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AirComm Corporation Bell Air Conditioner 206L L1 L3 Instrudtion for Continued Airworthiness TORQLOK Plumbing User Manual

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    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 25 
     
    Liquid R134a at normal atmospheric pressure and temperature evaporates so 
    quickly that it will freeze anything that it contacts. Care must be taken to prevent 
    any liquid refrigerant from coming in contact with the skin, especially the eyes. 
    R134a is readily absorbed by most types of oil, therefore it is recommended a 
    bottle of clean mineral oil and weak solution of boric acid be kept nearby when 
    servicing the refrigerant system. 
     
    CAUTION 
    Always wear safety goggles when servicing any part of the refrigerant system. Should any 
    liquid refrigerant get into the eyes, use a few drops of mineral oil to wash them out, then 
    use a weak solution of boric acid to wash eyes, and seek aid from a doctor immediately 
    even though the irritation has ceased. 
     
    It is important to keep the system tightly sealed because the refrigerant 
    system is always under pressure. Heat applied to any part of the 
    system will cause the pressure to build up excessively. 
     
    CAUTION 
    To avoid explosion, never weld, use a flame-type leak detector, blow torch, solder, stem 
    clean, bake on aircraft finish, or use excess amounts of heat on, or in the immediate area 
    of any part of the air conditioning system or refrigerant supply tank, while they are closed 
    to the atmosphere. 
     
    4. TOOLS, EQUIPMENT, AND CONSUMABLES 
    A. Service Equipment: (Suggested) 
    Recovery / Recycling / Recharging Station. 
    Robinair Model 34700 or Equivalent 
    Montpelier, OH 
    1-800-822-5561 
    B. Electronic Leak Detector: (Suggested) 
    Micron – Tech III or Equivalent 
    Model 209907 
    Murray (NAPA) 
    C. O-ring:  
    CAUTION 
    This system is charged with R134a Refrigerant and must be fitted with 
    HSN O-rings (green in color).  
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 26 
     
    D. Lubricant 
     CAUTION  
    This system may be serviced with either Polyolester (POE) or Double End Capped 
    Polyalkylene Glycol (DEC PAG).  Polyalkylene Glycol is preferred due to its superior 
    lubricating properties and improved compressor service life.  There are several types of 
    PAG available. Only the “Double End Capped” type is permissible in Air Comm 
    Corporation air conditioning systems.  Double End Capped PAG oil is available from Air 
    Comm Corporation in 8 ounce bottles (P/N ES94006-13).  Mixing of POE and PAG is 
    acceptable.  Disregard previous statements to the contrary. They referenced PAG oil that 
    was not “Double End Capped”.  Current versions of compressors are designed to be 
    operated using PAG oil.  Testing by Air Comm Corporation has shown that “Double End 
    Capped” PAG is compatible with POE and can therefore be mixed. “Double End 
    Capped” is a reference to the chemical structure of the molecule and not to the container. 
     
    Do not use Mineral oil in this system with R134a refrigerant. Do not use any 
    refrigerant oil other than Double End Capped Polyalkylene Glycol (also known as 
    “ULTRA PAG”) or Polyolester (also POE). 
     
    Containers of DEC PAG or POE will absorb moisture if left open (hygroscopic). Keep 
    containers tightly capped when not in use and keep all system components capped while 
    servicing system. 
     
    The quantity of lubrication in the system is critical. If too little lubrication is in the system 
    the compressor life may be reduced. No other component in the A/C system requires 
    lubrication. Too much lubricant in the system will retard heat transfer in the evaporator and 
    condenser coils and reduce the cooling capacity of the system.  
     
    The  following  chart  may  be  used  to  calculate  the  amount  of  oil  to  be  added  in  case  a 
    component is being replaced with a new part.  
     
    Component Oil Amount 
    Compressor See Instructions  
    Evaporator 1.0 oz. per evaporator 
    Condenser 1.5 oz. 
    Receiver Drier 1.5 oz. 
    Hose - Vapor 1.0 oz. per 10 foot 
    Hose – Liquid 1.0 oz. per 20 foot 
     
    E. Refrigerant:   DuPont HFC R134a 
     
    SYSTEM REFRIGERANT & OIL CHARGE 
    System Description Refrigerant Charge Oil Charge 
    206EC-206  Air  Conditioner 
    system, Single FWD evap 
    2.4 lbs. 1.1 kg. 8.0 fl oz. 238 ml. 
    206EC-206  Air  Conditioner 
    system, Dual FWD evap 
    2.6 lbs. 1.2 kg. 8.0 fl oz. 238 ml.  
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 27 
     
    CHAPTER 7  
    STANDARD PRACTICES 
     
    1. O-RING TYPE FITTINGS 
    Shown below are the TORQ LOK® type fittings on the left and the insert O ring type 
    fittings on the right.  These two types of fittings are used throughout the refrigerant 
    plumbing system.  When connecting either type of fittings always lubricate the O-Rings 
    with refrigerant oil before installing.  Slide B-Nut back from end of tubing and inspect 
    formed end of tube for defects.  Confirm there are no nicks or debris on connection.  
    Engage male end into female fitting being careful to maintain alignment and not pinch the 
    O-Ring during this step.  Hold fitting together while sliding the B-nut forward and engage 
    threads.  Tighten B-nut to the following torque specifications.  Always use a backup 
    wrench while tightening the B-nut. 
     
