): Hand tighten, then turn an additional 30 deg.
INSERT O-RING FITTINGS TORQ-LOK ® FITTINGS
Once the system is charged, check each fitting with an electronic leak detector. A “bubble”
check is inadequate for identifying small leaks. (An electronic leak detector is the only
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 Revision 6 Page 38 reliable method of checking for refrigerant leaks). Once the fittings have been checked and are found to be free of leaks, torque seal as appropriate. 2. REMOVAL, REPLACEMENT & ADJUSTMENT OF COMPRESSOR DRIVE BELT REMOVAL A. It is necessary to access the transmission compartment to remove, replace, or adjust the Compressor Drive Belt. B. Remove the safety wire from the Compressor Belt Tensioning Link jam nuts and loosen them. See Fig. 4-5, sh 15. C. Before attempting to remove the drive belt tension, insure that the compressor mounting / attaching bolts have been loosened to allow free rotational movement of the compressor body on the compressor mount. D. Remove the Main Gearbox Engine Coupling per Airbus maintenance instructions to expose the compressor drive pulley. E. Adjust the Belt Tension Link to loosen the belt, and remove the belt from the compressor & drive pulley. REPLACEMENT A. With the Main Gearbox Engine Coupling removed (per Airbus maintenance instructions) install the drive belt on the compressor pulley & drive pulley. B. Adjust belt tension (See Adjustment below). C. Tighten the compressor belt tensioning link jam nuts and re-safety using .032 safety wire. D. Re-torque the compressor mounting / attaching bolts / nuts per the torque notes in Fig. 4-5. NOTE The locking nuts are to be maintained and replaced per the guidelines in NASM33588 E. Re-install the Main Gearbox Engine Coupling per Airbus maintenance instructions. NOTE Care should be taken to insure that the new belt is not damaged (nicked or cut) during installation.
AIR CONDITIONER SERVICE MANUAL EC130-200M-1
Revision 6 Page 39
CAUTION
A minimum of 0.4” clearance must be maintained between the compressor pulley and the
transmission support tube to prevent damage to the aircraft.
ADJUSTMENT
NOTE
Proper belt tension is important to insure a long belt service life and to avoid excessive loads on
the compressor and bearing assemblies.
A. The correct belt tension for the belt is 5 lbs. This can be achieved with the aid of a
belt tensioning tool (Kent-Moore® BT-33-73F Belt Tension Gauge or Equivalent).
(This is the preferred method of obtaining proper belt tensioning).
B. An alternate method is to observe a .10” belt deflection when 5 lbs of force is applied
at the belt midpoint of the span between the pulleys.
Tail rotor drive shaft pulley
Compressor drive pulley
NOTE
The belt tension should be checked and re-adjusted if necessary after the first two hours of
operation for a newly installed belt.
3. REMOVAL, INSTALLATION / REPLACEMENT OF COMPRESSOR ASSEMBLY
REMOVAL
A. Remove the drive belt per Section 2 (above).
B. Discharge the refrigerant per Chapter 6 SERVICING of this manual.
Deflection should be .10”
Apply 5 lbs. at midpoint
AIR CONDITIONER SERVICE MANUAL EC130-200M-1
Revision 6 Page 40
CAUTION
Refrigeration servicing should be performed by qualified personnel only!
C. Disconnect the refrigerant hoses from the suction and discharge ports located on the aft
end of the compressor housing.
D. Remove the attaching hardware from the top of the belt tensioning link and the
compressor mount assembly. Remove the mounting bolt that attaches the compressor
body to the top of the compressor mount and remove the compressor assembly.
CAUTION
It is recommended that removing the compressor attachment hardware is a two person
operation due to the weight and position of the compressor.
INSTALLATION / REPLACEMENT
A. Calculating and measuring the lubricant in the new compressor:
The amount of oil in the replacement compressor needs to be adjusted to match the
amount of oil in the old compressor. To properly calculate the amount of oil required in
the replacement compressor, it is necessary to pour the oil out of the old compressor into
a clean container. Drain the oil out of the fill plug hole and then pour oil out of the suction
and discharge ports while rotating the center shaft clockwise. Measure the total amount
of oil removed from the old compressor. Note that the compressor (new or old) retains .5
oz. of unrecoverable oil even after completely draining. This total is what is needed to be
in the new compressor. New compressors come from Air Comm charged with 8.0 oz. of
oil. This should be adjusted according to the amount of oil recovered from the old
compressor and any other components being replaced. The receiver drier should always
be replaced when the compressor is replaced or when the system has been open for an
appreciable time, which accounts for another 1.5 oz. of oil that should be added.
Below is an example of a compressor (and receiver drier) replacement oil calculation for
illustration:
Evacuating the system recovers 1.5 oz. of oil. Draining the old compressor recovered
2.0 oz. of oil. The new receiver/drier requires an additional 1.5 oz. so the total oil
needed in the replacement compressor for this case is 1.5 + 2.0 + 1.5 = 5.0 oz, plus
the .5 oz of unrecoverable oil for a total of 5.5 oz. Since the new compressor comes
with 8.0 oz. of oil, remove the oil fill plug and pour out 2.5 oz. of oil.
