AirComm Corporation Airbus EC130 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual

							 
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 
Revision 6                                                                                                         Page 44 
INSTALLATION / REPLACEMENT 
 
A. Locate the Aft Evaporator Blower Assembly into the aft evaporator. 
 
B. Install the AN525-10R8 screws and AN960-10L washers to secure the motor. 
 
C. Re-make the electrical connection between the blower and the evaporator. 
 
 
7. REMOVAL, INSTALLATION OF THE CONDENSER SCOOP ASSEMBLY, EC130-200 
KITS 
 
REMOVAL 
 
CAUTION 
It is recommended that the battery and external power be disconnected before starting work. 
 
A. Remove the AN3-3A bolts that attach the EC130-7002-1 Condenser Scoop Assembly to 
the lower contour of the belly panel. This will allow the Condenser Scoop Assembly to 
pivot on the forward hinged support plate. 
 
CAUTION 
Be sure to support this assembly when removing the attaching hard ware to prevent damage to 
the Condenser Scoop Assembly, or the aircraft. 
 
B. Remove the AN525-10R Screws that attach the forward hinge support plate to the 
aircraft belly panel. 
 
C. Disconnect the Molex Connector that attaches the power wires from the Condenser 
Scoop Assembly to the aircraft wiring, and remove the EC130-7002-1 Condenser Scoop 
Assembly from the aircraft. 
 
 
INSTALLATION / REPLACEMENT 
 
A. Locate the condenser scoop assembly per figures 4-9 p.19 and 4-10 p.20 
 
B. Install the AN525-10R Screws that attach the forward hinge support plate to the aircraft 
belly panel. This will allow the Condenser Scoop Assembly to pivot on the forward 
hinged support plate. 
 
C. Connect the Molex Connector that attaches the power wires from the Condenser Scoop 
Assembly to the aircraft wiring. 
 
D. Install the AN3-3A bolts that attach the EC130-7002-1 Condenser Scoop Assembly to 
the lower contour of the belly panel.  
 
E. Re-apply battery power.  
						

							 
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 
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NOTE 
Perform a maintenance operational check of the Condenser Scoop Assembly on completion of 
the installation to insure that there is no rubbing or binding of the Scoop Door. 
 
NOTE 
The Condenser Scoop Door is rigged at the factory with a .20 to .40  + .10 inch gap between 
the Scoop Door and the Scoop Plate assemblies with the Scoop Door in the full up position. 
 
CAUTION 
Do not attempt to disassemble or readjust the Scoop Door, as altering the rigging may damage 
the Scoop Door Bellcrank, or Scoop Door Actuator. 
 
 
 
8. REMOVAL, INSTALLATION OF THE CONDENSER ASSEMBLIY, EC130-200 KITS 
 
REMOVAL 
 
A. Refer to figures 4-9 p.19 and 4-20 p.20. It is necessary to remove the Condenser Scoop 
Assembly EC130-7002-1 prior to removing the Condenser Assembly. See previous 
section 7 for the removal and installation of the Condenser Scoop Assembly. 
 
B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or 
replace the condenser assemblies. Instructions for servicing of the system are found in 
Chapter 6 SERVICING. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
 
C. Disconnect the refrigerant lines from the Condenser Assembly. 
 
CAUTION 
Always use a back-up wrench when removing or installing the refrigerant line fittings. 
 
D. Remove the Condenser. 
 
INSTALLATION / REPLACEMENT 
 
A. Install the condenser assembly per figures 4-19 p.19 and 4-20 p.20. Torque all attaching 
hardware to 50 – 70 inch lbs (5.7-8.0 Nm) and replace all O-rings. 
 
B.  Recharge the refrigerant per the servicing instructions on pg 31 thru 34, Chapter 6, 
Sections 2 thru 4. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
  
						

							 
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 
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CAUTION 
Always use a back-up wrench when removing or installing refrigerant line fittings. 
 
NOTE 
There should be no air leakage paths other than through the inlet and outlet. Seal all other 
openings including those around the condenser refrigerant tubes. 
 
 
 
 
9. REMOVAL & REPLACEMENT OF CONDENSER BLOWER FAN ASSEMBLY, EC130-
200 KITS 
 
REMOVAL 
CAUTION 
It is recommended that the battery and external power be disconnected before starting work. 
 
