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AirComm Corporation Bell 429 Air Conditioning 429EC200M1Rev9 User Manual
AirComm Corporation Bell 429 Air Conditioning 429EC200M1Rev9 User Manual
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AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 July 15, 2015 AIR COMM CORPORATION 1575 W. 124th Avenue WESTMINSTER, CO. 80234 PHONE: 303-440-4075 FAX: 303-440-6355 [email protected] INSTRUCTIONS FOR CONTINUED AIRWORTHINESS BELL HELICOPTER 429 AIR CONDITIONING SYSTEM
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page ii THIS PAGE INTENTIONALLY LEFT BLANK
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page iii RECORD OF REVISIONS Rev Date Description of Change Approval 0 4/27/2009 Original Issue N/A Prepared by RM 1 9/8/2009 Inspection and Provision kit N/A Prepared by RM 2 10/28/2009 Single fwd & aft evaporator configuration N/A Prepared by GP 3 9/21/2010 New fwd & aft evaporator motor part numbers N/A Prepared by MS 4 3/21/2011 Aft evaporator drain design change. N/A Prepared by KP 5 8/15/2013 Minor ICA change to clarify refrigerant oil requirements, updated revisions history page, added specific installation / replacement instructions, and updated formatting and corrected typographical errors (revision bars were omitted for formatting and typographical or spelling and grammar updates). Prepared By: Karen G. Blecha (KGB) 8/28/2013 Signature Date ACC Approval: /S/ Mike J. Knap 9/6/13 Signature Date FAA Acceptance (Major Change): N/A – Meets Minor Change Agreement MR-100-134 8/28/2013 Signature Date 6 9/16/2013 Updated to include design change to upgrade condenser blower. Add new configurations throughout. Added weight and balance information. Prepared By: Karen G. Blecha (KGB) 9/16/2013 Signature Date ACC Approval: /S/ M. J. Knap 9/19/13 Signature Date FAA Acceptance (Major Change): /S/ J. E. Cox 11/6/13 Signature Date 7 12/3/2014 Pg 28,29: corrected p/n in label, Pg 22 thru 29: added kit p/n’s, Pg 58-64: re-titled figures for clarity. Prepared By: J Byrnes 12/3/2014 Signature Date ACC Approval: ___MJK_____ 12/10/2014 Signature Date FAA Acceptance (Major Change): /S/ J.E. Cox 1/14/2015 Signature Date
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page v LIST OF EFFECTIVE PAGES LIST OF REVISIONS Revision 0 (Original Issue)........................................................................... April 27, 2009 Revision 1 (Inspection or Provisions kit) .............................................. September 8, 2009 Revision 2 (Single fwd. & aft evaporator configuration) .......................... October 28, 2009 Revision 3 (New fwd & aft evaporator motor part numbers) ............... September 21, 2010 Revision 4 (Aft Evap Drain Design Change) ............................................. March 21, 2011 Revision 5 (Lubrication Information Update and reformat) ....................... August 28, 2013 Revision 6 (Upgraded Condenser Blower) ......................................... September 16, 2013 Revision 7 (General updates & format changes)………..………………December 3, 2014 Revision 8 (Ref. Relay panel wire updates)……………………..……….February 26, 2015 LIST OF EFFECTIVE PAGES Title Page(s) Revision No. Title Page i 9 Page ii Intentionally Left Blank ii 9 Record of Revisions iii 9 List of effective Pages v 9 Page vi Intentionally Left Blank vi 9 Table of Contents vii to viii 9 Chapter 1 Introduction 1 to 6 9 Chapter 2 Airworthiness Limitation Section 7 9 Page 8 Intentionally Left Blank 8 9 Chapter 3 Inspections 9 to 12 9 Chapter 4 Location and Access 13 to 33 9 Chapter 5 Placards and Markings 34 9 Page 28 Intentionally Left Blank 35 9 Chapter 6 Servicing 36 to 42 9 Page 36 Intentionally Left Blank 43 9 Chapter 7 Standard Practices 44 to 55 9 Chapter 8 Troubleshooting 56 to 66 9 Appendix A Weight and Balance information 67-70 9
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AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page vii TABLE OF CONTENTS Chapter Page CHAPTER 1 .................................................................................................................... 1 INTRODUCTION ......................................................................................................... 1 1. Scope .............................................................................................................. 1 2. Purpose .......................................................................................................... 1 3. Arrangement ................................................................................................... 1 4. Applicability ..................................................................................................... 1 5. Definitions ....................................................................................................... 1 6. Abbreviations .................................................................................................. 2 7. Precautions ..................................................................................................... 2 8. Units of Measure ............................................................................................. 2 9. Information Essential to Continued Airworthiness ........................................... 2 10. Reference Documents .................................................................................... 2 11. Distribution ...................................................................................................... 2 12. Changes to Instructions for Continued Airworthiness ..................................... 3 13. Air Conditioner Features ................................................................................. 3 14. Description of Vapor Cycle Air Conditioner and Installation ............................ 5 15. Refrigeration Cycle Illustration ........................................................................ 6 CHAPTER 2 .................................................................................................................... 7 AIRWORTHINESS LIMITATION SECTION ................................................................ 7 1. Airworthiness Limitations ................................................................................ 7 CHAPTER 3 .................................................................................................................... 8 INSPECTIONS AND OVERHAUL ............................................................................... 8 1. Inspection Requirements ................................................................................ 8 2. Inspection Procedures .................................................................................... 9 3. Component Overhaul / Replacement Schedule ............................................ 12 CHAPTER 4 .................................................................................................................. 13 LOCATION AND ACCESS ........................................................................................ 13 1. Location of Air Conditioner Components ...................................................... 13 CHAPTER 5 .................................................................................................................. 34 PLACARDS AND MARKINGS ................................................................................... 34 1. Placard and Marking Information .................................................................. 34 CHAPTER 6 .................................................................................................................. 35