B. Install the attaching hardware into the top of the belt tensioning link and the compressor
mount assembly. Install the mounting bolt that attaches the compressor body to the top
of the compressor mount and position the compressor assembly. Do not torque the
fasteners at this time.
C. Adjust the belt tension per the procedure shown on Page 39.
D. Torque all compressor mount fasteners per the notes in Fig 4-5.
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 Revision 6 Page 41 NOTE The locking nuts are to be maintained and replaced per the guidelines in NASM33588 E. Safety wire the tension link jam nuts using .032 safety wire. F. Replace the O-rings on the refrigerant hoses and re-connect the hoses to the compressor housing. Torque the #10 hose fitting to 50 – 55 inch lbs (5.7-6.3 Nm). and torque the #8 hose fitting to 40 – 45 inch lbs (4.6-5.1 Nm). G. Recharge the refrigerant per the servicing instructions pg 31 thru 34, Chapter 6, sections 2 thru 4. CAUTION Refrigeration servicing should be performed by qualified personnel only! NOTE An electronic leak detector should be used any time a component is replaced or the system has been opened, to ensure trouble free operation of the air conditioner system. 4. REMOVAL, INSTALLATION / REPLACEMENT OF FORWARD EVAPORATOR ASSEMBLY REMOVAL A. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace the forward evaporator assembly. Instructions for servicing of the system are found in Chapter 5 Servicing. CAUTION Refrigerant servicing should be performed by qualified personnel only! B. Remove attaching hardware (AN3-5A Bolts) (4) four places in mounting brackets on aft of evaporator assembly. C. Disconnect the ducting that attaches the forward evaporator to the forward blower outlets. D. Disconnect the electrical connector from the forward evaporator assembly. E. Disconnect drain line from bottom of evaporator housing. F. Disconnect refrigerant plumbing from fittings and hoses located under the evaporator assembly area.
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 Revision 6 Page 42 CAUTION Always use a back-up wrench when removing, or installing refrigerant line fittings. INSTALLATION / REPLACEMENT A. Locate the forward evaporator assembly per figure 4-6, pg 16. Install attaching hardware (AN3-5A Bolts) (4) four places in mounting brackets on aft of evaporator assembly. B. Attach the refrigerant hoses located under the evaporator assembly area. Replace the fittings o-rings and torque the refrigerant lines per section 1 p.37. CAUTION Always use a back-up wrench when removing, or installing refrigerant line fittings. C. Connect the drain line to the bottom of the evaporator housing. D. Connect the ducting that attaches the forward evaporator to the forward blower outlets. E. Recharge the refrigerant per the servicing instructions on pg 31 thru 34, sections 2 thru 4. CAUTION Refrigerant servicing should be performed by qualified personnel only! NOTE An electronic leak detector should be used any time a component is replaced or the system has been opened to insure trouble free operation of the air conditioner system. 5. REMOVAL, INSTALLATION / REPLACEMENT OF AFT EVAPORATOR ASSEMBLY REMOVAL A. Open the right hand transmission cowling. B. Remove the (6) six AN3-3A bolts that retain the Aft Evaporator to the cabin roof. C. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or replace the aft evaporator assembly. Instructions for servicing of the system are found in Chapter 6 Servicing.
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 Revision 6 Page 43 D. Disconnect the refrigerant lines at the fittings to the evaporator housing. CAUTION Refrigerant servicing should be performed by qualified personnel only! CAUTION Always use a back-up wrench when removing or installing refrigerant line fittings. E. Disconnect wiring to the Temperature control module on the Aft Evaporator assembly by disconnecting the Molex connector. INSTALLATION / REPLACEMENT A. Locate the aft evaporator assembly in the aircraft per figure 4-17, p17 (EC130-200 kit) or per figure 4-18, p18 (EC130-202 kit). B. Install the six AN3-3A screws to secure the evaporator to the cabin roof. C. Connect the refrigerant lines and recharge the refrigerant per the service instructions on pg 31 thru 34, Sections 2 thru 4. CAUTION Refrigerant servicing should be performed by qualified personnel only! CAUTION Always use a back-up wrench when removing or installing refrigerant line fittings. 6. REMOVAL, INSTALLATION / REPLACEMENT OF AFT EVAPORATOR BLOWER MOTOR REMOVAL CAUTION It is recommended that the battery and external power be disconnected before starting work. A. Access the aft evaporator on the aircraft right transmission deck area. B. Remove the AN525-10R8 Screws, and AN960-10L Washers that attach the blower motor to the Aft Evaporator housing. C. Disconnect electrical connection to the Aft Evaporator Blower Assembly. D. Remove Blower Assembly from aircraft.