AirComm Corporation Bell Air Conditioner 206L4 Installation Instructions with TORQLOK Plumbing

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H  Page 5 
 
The low pressure (suction) line from the compressor is attached to the evaporator lines, 
and causes the refrigerant to be pulled out of the receiver-drier and through the expansion 
valves. The expansion valves serve as a controlled spray orifice, to spray the correct 
amount of refrigerant into the evaporator.  
This regulation of refrigerant allows the liquid to absorb the heat from the cabin air, and 
transform it to a vapor state just prior to its exiting the evaporator assembly.  
The low pressure vapor is then drawn into the compressor where its pressure is raised to 
approximately 200 psi (14.06 kg/cm), and its temperature to around 200º F (93.3º C) this 
high pressure / high temperature vapor then travels to the condenser, (a heat exchanger 
cooled by a flow of outside air). Heat is extracted from the refrigerant, and as it cools it 
condenses back into a liquid and flows into the receiver-dryer, ready to repeat the cycle.  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H  Page 6 
 
 
 
15. Refrigeration Cycle Schematic 
(PLEASE NOTE: This illustration is provided as a reference only and may not match actual 
installation)    
  
 
Figure 1:  Refrigeration Cycle Illustration 
 
 
 
High pressure liquid  
 
 Low pressure vapor 
Low pressure liquid  
High pressure vapor  
Compressor  
Condenser 
Evaporator  
Receiver 
Drier Bottle  
Bypass 
Valve  
Expansion 
Valves  
Evaporator   
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 7 
 
CHAPTER 2 
AIRWORTHINESS LIMITATION SECTION 
 
The Airworthiness Limitations section is FAA approved and specifies maintenance required 
under paragraph 43.16 and 91.403 of the Federal Aviation Regulations unless an alternate 
program has been FAA approved.  
 
1. Airworthiness Limitations 
 
No airworthiness limitations associated with this design change 
 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 8 
 
CHAPTER 3 
INSPECTIONS  
1. INSPECTION REQUIREMENTS:  
 
Periodic Inspections  
(Hours Are Aircraft time) 
 
Item Annual 
Every 200 
hours of 
operation 
Special inspection instructions. 
Fwd Evaporator  
Blower  
X  
 
Check for operation throughout 
entire speed range of blower 
operation.  
Aft Evaporator  
Blower  
X  Check for operation throughout 
entire range of speed for blower 
operation. 
Condenser blower 
motor and fan Assy  
X  Check for operation.  
Compressor Drive Belt  X X Check for signs of excessive wear 
(Example: Glazing, Cracks and 
Exposed Fibers). 
Air conditioner Placards 
and markings  
X  Check for security and legibility. 
Compressor Assy.  X X Check for Operation, Security of 
attaching hardware and signs of 
refrigerant or oil leaks. 
Compressor Mount  X X Check for cracks and security of 
attaching hardware. 
Plumbing and Fittings  X X Check for security and signs of oil or 
refrigerant leaks 
Air Conditioner 
Compressor drive 
pulley  
X X Check for security of attaching 
hardware  
Blower Electrical 
Connectors 
X  Visually inspect for signs of 
overheating 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 9 
 
2. INSPECTION PROCEDURES.  
NOTE 
Refer to “Chapter 4 Location and Access” to locate all components for inspection. 
 
 
A. Inspection of the FWD and AFT evaporator blower motors 
 
CAUTION 
Fans are designed to operate with the resistance of the entire ducting system. Operation of the 
evaporator fans with any part of the distribution system removed may cause permanent damage 
to the fan motor. 
 
WARNING 
Fans may take up to 10 seconds to start after the switch is turned on. 
Keep hands away from fan whenever switch is in Fan or A/C positions. 
 
a. At the Cockpits Air Conditioner Control Panel place the AIR COND switch 
in the FAN position and verify that: 
1. both the fwd and aft fans are activated and operating – Place blower 
switches to “low” and “high” to verify blowers increase and decrease 
speed accordingly. 
2. the condenser fan is non-operational. 
3. the compressor clutch is disengaged. 
 
b. Place the AIR COND switch om the OFF position and verify that: 
1. both the fwd and aft fans deactivate 
2. the compressor clutch remains disengaged.  
 
