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AirComm Corporation Bell Air Conditioner 206L4 Installation Instructions with TORQLOK Plumbing
AirComm Corporation Bell Air Conditioner 206L4 Installation Instructions with TORQLOK Plumbing
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H January 19, 2015 1575 W. 124th Ave., Westminster CO 80234 Tel 303-440-4075 | Fax 303-440-6355 http://www.aircommcorp.com/ | [email protected] 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 206L4 AIR CONDITIONING SYSTEM THIS HANDBOOK INCLUDES THE MAINTENANCE INFORMATION REQUIRED TO BE AVAILABLE BY FAR PART 27 NOTE 206L4 service Instructions are applicable to 206L1 rotorcraft that have been modified IAW BHT-206- SI-2050 engine upgrade and BHT-206-SI-2052 increased gross weight Mod and 206L3 rotorcraft that have been modified IAW BHT-206-SI-2052 increased gross weight Mod.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page ii RESTRICTED DISCLOSURE NOTICE THIS PUBLICATION IS THE PROPRIETARY INTELLECTUAL PROPERTY OF AIR COMM CORPORATION AND IS DELIVERED TO THE RECIPIENT WITH THE EXPRESS CONDITION THAT IT AND THE INFORMATION CONTAINED HEREIN ARE NOT TO BE USED, DISCLOSED OR REPRODUCED IN PART OR IN WHOLE, FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN CONSENT OF AIR COMM CORPORATION. NO RIGHT IS GRANTED TO THE RECIPIENT TO DISCLOSE OR SO USE ANY INFORMATION CONTAINED IN THIS DOCUMENT OUTSIDE THE PURPOSE FOR WHICH IT WAS DELIVERED. THESE RESTRICTIONS DO NOT OPERATE TO NULLIFY OR LIMIT ANY RIGHTS GRANTED BY CONTRACT.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page iv LIST OF EFFECTIVE PAGES LIST OF EFFECTIVE PAGES Title Page(s) Revision No. Record of Revisions iii H List of effective Pages iv H Table of Contents v-vi H Chapter 1 Introduction 1-6 H Chapter 2 Airworthiness Limitation Section 7 H Chapter 3 Inspections 8-12 H Chapter 4 Location and Access 13-20 H Chapter 5 Placards and Markings 21-23 H Chapter 6 Servicing 24-26 H Chapter 7 Standard Practices 27-42 H Chapter 8 Troubleshooting 43-46 H Appendix A Weight and Balance information 47 H
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page v 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 .................................................................................................................. 3 8. UNITS OF MEASUREMENT ............................................................................................... 3 9. INFORMATION ESSENTIAL TO THE CONTINUED AIRWORTHINESS OF THE AIR CONDITIONER. .................................................................................................................. 3 10. REFERENCE DOCUMENTS .............................................................................................. 3 11. DISTRIBUTION ................................................................................................................... 3 12. CHANGES TO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ........................... 4 13. SYSTEM DESCRIPTION AND OPERATION ..................................................................... 4 14. DESCRIPTION OF THE VAPOR CYCLE AIR CONDITIONER AND ITS INSTALLATION . 4 15. Refrigeration Cycle Schematic ............................................................................................ 6 CHAPTER 2 ..................................................................................................................................... 7 AIRWORTHINESS LIMITATION SECTION ................................................................................. 7 CHAPTER 3 ..................................................................................................................................... 8 INSPECTIONS ............................................................................................................................. 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 FEATURES ............................................................. 13 CHAPTER 5 ................................................................................................................................... 21 PLACARDS AND MARKINGS .................................................................................................... 21 CHAPTER 6 ................................................................................................................................... 24 SERVICING ................................................................................................................................ 24 1. CHARGING PROCEDURE ............................................................................................... 24 2. REFRIGERANT PRESSURE ............................................................................................ 24 3. SAFETY PRECAUTIONS ................................................................................................. 24 4. TOOLS, EQUIPMENT, AND CONSUMABLES ................................................................. 25 CHAPTER 7 ................................................................................................................................... 27 STANDARD PRACTICES .......................................................................................................... 27 1. O-RING TYPE FITTINGS .................................................................................................. 27 2. SYSTEM LEAK CHECK. ................................................................................................... 28 3. TORQUE SEAL. ................................................................................................................ 28 4. INSTALLATION & REPLACEMENT OF THE WIRE HARNESS ELECTRICAL CONNECTORS FOR THE EVAPORATOR AND CONDENSER BLOWERS ................... 28 5. REMOVE AND REPLACE COMPRESSOR (Figure 11) ................................................... 30
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page vi 6. REMOVE AND REPLACE COMPRESSOR DRIVE BELT (Figure 12). ............................ 31 7. REMOVE AND REPLACE COMPRESSOR DRIVE PULLEY (Figure 12) ........................ 35 8. REMOVE AND REPLACE FORWARD EVAPORATOR (Figure 14) ................................. 35 9. REMOVE AND REPLACE AFT EVAPORATOR (Figure 15) ............................................ 36 10. REMOVE AND REPLACE AFT EVAPORATOR BLOWER (Figure 15) ............................ 37 11. REMOVE AND REPLACE CONDENSER BLOWER ASSEMBLY (Figure 16 and Figure 17). .................................................................................................................................... 38 12. REMOVE AND REPLACE CONDENSER HEAT EXCHANGER (Figure 18). ................... 38 13. REMOVE AND REPLACE BYPASS VALVE (Figure 19). ................................................. 41 14. REMOVE AND REPLACE BINARY SWITCH (Figure 19)................................................. 41 CHAPTER 8 ................................................................................................................................... 43 TROUBLESHOOTING ................................................................................................................ 43 1. System Troubleshooting ................................................................................................... 43 2. ELECTRICAL .................................................................................................................... 43 3. SYSTEM CHARGE ........................................................................................................... 44 4. EXPANSION VALVE MALFUNCTION .............................................................................. 44 5. COMPRESSOR MALFUNCTION ..................................................................................... 44 6. SYSTEM LEAK CHECK .................................................................................................... 44 APPENDIX A .................................................................................................................................. 47 WEIGHT AND BALANCE DATA ................................................................................................. 47
