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

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 35 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
9. REMOVE AND REPLACE AFT EVAPORATOR (Figure 14) 
 
9.1 REMOVE AFT EVAPORATOR 
a. Remove plastic Hat Rack from aft end of cabin. 
b. Open baggage door and remove oval ceiling panel. 
c. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station 
or equivalent. 
d. Remove Suction and Pressure hoses from evaporator. 
e. Install caps and plugs over outlets and hoses.   
f. Disconnect electrical connector. 
g. Disconnect air inlet and outlet ducts from evaporator. 
h. Remove and retain evaporator mounting hardware. 
i. Remove evaporator. 
 
9.2 REPLACING AFT EVAPORATOR 
a. Reinstall the evaporator and mounting hardware. 
b. Reconnect air inlet and outlet ducts to evaporator. 
c. Reconnect electrical connectors. 
d. Remove caps and plugs over outlets and hoses. 
e. Reconnect suction and pressure hoses to evaporator. 
f. Replace the ES44012-2 and -4 O-Rings in hose fittings and install hoses per 
instructions on pg. 27. 
g. Service with R134a refrigerant per CHAPTER 6. 
h. Reinstall oval ceiling panel in baggage compartment. 
i. Reinstall plastic hat rack in aft end of cabin. 
Figure 13:  Forward Evaporator - View G-G S-6106EC-1 Evaporator
Air Outlet Ducting
5X AN525-10R12 Screw
5X NAS1149F0332P Washers
Drain Tube  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 36 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
10. REMOVE AND REPLACE AFT EVAPORATOR BLOWER (Figure 14) 
 
10.1 REMOVE AFT EVAPORATOR BLOWER 
a. Open baggage door and remove oval ceiling panel. 
b. Disconnect electrical connector on blower. 
c. Remove all three flex ducts from blower housing and adapter. 
d. Remove AN525-10R8 screws that support blower. 
e. Remove blower through access panel opening in baggage compartment ceiling. 
 
10.2 REPLACING AFT EVAPORATOR BLOWER 
a. Open baggage door and remove oval ceiling panel. 
b. Install blower through access panel opening in baggage compartment ceiling. 
c. Install all three flex ducts to blower housing and adapter using CT21 cable ties. 
d. Install 6 ea. AN525-10R8 screws that support blower. 
e. Connect electrical connector on blower. 
f. Test blower to ensure blower wheel does not rub and turns the right direction. 
Figure 14:  Evaporator Blower - VIEW E-E CT21 Tywrap
Evaporator
BlowerAft Evaporator
4X AN525-10R8 Screw4X NAS1149F0332P Washer        
No. 52 Clamp
6X AN525-10R8 Screw6X NAS1149F0332P Washer          
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 37 
 
11. REMOVE  AND  REPLACE CONDENSER  BLOWER  ASSEMBLY  (Figure 15 and 
Figure 16). 
 
11.1 REMOVE CONDENSER BLOWER ASSEMBLY 
a. Deactivate air conditioner circuit breaker on overhead circuit breaker panel. 
b. Working under aircraft beneath baggage compartment floor, remove 13ea AN525-
10R12 screws. 
c. Swing blower assembly down and disconnect Molex electrical connector. 
d. Remove 6 ea. AN525-10R8 screws MS21042L3 nuts and NAS1149F0332P washers.  
Remove condenser blower assembly. 
 
11.2 REPLACING CONDENSER BLOWER ASSEMBLY 
a. Install condenser blower assembly. 
b. Install the electrical connectors.  For kits prior to 2015 that use the Molex-style 
connector refer to CHAPTER 7, Section 4, page 28 for installation information. 
c. Secure condenser blower with retained hardware. 
d. Under aircraft beneath baggage compartment floor, install 13 AN525-10R12 screws. 
e. Activate air conditioner circuit breaker on overhead panel. 
f. Turn air conditioner switch to “ON”.  Ensure that scoop opens and blower draws air in 
through scoop and out through heat exchanger. 
 