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page viii SERVICING ............................................................................................................... 35 1. Safety Precautions ........................................................................................ 35 2. Servicing Information .................................................................................... 35 3. Lubrication Information ................................................................................. 41 4. System Leak Check ...................................................................................... 43 5. Suggested Equipment for Servicing .............................................................. 43 6. Consumable Materials .................................................................................. 44 7. Suggested Spares List .................................................................................. 44 CHAPTER 7 .................................................................................................................. 46 STANDARD PRACTICES AND INFORMATION ....................................................... 46 1. Fitting Torque Procedures and Values .......................................................... 46 2. Removal and Replacement of Forward Evaporator Blower Motor Assembly 47 3. Removal and Replacement of Forward Evaporator Assembly ...................... 48 4. Removal, Replacement and Adjustment of Compressor Drive Belt .............. 49 5. Removal and Replacement of Compressor Assembly .................................. 51 6. Removal and Replacement of Aft Evaporator Assembly .............................. 52 7. Removal and Replacement of Condenser Assembly .................................... 53 8. Removal and Replacement of Condenser Blower Assembly ........................ 55 9. Removal and Replacement of Receiver Drier ............................................... 55 10. Removal and Replacement of Bypass Valve ................................................ 56 11. Removal and Replacement of Binary Switch ................................................ 57 CHAPTER 8 .................................................................................................................. 59 TROUBLESHOOTING ............................................................................................... 59 1. System Troubleshooting ............................................................................... 59 2. System Schematics ...................................................................................... 60 APPENDIX A ................................................................................................................. 72 WEIGHT AND BALANCE INFORMATION ................................................................ 72
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 1 CHAPTER 1 INTRODUCTION 1. Scope The scope of this manual encompasses scheduled and unscheduled maintenance procedures for continued airworthiness of Air Comm Corporation air conditioning system installed in Bell 429 series helicopter. 2. Purpose The purpose of this manual is to provide aircraft field mechanic 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 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 Bell Helicopter model 429 equipped with Air Comm Corporation kit number 429EC-200, 429EC-202, 429EC-204, and 429EC-206 air conditioner system. 5. Definitions The following terms are provided to give a ready reference to the meaning of some words contained within this manual. These definitions may differ from those given by a standard dictionary. A. Ambient air temperature: Temperature of the air surrounding a person or object. B. Charging station: An air conditioning system service unit which is capable of evacuating and charging an air conditioner. C. Cold: The absence of heat. D. Condensation: The process of changing a gaseous phase into a liquid. E. Desiccant: Material used in a receiver/drier bottle, designed to absorb moisture from refrigerant. F. Evaporate: To change from a liquid into a vapor. G. Heat load: The amount of heat which the air conditioner is required to remove from the aircraft cabin. H. 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. I. Pressure, ambient: The pressure of the air surrounding a body, normally measured in pounds per square inch, or PSIG. J. 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. K. 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. L. 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
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 2 temperature of cooling air. M. Vacuum: A negative pressure, or pressure below atmospheric; it is usually expressed in inches of mercury. N. Vapor: The gas formed by boiling or evaporating a liquid. A gas at a temperature below its critical temperature. 6. Abbreviations InHg: Inches of Mercury Lbs: Pounds oz: Ounces Psig: Pounds Per Square Inch (gauge) gr: Grams kg: Kilograms Kg/cm: 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. 8. Units of Measure All measurements contained within this manual are given in United States standard measurement, followed by metric conversion in parentheses. 9. Information Essential to Continued Airworthiness This manual provides information which is required for operation and maintenance of the Air Comm air conditioning system installed in Bell model 429 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 SR00693DE. 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 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 and on the List of Revisions of this manual.