AirComm Corporation Airbus EC145 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 15 
 
CHAPTER 3 
LOCATION AND ACCESS (continued) 
 
6.  Cabin Headliner / Air Distribution. Fig 3-7 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(Kit S/N 001 thru 014) 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 16 
 
CHAPTER 3 
LOCATION AND ACCESS (continued) 
 
7.  Relay Panel & Circuit Breaker Assembly  Fig 3-8 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 17 
CHAPTER 3 
LOCATION AND ACCESS (continued) 
 
8.  Refrigerant Plumbing Schematic Fig 3-9 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 18 
 
CHAPTER 3 
LOCATIONS AND ACCESS 
 
9.  Aft Evaporator Installation Fig 3-10 
 
 
 
 
 
 
 
 
 
 
 
 
 
Cut and paste 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Aft Evaporator with 3rd Blower Motor Configuration 
(S/N 015 and Subsequent  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 19 
 
CHAPTER 4 
PLACARDS AND MARKINGS 
 
1.  PLACARD AND MARKING INFORMATION 
 
System Charging Instruction Placard 
 
 
 
 
 
 
SYSTEM CHARGING INSTRUCTIONS 
SYSTEM TO BE SERVICED BY QUALIFIED PERSONNEL 
 
R134a Refrigerant- Polyester oil-XH9 Desiccant 
System charge 4.5 lbs                                                                                                                                      
If exact weight of refrigerant charge is not known, 
use following procedure: 
     º Charge system in .25 LB increments until minimum outlet 
        temperature & system suction pressure is achieved. 
     º Allow several minutes after each charge increment, to 
       allow temperature & pressure to stabilize. 
NOTE: Refrigerant over charge or operation of the AC during low 
            Ambient temperature may cause tail rotor pedal feedback. 
AIR COMM CORPORATION 
BOULDER, COLORADO 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
This area intentionally left blank 
 
 
 
 
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 20 
 
CHAPTER 5 
SERVICING 
1.  SAFETY PRECAUTIONS 
 
CAUTION 
Refrigeration servicing should be performed by qualified personnel only! 
 
The refrigerant used in the air conditioning system is the environmentally safe HFC R134a. 
This refrigerant is non-explosive, non-flammable, non-corrosive, has practically no odor, and 
is heavier than air. Although R134a is classified as a safe refrigerant, certain precautions 
must be observed to protect the parts involved, and the person working on the system. 
 
Liquid R134a at normal atmospheric pressure and temperature evaporates so quickly that it 
tends to freeze anything that it contacts. Care must be taken to prevent any refrigerant from 
coming into contact with the skin, especially the eyes! 
 
WARNING 
Always wear safety goggles when servicing any part of the refrigerant system. Should any 
liquid refrigerant contact the skin or eyes, seek medical attention immediately even if the 
irritation ceases. 
 
WARNING 
Never weld, use a flame-type leak detector, blow torch, solder, steam clean, bake on aircraft 
finish, or use excess amounts of heat on, or in the immediate area of refrigerant supply tank. 
 
2.  SERVICING INFORMATION 
 
A.  This system should be serviced by QUALIFIED PERSONNEL ONLY! 
 
B.  A  list  of  suggested  servicing  equipment  is  provided  later  in  this  chapter  (Page  5-4, 
Paragraph 5). 
 
C.  Connect  the  service  manifold  and  vacuum pump  to  the  service  ports  located  in  the 
upper aft right hand corner of the baggage compartment. 
 
D.  Turn  on  the  vacuum  pump  and  open  both  valves  to  evacuate  the  system.  When  the 
pressure drops to 29.40 InHg (1.9 KgCm) moisture vaporizes and is drawn out of the 
system  by  the  vacuum  pump.  Complete  removal  of  moisture  is  important  to  prevent 
blockage of the expansion valves with ice. Leak check the system as described later 
in this chapter. 
NOTE 
Due to the drop in atmospheric pressure with an increase in altitude, the normal vacuum 
reading will drop approximately 1” InHg (1 KgCm) for each 1000 ft. (304.8 m) of 
altitude. 
 
E.  After the system has been evacuated, turn off both manifold valves, and then turn 
the vacuum pump off. Allow a minimum of one hour to check for vacuum leaks (if the 
system will not hold a vacuum, the system has a fitting leak). It may be necessary to 
charge the system with one or two lbs (.45 to .86 Kg.) of refrigerant and conduct a 
leak check survey using an electronic leak detector.  
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 21 
 
CHAPTER 5 
SERVICING (continued) 
 
2. SERVICING INFORMATION (Continued) 
CAUTION 
IT IS MANDATORY THAT THE SYSTEM BE LEAK FREE TO INSURE TROUBLE FREE 
OPERATION. CONTINUOUS OPERATION OF THE SYSTEM WITH INSUFFICIENT CHARGE WILL 
RESULT IN REDUCED COMPRESSOR LIFE. 
 