    NOTE 
     
    TORQ LOK® fittings always use ES44012-(x) O-Rings 
    and Insert O-Rings are ES44010-(x). 
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
    a. TORQ LOK® Fittings: Must be hand snug (metal to metal) and then add an additional 30 
    degrees (one half flat). 
    b. Insert O-Ring Fittings: Must be hand snug against O-ring, and then an additional 60 
    degrees (one flat). 
     
    CAUTION: 
    Excessive torque will damage fitting. 
    TORQ LOK® Insert O-ring 
    ES44012-(x) 
    O-Ring 
    ES44010-(x) 
    O-Ring ES44012-(x)O-Ring
    ES44010-(x)O-Ring  
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 28 
     
    2. SYSTEM LEAK CHECK. 
    Identification and elimination of any system fitting leaks is extremely important to ensure a 
    trouble free system.  A system that contains a partial charge can be leak tested and 
    recharged without evacuating the system.  The system can be pressurized with nitrogen 
    or R134a refrigerant.  A system which has been evacuated should be filled to a pressure 
    of at least 50 psig of refrigerant or 150 psig nitrogen prior to the leak survey (See 
    CHAPTER 8). 
     
    3. TORQUE SEAL. 
    Once system is charged, check each fitting with an electronic leak detector.  Once fittings 
    have been checked and are leak free, torque Seal as appropriate. 
     
    4. INSTALLATION  &  REPLACEMENT  OF  THE  WIRE  HARNESS  ELECTRICAL 
    CONNECTORS FOR THE EVAPORATOR AND CONDENSER BLOWERS 
    To avoid potentially serious overheating issues the Molex style connectors (identified by 
    their white plastic housing) installed on the aircraft harness for connecting to the evaporator 
    and condenser blowers for kits prior to 2015 must be installed per ACC procedure PPP23 
    and only using the appropriate terminal crimp tool. This document is available on the ACC 
    website www.aircommcorp.com/customer-support/service-manuals. 
     
      
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 29 
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
    Figure 10:  Air Conditioning System 
    Component General Arrangement HH
    GG
    FF
    E
    D
    E
    D
    Section B-B
    Section A-A
    CC
    BB
    AA  
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 30 
     
    5. REMOVE AND REPLACE COMPRESSOR (Figure 11) 
     
    5.1 REMOVE COMPRESSOR  
    a. Recover refrigerant using Robinair Model 34700 or equivalent. 
    Recover/Recycling/Recharge Station. 
    b. Remove Suction and Pressure hoses from Compressor. 
    c. Install caps and plugs over outlets and hoses.   
    d. Remove safety wire from belt S-3018EC-7 Link turnbarrel.  
    e. Remove inboard AN4 bolt from S-3018EC-7 Link. 
    f. Remove AN6H34A bolt and washer from Compressor mount. 
    g. Remove Compressor, then remove AN4H3A bolt and S-3001EC-12 rod. 
    h. Retain S-3001EC-12 rod and all hardware for installation. 
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
    Figure 11:  Compressor – View D-D S-3018EC-7 Link
    S-3001EC-12 Rod
    AN4H10A Bolt
    NAS1149F0432P Washer
    AN4H3A Bolt
    NAS1149F0432P Washer
    AN4H6A Bolt
    Pressure Line
    ES44010-2 O-Ring
    Suction Line
    ES44010-4 O-Ring
    .50 Dist from belt
    to belt guard
    S-3501EC-5 Sleeve
    AN6H34A Bolt
    AN960-616 Washer
    S-3008EC-6 
    Compressor  
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 31 
     
    5.2 REPLACE COMPRESSOR 
    a. Install S-3001EC-12 rod, AN4H3A bolt and NAS1149F0432P washer. 
    b. Install belt S-3018EC-7 Link on end of S-3001EC-12 rod and safety both bolts. 
    c. Install inboard bolt through S-3018EC-7 Link and collar. 
    d. Replace drive belt with new belt. 
    e. Adjust belt tension per Figure 2. 
    f. Safety all drilled head bolts and the S-3018EC-7 Link. 
    g. Replace the ES44010-2 and -4 O-Rings in hose fittings and install hoses per  
    instructions on pg. 27. 
    h. Service  with  R134a  refrigerant  per CHAPTER 6. 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.  Add  ½  oz.  to the 
    total  measured  to  account  for  unrecoverable  oil  in  the  old  compressor.  This  total  is 
    what  is  needed  in  the  new  compressor.  New  compressors  come  from  Air  Comm 
    charged  with  8  oz.  (240  cc) 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 for illustration: 
     
    Evacuating  the  system  recovers 1.5 oz.  of  oil.  Draining  the  old  compressor 
    recovered  2.0  oz.  of  oil.  Adding  0.5  oz.  of  residual  unrecoverable  oil  in the 
    compressor gives  2.5  oz.  The  new  receiver/drier requires  an  additional 1.5  oz.,  plus 
    1.5  oz.  lost  when  the  refrigerant  was  evacuated  from  the  system.  So  the  total  oil 
    needed  in  the  replacement  compressor  for  this  case  is  5.5  oz.  Since  the  new 
    compressor comes with 8 oz. of oil, remove the oil fill plug and pour out 2.5 oz. of oil.  
    Torque compressor oil fill cap to 132-216 in-lb. 
     
