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AirComm Corporation Airbus EC145 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual
AirComm Corporation Airbus EC145 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual
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AIR CONDITIONER SERVICE MANUAL EC145-200M-1 Revision 13 27 February, 2014 AIR COMM CORPORATION 1575 WEST 124TH AVENUE WESTMINSTER, CO 80234 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EUROCOPTER MBB-BK117-C1 & MBB-BK117-C2 (EC145) AIR CONDITIONING SYSTEM
AIR CONDITIONER SERVICE MANUAL EC145-200M-1 Revision 13 Page i THIS PAGE INTENTIONALLY LEFT BLANK
AIR CONDITIONER SERVICE MANUAL EC145-200M-1 RECORD OF REVISIONS Rev Date Description of Chan!!)e Approval 1 10-5-2006 Aft Evaporator Motor part number change NIA Prepared by GP 2 11-14-2006 Condenser mounting change & aft evap. TBO NIA change Prepared by GP 3 5-29-2007 New forward evaporator blower motor added. N/A Prepared by GP 4 6-22-2007 New HilLo pressure switch & condenser blower N/A motors. Weight & Balance revised. Prepared by GP 5 10-16-2007 EC135-8000-1 Control Panel Assy. Changed to NIA EC135-8000-3 Control Panel Assy. Prepared by RM 6 12-19-2007 Added 3rd blower configuration to aft evaporator. NIA Prepared by GP 7 3-6-2008 Added noise filters to electrical schematic NIA Prepared bv GP 8 6-11-2008 Added alternate hillo pressure switch N/A Prepared by GP 9 4-10-2009 Added part callout for Aft Evaporator Blower N/A Prepared by RM 10 Added EC145-205 configuration to distinguish 9-11-2009 between civilian and military configuration, and NIA changed aft evaporator blower part number Prepared by RM callout. 11 Added Note to Figure 3-5 for clarification. Added N/A 10-21-2011 current O-Ring part numbers and corrected Prepared by RM motor part number on Page 5-5. 12 7-17-2013 Minor ICA change to correct bolt callouts on page Prepared By: 11 Compressor Installation drawing. Updated part numbers in Chapter 5. Added new Record Karen G. Blecha (KGB) 7/24/2013 of Revisions sign off sheet. Signature Date ACC Approval: lSI Mike Knag 7/24/13 Signature Date FAA Acceptance (Major Change): N/A -Meets Minor Change Agreement MR-100-134 7/24/2013 Signature Date 13 212712014 Minor ICA change to update address, clarify (Jpared)l replacement schedule of compressor, clarify . fiu J.t;...2/;;7h4 wording of condenser blower replacement schedule. Revised to make all pages current Signature Date revision level. When any pages are updated, the entire document will be revised. 6/3/1,/ Si naturel Date FAA Acceptance (Major Change): N/A -Meets Minor Change Agreement MR-100-134 2/27/2014 Signature Date Revision 13 Page ii
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AIR CONDITIONER SERVICE MANUAL EC145-200M-1
Revision 13 Page iv
TABLE OF CONTENTS
Identification Title Page
CHAPTER 0 INTRODUCTION
1. Scope 1
2. Purpose 1
3. Arrangement 1
4. Applicability 1
5. Definitions 1
6. Abbreviations 2
7. Precautions 2
8. Units of Measurement 3
9. Information Essential to the Continued Airworthiness 3
of the Air Conditioner
10. Reference Documents 3
11. Distribution 3
12. Changes to Instructions for Continued Airworthiness 3
13. Air Conditioner Features 3
14. Description of the Vapor Cycle Air Conditioner and its Installation 5
CHAPTER 1 AIRWORTHINESS LIMITATION SECTION
1. Airworthiness Limitations 7
CHAPTER 2 INSPECTIONS
1. Inspection Requirements 8
2. Component Overhaul / Replacement Schedule 8
CHAPTER 3 LOCATION AND ACCESS
1. Location of Air Conditioner Features 9
Figure 3-1 Layout of Air Conditioner System 9
Figure 3-2 Top View - Model EC145 Fuselage 10
2. Compressor Installation Fig 3-3 11
3. Forward Evaporator Installation Fig 3-4 12
4. Aft Evaporator & Aft Evaporator Blower Assembly Installation Fig 3-5 13
5. Condenser Assembly Installation Fig 3-6 14
6. Cabin headliner / Air Distribution. Fig 3-7 15
7. Relay Panel & Circuit Breaker assy. Fig 3-8 16
8. Refrigerant Plumbing Schematic Fig 3-9 17
9. Aft Evaporator Installation. Fig 3-10 18
CHAPTER 4 PLACARDS AND MARKINGS
1. Placard and Marking Information 19
CHAPTER 5 SERVICING
1. Safety Precautions 20
2. Servicing Information 20
3. Lubrication Information 21
4. System Leak Check 22
5. Suggested Equipment for Servicing 22
6. Consumable Materials 22
7. Suggested Spares List 24
CHAPTER 6 STANDARD PRACTICES INFORMATION
1. Fitting Torqueing Procedures and Torque Value 25
2. Removal & Replacement of the Condenser Blower Motor & 26
Fan Assembly
3. Removal, Replacement & Adjustment of Compressor 27
Drive belt
AIR CONDITIONER SERVICE MANUAL EC145-200M-1
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TABLE OF CONTENTS
(Continued)
CHAPTER 6 STANDARD PRACTICES INFORMATION (CONTINUED)
Page
4. Removal, Installation / Replacement of 28
Compressor Assembly.