A.  Remove the belly panel from the lower left hand side of the aircraft to gain access 
to the condenser & blower assembly. 
 
CAUTION 
Be sure to support the blower assembly when removing the attaching hardware to prevent 
damage to the condenser housing, blower assembly, or the aircraft. 
 
B. Remove safety wire that secures the (4) AN3H-3A bolts (2) two on each side that 
attach the ES73186-1 Blower motor & Fan assembly to the condenser scoop 
assembly, and remove bolts. 
 
C. Disconnect the ES73186-1 Blower motor & Fan assembly at the Molex connector. 
 
D. Once the mounting bolts have been removed the blower can now be removed. 
 
REPLACEMENT  
 
A. Install the new blower assembly, torquing the blower attaching bolts to 50 to 70 inch 
lbs (5.7-8.0 Nm) and safety using .032 safety wire. 
 
B. Reconnect the Molex connector. 
 
C. Apply power and operate the air conditioner by moving the control switch into the 
A/C position several times to insure there is no binding of the scoop and for proper 
operation of the Blower motor & Fan assembly. 
 
D. Reinstall lower left hand belly panel to aircraft. 
  
						

							 
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 
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10. REMOVAL, INSTALLATION OF THE CONDENSER ASSEMBLIY, EC130-202 KITS 
 
REMOVAL 
 
A. Remove attaching hardware securing forward inner baggage compartment panel to 
condenser assembly. Remove baggage compartment panel. 
B. Disconnect refrigerant plumbing from condenser fittings once refrigerant is 
evacuated. Always use a back-up wrench. 
C. Remove attaching hardware securing blower support mount to condenser vane axial 
blower assembly. 
D. Remove lower attaching hardware securing baffle plate assembly support tube to 
aircraft structure. 
E. While supporting condenser assembly, remove attaching hardware securing 
condenser hangar brackets on each side of condenser to existing horizontal support. 
F. Remove condenser assembly. 
 
REPLACEMENT 
 
A. Position condenser and secure with attaching hardware to hangar brackets on each 
side of condenser to existing horizontal support. 
B. Install lower attaching hardware securing baffle plate assembly support tube to 
aircraft structure. Torque support tube bolt to 20-25 in-lbs (2.25-2.82 Nm) 
C. Secure blower support mount to condenser vane axial blower assembly with 
attaching hardware. 
D. Replace all O-rings before connecting refrigerant plumbing to condenser fittings 
using a back-up wrench. Torque refrigerant line connections per section 1, p.37. 
E. Install forward inner baggage compartment panel to condenser assembly. 
F. Service air conditioning system with refrigerant per Chapter 6. 
 
 
 
11. REMOVAL & REPLACEMENT OF CONDENSER BLOWER FAN ASSEMBLY,  EC130-
202 KITS 
 
REMOVAL 
CAUTION 
It is recommended that the battery and external power be disconnected before starting work. 
 
A. Access the condenser & blower assembly through the left side baggage door. 
 
CAUTION 
Be sure to support the blower assembly when removing the attaching hardware to prevent 
damage to the condenser housing, blower assembly, or the aircraft. 
 
B. Remove safety wire that secures the (6) AN3H-3A bolts (2) two on each side that 
attach the EC130-7536-1 Blower motor & Fan assembly to the condenser scoop   
						

							 
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 
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C. assembly, and remove bolts. 
 
D. Disconnect the ES73131-1 (or -2) Blower motor & Fan assembly from the electrical 
connector. 
 
E. Cut the safety wire attached to the three (3) motor mounting bolts on the 
EC130-7536-1 Vane Axial Blower, Remove the motor mounting bolts and spacers 
holding the ES73131 Motor & fan assembly to the blower housing. 
  
CAUTION 
Be sure to support the blower fan & Motor assembly prior to removing the mounting bolts, this 
will prevent any damage to the stator vanes in-side the blower housing. 
 
CAUTION 
Do not attempt to remove the fan blade assembly from the motor. The fan blade is threaded to 
the motor armature shaft, and damage will occur if proper tooling is not available. 
 
F. Once the mounting bolts have been removed, the blower can be removed and replaced 
as required. 
 
 
REPLACEMENT  
 
A. Locate the new blower on the condenser. Use the torque chart below for the re-
installation of the blower mounting bolts. Torque each bolt in succession around the 
blower housing until all three torque’s have been achieved. 
 