B. Inspection of the air conditioner condenser 
 
NOTE 
This inspection may be performed with the air conditioner charged with refrigerant or it 
may be performed with no refrigerant in the system. In the case where there is no 
refrigerant in the system or the system is low on refrigerant or in the case where the 
ambient temperature is low, the binary switch will need to be jumpered. The temporary 
installation of a jumper wire across the terminals of the binary switch will do no harm 
even if it was not necessary. 
 
CAUTION 
 
THE TEMPORARY JUMPER MUST BE REMOVED AFTER THIS INSPECTION IS 
COMPLETED. 
 
a. Visually inspect condenser air inlet for any obstructions or debris. Airflow 
in this area is critical for air conditioner operation. 
b. Install a jumper between the contacts of the binary switch if required.  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 10 
c. Connect 28V ground power to the aircraft and place the A/C mode switch 
in the “A/C” position and verify that: 
1. Condenser scoop opens. 
2. Condenser fan is activated and operating. This fan should pull air into 
the aircraft through the open scoop and exit at the screen below the 
condenser. 
3. Compressor clutch is engaged. Verify compressor clutch engagement 
by visually observing the clutch plate clamp to the compressor rotor or 
an audible click when the switch is moved to “on”. 
 
d. Place the A/C mode switch into the Off position and verify that: 
1. The condenser fan is deactivated. 
2. The condenser scoop closes. 
e. Ensure that the jumper wire is removed from the binary switch 
 
CAUTION 
This procedure requires the temporary installation of a jumper wire across the terminals of the 
binary switch. This wire MUST be removed after this inspection is accomplished. 
 
f. Visually inspect condenser air inlet for any obstructions or debris. Airflow 
in this area is critical for air conditioner operation. 
g. Install a jumper between the contacts of the binary switch. 
h. Connect 28V ground power to the aircraft and place the A/C mode switch 
in the “A/C” position and verify that: 
1. Condenser fan is activated and operating. This fan should pull air into 
the aircraft through the condenser assy.  
2. Compressor clutch is engaged.  
i.  Disconnect one of the electrical leads from the binary switch, remove 
jumper wire and: 
1. Reconnect the electrical lead removed from the binary switch.   
j.  Place the A/C mode switch into the Off position and verify that: 
1. The condenser fan is deactivated. 
 
C. Inspection of compressor drive belt 
a. Remove transmission cowling to gain access to compressor drive belt and 
visually inspect the A/C compressor drive belt for the following: 
1. Any signs of excessive wear. 
2. Any signs of glazing. 
3. Any cracks or missing pieces. 
4. Any exposed fibers. 
b. Verify proper belt tension as shown in the illustration shown in Figure 2.  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 11 
 
 
Figure 2:  Belt Tension Inspection 
 
D. Inspection of air conditioner placards and markings. 
a. Check all air conditioner placards and markings for security and legibility. 
 
E. Inspection of air conditioner compressor assembly 
NOTE: 
The air conditioning system must be serviced with refrigerant to perform this inspection. 
 
a. Connect 28V ground power to the aircraft and place the A/C mode switch 
in the “A/C” position and verify that : 
1.  The compressor clutch is engaged. 
b. Place air conditioner switch to the OFF position and verify that: 
1. The compressor clutch is disengaged.  
c. Visually inspect the compressor assembly for the following:  
1. Security of all attaching hardware. 
2. Signs of refrigerant or oil leaks.  
3. Signs of excessive belt slippage or excessive heat.  
 
F. Inspection of Air Conditioner Compressor Mount Assy. 
a. Visually inspect compressor mount for any signs of the following: 
1. Any cracks. 
2. Security of attaching hardware (loose hardware).  
3. Elongation of component mounting holes. 
4. Any loose rivets. 
 