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5. Removal, Installation / Replacement of 30
Forward Evaporator Assembly
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6. Removal, Installation / Replacement of 32
Aft Evaporator Assembly
7. Removal, Installation / Replacement of 33
Condenser Assembly
8. Removal, Installation / Replacement of 34
Receiver Drier Bottle
9. Removal, Installation / Replacement of 34
Binary Switch
10. Removal, Installation / Replacement of 35
By-pass Valve Assembly
11. Removal, Installation / Replacement of Aft Evaporator Blower Motor 3 6
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CHAPTER 7 TROUBLESHOOTING
1. System Troubleshooting 38
Figure 7-1, General Arrangement – Air Conditioning 40
System Installation
Figure 7-2, Air Conditioning System Electrical Schematic. 41
Figure 7-3, Air Conditioning System Electrical Schematic. 42
(Relay Panel)
Figure 7-4, Refrigerant Plumbing Schematic 43
Figure 7-5, Air Conditioning System Electrical Schematic. 44
(EC145-203)
Appendix A Weight and Balance Information A-1
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AIR CONDITIONER SERVICE MANUAL EC145-200M-1 Revision 13 Page 1 CHAPTER 0 INTRODUCTION 1. SCOPE The scope of this manual encompasses the scheduled and unscheduled maintenance procedures for the continued airworthiness of the Air Comm Corporation air conditioning system installed in the Eurocopter MBB-BK117-C1 & MBB-BK117-C2 (EC145) series helicopter. 2. PURPOSE The purpose of this manual is to provide the aircraft mechanic in the field the necessary information to maintain the air conditioning system. 3. ARRANGEMENT This manual is arranged by chapters which are broken down into paragraphs and sub- paragraphs. All of the chapters and paragraphs are listed in the front of this manual in the Table of Contents, and are further identified by their individual page number. 4. APPLICABILITY This manual is applicable to Eurocopter Helicopter models MBB-BK117-C1 & MBB-BK117-C2 (EC145) that are equipped with the Air Comm Corporation kit number EC145-200, EC145-202, EC145-203, & EC145-205 air conditioner systems. 5. DEFINITIONS The following terms are provided to give a ready reference to the meaning of some of the words contained within this manual. These definitions may differ from those given by a standard dictionary. Ambient air temperature: The temperature of the air surrounding a person or object. Charging station: An air conditioning system service unit which is capable of evacuating and charging an air conditioner. Cold: The absence of heat. Condensation: The process of changing a vapor into a liquid. Desiccant: A material used in the receiver/drier bottle, designed to absorb moisture from the refrigerant. Evaporate: To change from a liquid into a vapor. Heat load: The amount of heat which the air conditioner is required to remove from the aircraft cabin. Inches of mercury: A measurement of pressure, normally used for pressures below atmospheric, one inch of mercury is equal to approximately one half pound per square inch.
AIR CONDITIONER SERVICE MANUAL EC145-200M-1 Revision 13 Page 2 CHAPTER 0 INTRODUCTION (continued) 5. DEFINITIONS (continued) Pressure, ambient: The pressure of the air surrounding a body, normally measured in Pounds Per Square inch, or PSIG. Refrigerant: A fluid which is used in an air conditioning system to absorb heat from the cabin and carry it outside the helicopter where it can be transferred to the outside air. Relative humidity: The ratio of the amount of water vapor in the air to the amount of water vapor required to saturate the air at the existing temperature. Thermostat: An air conditioning control which senses the temperature of the evaporator coil and causes the system to cycle or by-pass to maintain the proper temperature of cooling air. Vacuum: A negative pressure, or pressure below atmospheric; it is usually expressed in inches of mercury. Vapor: The gaseous state of a material. 6. ABBREVIATIONS InHg: Inches of Mercury Lbs: Pounds oz: Ounces Psig: Pounds Per Square Inch (gauge) gr: Grams kg: Kilograms Kgcm: Kilograms Per Centimeter ml: Milliliters mm: Millimeters Nm: Newton-meters 7. PRECAUTIONS The following precautions are found throughout this manual, and will vary depending on the seriousness of the Hazard or Condition: WARNING: May be a maintenance procedure, practice, condition, etc., which could result in personal injury or loss of life. CAUTION: May be a maintenance procedure, practice, condition, etc., which could result in damage or destruction of equipment. NOTE: May be a maintenance procedure, practice, condition, etc., or a statement which needs to be highlighted.