Torque Chart 
 
Blower Part Number Torque Blower Mounting Bolts as Follows 
EC130-7536-1 1st Torque 2nd Torque 3rd Torque 
(motor ES73131) 30 in/lbs. 45 in/lbs. 60 in/lbs 
 
 
B. Reconnect the electrical connector. 
 
C. Apply power, and operate the Air conditioner by placing the control switch in the A/C 
position several times to insure there is no binding and for proper operation of the 
Blower motor & Fan assembly. 
 
D. Secure the left hand baggage compartment door. 
 
 
 
 
 
 
  
						

							 
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 
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12. REMOVAL, INSTALLATION / REPLACEMENT OF RECEIVER DRIER BOTTLE 
 
REMOVAL 
 
A.  Access the refrigerant plumbing to Receiver Drier Bottle. For the EC130-200 kits the 
bottle is located near the condenser assembly. For the EC130-202 kits the bottle is 
mounted to the side of the condenser assembly. 
 
B.  It will be necessary to evacuate (discharge) the refrigerant from the system to remove or 
replace the receiver drier bottle. Instructions for servicing of the system are found in 
Chapter 6 SERVICING. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
C.  Disconnect refrigerant lines from both sides of the receiver drier connection fittings. 
 
CAUTION 
Always use a back-up wrench when removing or installing refrigerant line fittings. 
 
D.  Loosen the retaining clamp holding the receiver drier bottle to the support bracket. 
 
E.  Remove the receiver drier bottle. Temporarily cap the exposed ends of the refrigerant 
lines to minimize the exposure to contaminants and moisture. 
 
 
INSTALLATION / REPLACEMENT 
 
A.  Lubricate new o-rings with refrigerant oil and install onto cleaned tube ends. Install the 
bottle and torque the tube ends and mounting clamp. 
 
NOTE 
Never reuse a receiver drier bottle, and keep new receiver drier bottles capped until just 
prior to their installation. 
 
B.  Recharge the refrigerant per the servicing instructions on pg 31 thru 37, Section 6. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
CAUTION 
Always use a back-up wrench when removing or installing refrigerant line fittings. 
  
						

							 
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13. REMOVAL, INSTALLATION / REPLACEMENT OF BINARY PRESSURE SWITCH 
 
REMOVAL 
 
A.  Access the Binary Pressure Switch located downstream from the condenser assembly 
(refer to the plumbing schematics Fig 4-17 thru -19). The switch will be located on a 
machined Y-fitting mounted to the forward bulkhead of the fuel tank bay. It is not 
necessary to discharge the refrigerant for this servicing operation. 
 
B.  Disconnect the electrical connectors from the binary pressure switch. 
 
 
C. Unscrew the switch from the Schrader valve on the Y fitting.  
 
NOTE 
Use the flats provided on the top of the switch body to rotate the switch. Do not attempt to 
tighten or loosen the pressure switch by hand. 
 
 
INSTALLATION / REPLACEMENT 
 
A. Wrap a small amount of thread sealant Teflon tape (or pipe dope) onto the threads of 
the Schrader port on the Y fitting. Install the binary pressure switch and tighten. 
 
B. Install the electrical connector onto the switch. 
 
 
 
 
14. REMOVAL, INSTALLATION/ REPLACEMENT OF BY-PASS VALVE ASSEMBLY 
 
REMOVAL 
 
A.  Access the By-pass Valve (refer to the plumbing schematics Fig 4-17 thru -19). The 
valve will be located on the forward bulkhead of the fuel tank bay, adjacent to the binary 
pressure switch. 
 
B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove or 
replace the by-pass valve. Instructions for servicing of the system are found in Chapter 
6 SERVICING.  
						

							 
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CAUTION 
Refrigerant servicing should be performed by qualified personnel only! 
 
C.  Remove the safety wire and mounting screws that attaches the support bracket to the 
valve coil assembly. 
 
D. Disconnect the electrical connector to the by-pass valve assembly. 
 
E. Disconnect the refrigerant lines from both sides of the by-pass valve assembly. 
 
CAUTION 
Always use a back-up wrench when removing or installing refrigerant line fittings. 
 
F. Remove the by-pass valve from the support bracket. 
 
INSTALLATION / REPLACEMENT 
 
A. Lubricate new o-rings with refrigerant oil and install onto cleaned tube ends. Install the 
by-pass valve and torque the tube ends and support bracket fasteners. 
 