F.  After the system is proven to be leak free, the system should be evacuated for a minimum of 
½ hour before being charged with HFC R134a. 
 
G.  Charging the system with 4.5 lbs. (2.04 Kg.) Single forward evaporator of R134a refrigerant, 
is the most accurate method of charging. This should be accomplished using the suggested 
servicing equipment called out in this chapter. 
 
H.  If a charging station is unavailable, the following procedure should be followed. Add an initial 
refrigerant charge of 2.0 lbs (0.9 Kg.) then continue to add refrigerant until the evaporator 
outlet air temperature and system suction pressures reach a minimum. When adding the 
refrigerant after the initial charge, it should be done in increments of 0.2 lbs (.09 Kg.) and two 
minutes allowed to elapse before adding each additional 0.2 lbs. (.09 Kg.) refrigerant charge. 
The optimum charge occurs when evaporator outlet temperatures are at their lowest. Any 
additional refrigerant will cause the outlet air temperature to increase and system 
performance to be degraded.  
 
 
WARNING 
If the system is to be charged by operating the compressor it must be charged through the Lo  
(Blue fitting) pressure (suction) port ONLY!! 
Never open the Hi (Red fitting) pressure (discharge) valve while the system is operating!! 
 
I.  Test run the system after charging, to confirm the system is working properly. 
 
CAUTION 
When reclaiming refrigerant, be sure to note any oil that is removed from the system, and replace the 
lost oil before or during re-servicing. Reduced compressor life will result if the total system oil charge 
is not maintained. 
 
SYSTEM REFRIGERANT & OIL CHARGE 
System Description  Refrigerant Charge  Oil Charge 
EC145 Air Conditioner system 
Single fwd Evaporator 
4.3 lbs.  1.95 kg.  7.5 fl oz.  222.7 ml. 
EC145 Air Conditioner system 
Dual fwd Evaporator 
4.5 lbs.  2.04 kg.  7.5 fl oz.   222.7 ml. 
 
3.  LUBRICATION INFORMATION 
 
The total system oil charge is 7.5 floz. (222.7 ml.) of R134a Polyester Refrigerant Oil. The 
compressor is charged with 3.5 fl oz (103.9 ml.) of oil at the factory, an additional 4.0 floz. (118.8 ml.) 
of oil must be added at the time of the system installation. This oil should be added to the compressor 
discharge line prior to system charging. 
 
If oil is spilled during installation / maintenance, or is lost due to a leak in the system, it is necessary 
to approximate the amount of lost oil and add this amount to the system. 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 22 
 
CHAPTER 5 
SERVICING (continued) 
 
3. LUBRICATION INFORMATION (continued) 
 
The oil charge is continuously circulated by the refrigerant during the operation of the system. A 
quantity of oil is trapped by the compressor.  
 
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 Polyester Based Refrigerant Oil. The use of Polyalkylene glycol 
(PAG), or Mineral Oil in this system will cause damage to the air conditioner compressor 
and expansion valves. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 23 
 
CHAPTER 5 
SERVICING (continued) 
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. 
 
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 is to be serviced with R134a compatible Polyester Refrigerant Oil. 
(Do not use Polyalkylene glycol (PAG), or Mineral Oil in this system). 
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL EC145-200M-1 
 
Revision 13  Page 24 
 
CHAPTER 5 
SERVICING (continued) 
 
6. CONSUMABLE MATERIALS (continued) 
 
O-rings: 
 
As this system is charged with R134a refrigerant, it must be fitted with Highly Saturated Nitrates 
(HSN) O-rings. This system incorporates HSN O-ring for the Insert fittings that are GREEN in 
color and HSN O-rings for the Tork-Lok fittings that are Black in color. 
 
7.  SUGGESTED SPARES LIST 
 
Item                Part Number 
 
Blower Motor – Aft Evaporator          S-6222EC-2 
                 S-6220EC-1 (ALT) 
 
Blower Motor – Forward Evaporator         ES61064-1 
 
Compressor Assembly            EC145-3006-1   
 
Compressor Drive Belt             ES35145-1 
 
Receiver / Drier Bottle            ES43030-6   
 
Binary Switch              ES57178-1 
 
By-pass Valve              ES26194-24 
 
Condenser Blower replacement (Standard)        ES73186-4 
 
Condenser Blower replacement (High output)      ES73192-3 
 
 
 
HSN O-rings; Insert type (Green)           
Size  
#6 O-ring                ES44010-2 (WAS 440-840)   
#8 O-ring                ES44010-3 (WAS 440-841)   
#10 O-ring                ES44010-4 (WAS 440-842) 
 
HSN O-rings; Torq-Lok Type (Black) 
Size 
#6 O-ring                ES44012-2 (WAS 2-012-N1173) 
#8 O-ring                ES44012-3 (WAS 2-014-N1173) 
#10 O-ring                ES44012-4 (WAS 2-016-N1173)