G. Inspection of Air Conditioner Refrigerant Plumbing. 
a. Visually inspect plumbing and fittings for any signs of the following: 
1. Refrigerant gas or oil leaks. 
2. Chaffing or excessive corrosion.  
3. Security of attaching hardware. 
   
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 12 
H. Inspection of Compressor Drive system 
a. Cut the safety wire on the belt tensioning link assembly jam nuts and adjust 
the tensioning link assembly to loosen the compressor drive belt.  
b. Check S-3520 drive pulley for play relative to the tail rotor drive shaft, both 
in the direction of rotation as well as for lateral movement relative to the 
shaft, and inspect area around the base of the drive ring at the shaft for any 
buildup of metal dust/powder residue. 
c. If there is any detectable looseness, and/or if there is significant metal 
dust/powder residue present, refer to Section 8 for removal instructions to 
allow removal and further inspection to determine if the pulley or drive ring 
need to be replaced. 
d. If there is no detectable looseness, and no significant metal dust/powder 
residue present, re-tension the belt per Section 8. 
e. Check security and condition of all related fasteners. 
 
I. Inspection of Blower Electrical Connectors 
1. Locate the electrical connectors that power the evaporator and 
condenser blowers. The connectors are at the interface between the 
blower harness and the aircraft harness and identified by their white 
plastic housing. 
 
Note: 
For 206EC-208 AC kits the evaporator blowers have an additional connector to inspect 
located several inches away from the harness connector.  
 
2. De-mate each connector and inspect both mates for signs of 
overheating (discoloration or plastic deformation).  
3. If any signs of overheating of the housing are present the system must 
be rendered inoperative and the connector housing and contacts 
replaced before further operation. 
 
3. COMPONENT OVERHAUL / REPLACEMENT SCHEDULE 
 
COMPONENT OVERHAUL / REPLACEMENT SCHEDULE 
 
Part Number Description Recommended replacement 
ES61064-1 
Forward 
Evaporator Blower 
Motor 
On Condition 
ES61142-1 Aft Evaporator 
Blower Motor On Condition 
ES73186-1 Condenser Blower 
motor 
On Condition 
7270, 7265 ALT. Compressor Drive 
Belt On Condition 
S-6008EC-6 Compressor On Condition 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 13 
 
CHAPTER 4  
 LOCATION AND ACCESS  
 
1. LOCATION OF AIR CONDITIONER FEATURES  
 
Nomenclature Description of Location 
Air Conditioner Control Panel  
 
The air conditioner control panel is located in 
the existing overhead circuit breaker panel 
between the pilots and co-pilots seats.  
Forward (Flight Deck) Evaporators The forward evaporator(s) are mounted to the 
center pedestal below the instrument panel in 
the chin bubble area  
Aft (Main Cabin) Evaporator The aft evaporator(s) are located aft of the hat 
shelf above the baggage compartment.  
Condenser Assembly The condenser assembly is located below the 
baggage compartment floor.  The condenser 
may be accessed from below the cabin aft of 
the rear landing gear cross tube. 
Compressor Assy The compressor assembly is mounted on the 
forward left hand side of the rear engine 
firewall and is driven off the oil cooler impeller 
shaft.  
Refrigerant Plumbing The refrigerant plumbing is routed from the 
compressor, to the condenser and all the other 
components. 
(As the refrigerant plumbing connects the 
compressor, condenser and evaporators, it 
may be necessary to remove several panels to 
gain access to its components) 
Servicing Ports The air conditioning service ports are located 
on the opposite wall of the baggage 
compartment. 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 
 
Revision H   Page 14 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 
3:  Layout
 of Air Conditioning
 
Single Fwd Evaporator
 Electrical Instl
Aft Evaporator Instl
Condenser Instl
Fwd Evaporator Instl
Air Distribution System
Compressor Instl
Condenser Instl
Air Outlets