B. Mate the electrical connector to the harness. 
 
C. Charge the system with refrigerant per instructions in Chapter 6. 
 
CAUTION 
Refrigerant servicing should be performed by qualified personnel only!  
						

							 
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 
Revision 6                                                                                                         Page 52 
CHAPTER 8 
TROUBLESHOOTING 
 
1. SYSTEM TROUBLESHOOTING 
Prior to troubleshooting a defective system, it is advisable to conduct a visual inspection for general condition, 
and obvious signs of damage or failure.  
 
The following matrix lists the easiest checks, and the most likely problems. 
 
Problem Probable Cause Solution 
System not Cooling 
(Evaporator blowers still operating) 
a. System is low or empty of 
refrigerant. 
 
a. Evacuate the system, determine 
the origin of the refrigerant leak, 
and re-charge the system as 
prescribed in chapter 6. 
 
b. Moisture, or air in the system. b. Evacuate the system, Replace 
the receiver / drier, and place 
the system under a vacuum for 
a minimum of 30 minutes before 
recharging the system. ¹ 
 
c. Compressor  c. If the compressor has failed, it 
must be replaced, as shown in 
chapter 7. ¹ 
 
d. Compressor drive belt  d. If the compressor drive belt has 
failed it will need to be replaced. 
Replace and adjust compressor 
drive belt as shown in chapter 7. 
¹ 
 
e. By-pass valve  e. Check to insure the temperature 
control knob on the A/C control 
panel in the cockpit is in the full 
cold position, and the 
temperature control circuit 
breaker has not tripped. If the 
valve remains open (by-passing 
refrigerant) the valve will need 
replacement, as shown in 
chapter 7. ¹ 
 
f. Condenser blower motor / fan 
assembly. 
       
f. Check to insure the condenser 
blower motor / fan assembly are 
receiving power, and the circuit 
breakers have not tripped. If the 
blowers still do not function, 
they may have failed internally 
and must be replaced as shown 
in chapter 7.   
 
g. Condenser Scoop Door & Scoop 
Door Actuator 
(EC130-200 Installation only) 
g. Check to insure the condenser 
scoop door is fully extended 
when the air conditioner is 
running. If the scoop door is 
closed or not fully extended the 
scoop actuator circuit breaker 
may have tripped, or the scoop 
door actuator may have failed, 
and must be replace as shown 
in chapter 7.   
System not cooling 
(Evaporator blowers not operating) 
h. Air conditioner control circuit 
breaker tripped. 
h. Reset circuit breaker. If breaker 
will not reset, check for short in 
circuit.  
						

							 
AIR CONDITIONER SERVICE MANUAL EC130-200M-1 
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Problem Probable Cause Solution 
System not cooling 
(Evaporator blowers not operating) 
i. Forward or Aft evaporator 
blower circuit breaker tripped. 
i. Reset circuit breaker. If breaker 
will not reset, check for short in 
circuit. 
System not cooling 
(Evaporator blowers not operating) 
j. Forward and aft evaporator 
blower motor(s)   
 
     
j. Check for power to the motor(s), 
and for the free movement of 
the blower wheel. If the motor 
shaft does not turn smoothly the 
motor must be replaced, as 
shown in chapter 7. ¹ 
Loss of cooling limited to one 
evaporator. 
k. Expansion valve malfunction. k. If cooling is lost in only one of 
the evaporators, and the 
blowers continue to function, it 
is most likely a blockage at the 
expansion valve orifice. This is 
most often caused by dirt in the 
system forming a blockage as 
the refrigerant passes through 
the valve. Evacuating the 
system and changing the 
receiver drier should cure this 
problem. If the above actions do 
not resolve the problem, the 
evaporator assembly should be 
returned to Air Comm 
Corporation for repair. ¹ 
External moisture (Condensate) in 
the area of forward  / aft evaporator 
l. Leak in evaporator, or 
evaporator drainage system. 
l. If water is noted in the area near 
the evaporators. This is normally 
caused by a loose, cracked, 
plugged, or disconnected drain 
line.  
NOTE 
       The drain line consists of a tube 
which extends from the lower 
surface of the evaporators 
through the outer contour of the 
helicopter. 
(1) Contact Air Comm Corporation Service Department for current pricing and availability of 
replacement components and parts.