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 1 CHAPTER 1 INTRODUCTION 1. SCOPE The scope of this manual encompasses the scheduled and unscheduled maintenance procedures for the continued airworthiness of the Air Comm Corporation air conditioning system installed in the Bell 206L4 series helicopter. 2. PURPOSE The purpose of this manual is to provide the aircraft mechanic in the field the 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 of the 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 206L4 models that are equipped with the Air Comm Corporation kit number 206EC-210 air conditioner system. NOTE 206L4 service Instructions are applicable to 206L1 rotorcraft that have been modified IAW BHT-206-SI-2050 engine upgrade and BHT-206-SI-2052 increased gross weight Mod and 206L3 rotorcraft that have been modified IAW BHT-206-SI-2052 increased gross weight Mod. 5. DEFINITIONS The following terms are provided to give a ready reference to the meaning of some of the words contained within this manual. These definitions may differ from those given by a standard dictionary. Ambient air temperature: The temperature of the air surrounding a person or object. Charging station: An air conditioning system service unit capable of evacuating and charging an air conditioner. Condensation: The process of changing a vapor into a liquid. Desiccant: A material used in the receiver/drier bottle, designed to absorb moisture from the refrigerant. Glazing: A shiny coating caused by excessive heat. Heat load: The amount of heat which the air conditioner is required to remove from the aircraft cabin. 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.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 2 Pressure, ambient: The pressure of the air surrounding a body, normally measured in Pounds Per Square inch gauge, or PSIG. 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. 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. 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 temperature of cooling air. Vacuum: A negative pressure, or pressure below atmospheric; it is usually expressed in inches of mercury. Vapor: The gaseous state of a material. 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
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 3 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 MEASUREMENT All measurements contained within this manual are generally given in the United States standard measurement, with metric conversions in parentheses as needed. 9. INFORMATION ESSENTIAL TO THE CONTINUED AIRWORTHINESS OF THE AIR CONDITIONER. This manual provides information which is required for operation and maintenance of the Air Comm air conditioning system installed in the Bell model 206L 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 SH2750NM 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”, and 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 (page iii), and on the List of Effective Pages (page iv) of this manual. In addition to the revision of the manual, those changes categorized as “Safety of Flight” shall have a Service Bulletin issued to the operator providing the necessary information to comply with, and or to correct, the “Safety of Flight” issue. Replacement, and or revised copies of this manual may be obtained by contacting: Air Comm Corporation Service Department 1575 W. 124th Ave STE 210 Westminster, CO.80234 Phone No. 303-440-4075 Fax No. 303-440-6355 [email protected]
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 4 12. CHANGES TO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS Changes made to a line or paragraph of this document will be indicated by a vertical bar in the right hand margin, while a complete page change will be indicated by a vertical bar next to the page number. (Example: Any change will appear with a vertical bar next to that change). 13. SYSTEM DESCRIPTION AND OPERATION The 206EC-206 system is a vapor cycle type Air Conditioner consisting of a Compressor, Condenser, Dryer, By-pass valve, and Multiple Evaporator assemblies. The Compressor is belt driven off of the tail rotor drive shaft, which is located in the engine compartment. The Condenser assembly is located below the baggage compartment floor. Cooling air is forced through the condenser by a 28V DC electric blower, and an electrically actuated scoop that opens and closes when the system is switched from OFF to ON to OFF. Each evaporator assembly contains a 28V DC, two speed electric blower that allows the system to be switched to ether a High or Low setting. A refrigerant gas by-pass valve is located aft of the baggage compartment. The purpose of this valve, (which is set at the factory) is to prevent evaporator heat exchanger freeze-up by controlling the minimum evaporator pressure (temperature). The system incorporates a binary high/low pressure “cut-out” switch. This switch is intended to protect the compressor in case of system over-pressure or loss of refrigerant. The switch is located adjacent to the system charging ports ( Aft of the baggage door on the L/H side of the aircraft) and is wired in series with the compressor clutch. Switch operating pressures: Low Pressure function – Open @ 28 ± 2.8 psi Close @ 29 ± 4.3 psi High Pressure function – Open @ 384 ± 30 psi Close @ 289 ± 43 psi 14. DESCRIPTION OF THE VAPOR CYCLE AIR CONDITIONER AND ITS INSTALLATION This section contains a general overview of a Vapor-cycle air conditioning system and how it functions. This type of system operates in a closed loop, in which the refrigerant absorbs heat from the cabin, and rejects it into the outside air. The refrigerant then returns to the cabin to repeat the cycle. The operation of the system is described below, and illustrated schematically in Figure 1. Liquid refrigerant is contained in the receiver-drier under pressure from the compressor. The receiver-drier also filters the refrigerant through a material know as desiccant. The desiccant ensures that the fluid leaving this component is free of any water or other contaminants.