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