    6. REMOVE AND REPLACE COMPRESSOR DRIVE BELT (Figure 12). 
     
    6.1 REMOVE COMPRESSOR DRIVE BELT 
    a. To remove the compressor drive belt it is necessary to remove the tail rotor drive shaft 
    segment between the engine gearbox and the air conditioner drive pulley. (see BHT 
    Service Manual). 
    b. Remove safety wire from belt S-3018EC-7 Link turnbarrel.  
    c. Loosen jam nuts on both ends of turn barrel. 
    d. Rotate turn barrel to loosen drive belt. 
    e. Remove outboard AN4H3A bolt from S-3018EC-7 Link. 
    f. Pivot compressor inboard, then remove drive belt.  
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 32 
     
    6.2 REPLACE COMPRESSOR DRIVE BELT 
    g. Install new drive belt over drive pulley and compressor pulley then reinstall tail rotor 
    drive shaft. 
    h. Ensure that all of the washers are installed correctly.  Torque all coupling nuts to 150-
    180 In-lbs. 
    i. Reinstall tension link to S-8001EC-12 rod and safety lock wire bolt. 
    j. Rotate turn barrel to tighten drive belt. 
    k. Proper belt tension in important to ensure a long belt service life and to avoid 
    excessive side load on the tailrotor driveshaft bearing. 
    l. For proper belt tension add a 3 lb. force at a point mid-way between both pulleys. 
    Tension is correct when the belt deflects 0.1 inch. 
    m. Tighten jam nuts against turn barrel.   Safety lock wire turn barrel. 
     
     
    CAUTION 
     
    RESET BELT TENSION AFTER TWO HOURS OF 
    OPERATION OF NEW BELT.  
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 33 
     
     
     
     
     
     
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    Figure 
    12
    :  Compressor Drive Belt 
    – View H
    -H 
    (7265 ALT)
     Max Pulley Shesveoffset is ±.08
    206-040-320 Shaft Assy Ref
    S-3520EC-1 Drive PulleyS-3016EC-1 Belt Guard7270 BeltAft Firewall (Ref)
    4X AN174-6A Bolt
    32721-1 Disc Assy
    Existing
    3X 206-040-340-329-1 
    Washer  
    206-040-325 Shaft Assy  
    Ref
    AN320-6 Nut
    AN380-3-3 Cotter KeyTorque to 40-60 in lbs
    NAS1149F0663P & NAS1149F0632P
    Washer A/R
    S-3014EC-10 Plug
    192.3Sta±2° Max
    S-3014EC-1 Bolt Assy
    .305 Max. Between SplineAdapter & Oil Cooler Shaft  
    						
    							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
     
    Revision G   Page 34 
     
    7. REMOVE AND REPLACE COMPRESSOR DRIVE PULLEY (Figure 12) 
     
    7.1 REMOVE COMPRESSOR DRIVE PULLEY 
    a. Remove compressor drive belt per section 6 (Above).  Retain all hardware and disc.      
    (Page 30). 
    b. Remove cotter pin from fwd end of S-3014EC-1 bolt assembly and remove AN320-6 
    nut. 
    c. Remove drive pulley from 206-040-320 shaft assembly. 
     
    7.2 REPLACE COMPRESSOR DRIVE PULLEY 
    a. Apply anti seize lubricant to inside spline of drive pulley and install on 206-040-320 
    shaft assembly. 
    b. Torque AN320-6 nut to 40-60 in/lbs and install new AN380-3-3 cotter key. 
    c. Re-install belt per section 6.  (Page 31). 
      
    8. REMOVE AND REPLACE FORWARD EVAPORATOR (Figure 13) 
     
    8.1 REMOVE FORWARD EVAPORATOR 
    a. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station 
    or equivalent. 
    b. Remove instrument side panel just aft of evaporator. 
    c. Remove suction and pressure hoses from evaporator. 
    d. Install caps and plugs over outlets and hoses.   
    e. Disconnect electrical connector. 
    f. Disconnect air outlet duct from evaporator. 
    g. Remove and retain evaporator mounting hardware. 
    h. Remove evaporator. 
     
    8.2 REPLACING FWD EVAPORATOR 
    a. Re-install the evaporator and its mounting hardware. 
    b. Reconnect air outlet duct to evaporator. 
    c. Reconnect electrical connectors. 
    d. Remove caps and plugs over outlets and hoses. 
    e. Replace the ES44012-2 and -4 O-Rings in hose fittings and install hoses per 
    instructions on pg. 27. 
    f. Reconnect suction and pressure hoses to evaporator. 
    g. Re-install instrument side panel just aft of evaporators. 
    h. Service with R134a refrigerant per CHAPTER 6.  
    						
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