AIR CONDITIONER SERVICE MANUAL EC145-200M-1 Revision 13 Page 3 CHAPTER 0 INTRODUCTION (continued) 8. UNITS OF MEASUREMENT All measurements contained within this manual are given in the United States standard measurement, followed by the metric conversion in parentheses. 9. INFORMATION ESSENTIAL TO THE CONTINUED AIRWORTHINESS OF THE AIR CONDITIONER. This manual provides information which is required for operation and maintenance of the Air Comm air conditioning system installed in the Eurocopter model MBB-BK117-C1 & MBB-BK117- C2 (EC145) series helicopter. After completion of the air conditioner installation this document must be placed with the appropriate existing aircraft documents. 10. REFERENCE DOCUMENTS The approval basis of the system covered by this ICA is Supplemental Type Certificate SR00601DE. 11. DISTRIBUTION This document is to be placed with the aircraft maintenance records at the time of system installation. Changes will be made to this document in response to “Safety of Flight”, and or “Non-safety of Flight” issues. Any changes will result in a revision to this document. Revisions shall be noted in the Record of Revisions (page i), and on the List of Revisions (page ii) of this manual. In addition to the revision of the manual, those changes categorized as “Safety of Flight” shall have a Service Bulletin issued to the operator providing the necessary information to comply with, and or to correct, the “Safety of Flight” issue. Replacement, and or revised copies of this manual maybe purchased by contacting: Air Comm Corporation Service Department 3330 Airport Road Boulder, CO.80301 Phone No. 303-440-4075 Fax No. 303-440-6355 12. CHANGES TO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS Changes made to a line or paragraph of this document will be indicated by a vertical bar in the right hand margin, while a complete page change will be indicated by a vertical bar next to the page number. (Example: Any change will appear with a vertical bar next to that change). 13. AIR CONDITIONER FEATURES The vapor cycle air conditioner features two forward (optional single forward evaporator) mounted evaporator (cockpit), one aft mounted evaporator assembly (above the main cabin), one condenser, and a compressor driven by a belt just aft of the aft main transmission. These components combine to provide “conditioned air” through sections of the existing air distribution system when the engines are operating during both ground and flight operations.
AIR CONDITIONER SERVICE MANUAL EC145-200M-1 Revision 13 Page 4 CHAPTER 0 INTRODUCTION (continued) 13. AIR CONDITIONER FEATURES (continued) This system can be operated in either the Air Condition (A/C), or Fan mode. In the A/C mode, conditioned air is provided by the forward and aft evaporators to the cockpit and main cabin areas respectively. In the Fan mode, the evaporator blowers are used to circulate cabin air, while the compressor clutch remains disengaged. When using the cabin heater it is acceptable to operate the air conditioner if desired, to assist in defogging the cabin windows. The air conditioning system is connected electrically to the aircraft’s DC Power Panel 28 VDC Bus. The control panel for the air conditioner system is located on the existing center console between the pilot’s and co-pilot’s seats. This panel consists of the A/C & Fan switch, two switches, for the control of the Cockpit & Cabin evaporator blower fan speeds, a “FRESH” / “RECIRC” switch which opens and closes an air inlet box located above the main cabin overhead air outlets, a Temperature control rheostat knob, and compressor on annunciator. COCKPIT A/C CONTROL PANEL The Fan motors feature dual speed operation (Hi or Lo), and this feature can be used in both the air conditioner or fan modes. The compressor is mounted to the surface of the Main Rotor Gear Box, in the aft aircraft center portion of the transmission compartment. It is driven by a Ploy V-belt and a pulley which is mounted to the rotor break disk flange portion of the drive shaft. Access to the compressor is provided by transmission compartment access doors. One condenser mounted aft of the engine compartment (aircraft left). Airflow through the condenser heat exchanger is provided by two 28 volt DC high performance blowers. The aft evaporator is equipped with a Freeze Switch. The Freeze Switch probe is located in the core of the evaporator heat exchanger. This unit performs two functions; 1. It acts to prevent coil freeze-up by limiting the minimum coil temperature to 32º F (0º C), and 2. It acts in conjunction with the cabin air temperature control system, by controlling the bypass of refrigerant through the evaporator coil in response to adjustment of the thermostat switch located on the control panel assy. between the pilot and co-pilots seats.