12. REMOVE AND REPLACE CONDENSER HEAT EXCHANGER (Figure 17). 
 
12.1 REMOVE CONDENSER HEAT EXCHANGER 
a. Remove aft panel in baggage compartment. 
b. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station 
or equivalent. 
c. Remove Suction and Pressure hoses from condenser heat exchanger. 
d. Install caps and plugs over outlets and hoses.   
e. Remove condenser blower assembly per step 11above. 
f. Remove heat exchanger retaining screws from under side of baggage compartment. 
g. When heat exchanger is loose, remove it through the blower assembly opening. 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 38 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 16:  Condenser Install - View C-C 
 Figure 15:  Condenser Install  VIEW LOOKING UP
AN525-10R8 ScrewsMS21042L3 NutsNAS1149F0332P Washers          6 PlsS-7060EC-1Blower Assy
FWD
SECTION VIEW OF LEFT SIDE
155.8STA
Lower contour ofbelly panel
AN525-10R12 Screws          13 Pls  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 39 
 
 
 
 
Figure 17:  Condenser Install - View E-E 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 40 
 
 
12.2 REPLACING CONDENSER HEAT EXCHANGER 
a. Replacing the heat exchanger is the reverse of removal. 
b. Insert heat exchanger through the blower assembly opening. 
c. Secure heat exchanger in place using original hardware. 
d. Replace the ES44012-2 and -3 O-Rings in hose fittings and install hoses per 
instructions in section 12. 
e. Service with R134a refrigerant per CHAPTER 6. 
f. Reinstall condenser blower assembly per Step 11 of this section. 
 
13. REMOVE AND REPLACE BYPASS VALVE (Figure 18). 
 
13.1 REMOVE BYPASS VALVE 
a. Remove aft panel in baggage compartment. 
b. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station 
or equivalent. 
c. Remove 2X MS35275-240 Screws from valve mount bracket. 
d. Cut wires at splices.  
e. Disconnect tubing from valve and remove valve from aircraft. 
 
13.2 REPLACE BYPASS VALVE 
a. Install valve in aircraft and connect tubing. 
b. Re-connect wires using new M81824/1-2 splices. 
c. Reinstall retained screws in valve mount bracket. 
d. Service with R134a refrigerant per CHAPTER 6. 
e. Always install new O-Rings in fittings. 
f. Always use back-up wrenches when tightening tube or hose fittings. 
g. Reinstall aft panel in baggage compartment. 
 
14. REMOVE AND REPLACE BINARY SWITCH (Figure 18). 
 
14.1 REMOVE BINARY SWITCH 
a. Remove aft panel in baggage compartment. 
b. Remove electrical connectors from switch. 
c. Remove switch from tube.   
NOTE 
Not necessary to discharge system. 
d. Place cap over tube fitting. 
 
14.2 REPLACE BINARY SWITCH 
a. Remove cap from tube fitting and install switch. 
NOTE 
Do not over tighten switch. 
b. Re-connect wires to Binary Switch. 
c. Reinstall aft panel in baggage compartment.  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 41 
 
 
  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 18:  Binary Switch – View F-F 
 Binary Switch
Solenoid Bypass Valve
2X MS35275-240 Screw  
Drier/Receiver  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 42 
CHAPTER 8  
TROUBLESHOOTING 
1. System Troubleshooting 
 
Prior to troubleshooting a defective system, it is advisable to conduct a visual inspection 
for general condition and obvious signs of damage or failure. 
 
The following matrix lists the easiest checks and the most likely problems. 
 
Problem Cause Solution 
Premature Belt Failure a. Belt too loose 
b. Compressor misalign. 
c. System over charged 
a. Adjust belt tension 
b. Re-install/align compressor 
c. Adjust system charge 
Condenser blower motor 
Circuit Breaker “Pops” 
a. Probable cause- 
Overheating of condenser blower motor 
a. Check for loose or rubbing of fan 
blade, or possible replacement of motor 
Water (Condensate) in 
area of the aft evaporator 
a. Condensate drain fitting on 
evaporator not sealed 
b. Evaporator housing not sealed 
c. Drain line / check valve not installed 
properly 
d. Condensate forming on plumbing 
fittings 
a.b.c. Verify that installation conforms to 
drawing requirements. (remove 
evaporator inlet duct, and pour 1/2 ltr. Of 
water into housing assy. To check for 
leaks & drainage. 
d. apply cork insulation to all exposed 
refrigerant lines. 
Water in chin bubble 
area of forward 
evaporator 
a. Forward evaporator housing not 
sealed 
b. Condensate drain line fittings not 
secure at evaporator connection. 
c. Drain line check valve not installed 
a. Same as above. 
Conditioned air outlet 
louvers broken / loose 
 a. Replace Louvers 
Evaporator Coil freeze 
up 
a. System suction pressure 
(temperature) too low. System 
suction pressure should not be 
below 20 psi. 
a. Adjust system charge to obtain 25 – 32 
psi. 
System not Cooling a. Loss of refrigerant 
b. Water in system 
a. Leak check, evacuate system and 
recharge. 
b. Evacuate system, replace receiver drier 
bottle, & recharge  
System with Poor 
Cooling 
a. By-pass Valve a. Check to ensure the temperature 
control knob is in the full cold position, 
and the temperature control circuit 
breaker has not tripped. If the valve 
remains open (by-passing refrigerant) 
the valve will need replacement. 
 
2. ELECTRICAL 
 
With the engine off turn switch to “Blower” and make sure all evaporator blowers operate 
in both Hi and Low modes. Pull evaporator circuit breaker in battery compartment, and 
turn switch to A/C. Check that the condenser blower and actuator assembly is working, 
and the compressor clutch is engaging. 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-260M-1 
 
Revision G   Page 43 
3. SYSTEM CHARGE 
 
See page 24 “Charging Procedures”. 
 
4. EXPANSION VALVE MALFUNCTION 
 
If the cooling loss is limited to only one evaporator, it is most likely a defective expansion 
valve. 
 
Loss of cooling in all evaporators (assuming that there were no problems identified during 
steps 1 or 2) could be caused by refrigerant flow blockage at the expansion valves. This 
blockage could be due to ice or dirt. 
 
Replacement of the drier bottle and a thorough system evacuation might be a fix (remove 
the possibility of ice at the expansion valve nozzles). 
 
5. COMPRESSOR MALFUNCTION 
 
If the system will not maintain the pressures and there are no system leaks, the problem 
could be a failed compressor. The compressor must then be replaced. 
 
6. SYSTEM LEAK CHECK  
 
The system should be leak tested using an electronic leak detector. Initial leak check can 
be accomplished with a refrigerant charge of .5 lbs and the electronic leak detector. Each 
fitting should be checked and repaired prior to the final charging process. 
Do not use compressed air for the pressure check! Compressed air can introduce 
moisture in the system which will cause it to operate poorly or not at all. Take your time, 
and check all around each fitting. A little extra time during the leak check will save a 
significant amount of time later during servicing or troubleshooting. 
 
All leak checks should be conducted with the air conditioner “off”. Since the refrigerant is 
heavier than air, leaks are most likely detected on the underside of hoses and fittings. 
Also, the refrigerant can collect in low areas and provide an erroneous leak indication. A 
stream of “shop air” through a nozzle is useful in clearing an area just before checking for 
leaks. 
 
If a leak is detected at an O-ring fitting, reclaim the system and install a new O-ring. 
Lubricate the O-ring with refrigerant oil prior to installation. 
 
A small amount of leakage (one ounce per year) past the compressor seal is normal. Most 
leak detectors are sensitive enough to show a leak of this magnitude. 
 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS-206EC260M-1 
Revision G   Page 44 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 Figure 19:  Electrical Schematic Figure 7-1
Electrical Schematic
ACCA10B20N
ACCA13E20NACCA13D20
ACCA10E20N
ACCA10E20
ACCA1CB20
ACCA10A20
ACCA10B20
ACCP1A4
ACCA5B12
ACCA13C20N
ACCA11B20
ACCA7A12
ACCA2E14
ACCA9A18ACCA8A18ACCA5C12ACCA5D12N
ACCA7B18
ACCA7D18
ACCA7C18
ACCA12C18N
ACCA12B18
ACCA12A18
ACCA6B18ACCA6A12
ACCA12A20
ACCA5A12ACCA1A12
ACCA1B12
ACCA13A20ACCA13B20
ACCA16A20ACCA15A20
ACCA3D14ACCA2D14
ACCA4E14N
ACCA4D14N
ACCA3E14
ACCA15B20N
ACCA16B20N
ACCA1E14
ACCA1D14
ACCA1C12