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AirComm Corporation Cabin Air Conditioner A119 Instructions for Continued Airworthiness User Manual
AirComm Corporation Cabin Air Conditioner A119 Instructions for Continued Airworthiness User Manual
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AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 12 February 11, 2015 3330 Airport Rd., Boulder CO 80301 | 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 AGUSTA A119 & AGUSTA WESTLAND AW119 MKII AIR CONDITIONING SYSTEM THIS HANDBOOK INCLUDES THE MAINTENANCE INFORMATION REQUIRED TO BE AVAILABLE BY FAR PART 27
AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 12 Page ii THIS PAGE INTENTIONALLY LEFT BLANK
AIR CONDITIONER SERVICE MANUAL A119-206M-1
Revision 12 Page iii
RECORD OF REVISIONS
Rev Date Description of Change Approval
0 6-30-2005 Original Issue
N/A
1 8-29-2005 Compressor belt part number & views
N/A
2 5-5-2006 High output condenser scoop and blower N/A
3 12-15-2006 Installation of fwd evaporator S-6118EC-1
N/A
4 7-2-2007 Addition of AW119 MKII & periodic Insp.
N/A
5 1-17-2008 Changed ES57008-2 to ES57178-1
N/A
6 7-14-2008 Changed condenser blower & views
N/A
7 6-4-2009 Added High Output Configuration
N/A
8 10-12-2009 Added periodic inspection information
N/A
9 Not Published Updated electrical air box feature
N/A
10 7-22-2013 Updated format, removed electric air box
information from revision 9, updated location
illustrations, edited removal instructions,
added specific installation instructions
(rather than “installation is opposite of
removal”) corrected pressure switch specs,
updated charging placard, provided IDS and
G1000 info, updated schematic, added new
revision block with sign off (all previous
version do not have an approval /
acceptance signature). No FAA Signature
required – meets minor change agreement
MR-100-134.
Prepared By: Karen G. Blecha (KGB) 7/22/2013 Date
ACC Approval: MJK 7/22/2013 Signature Date
FAA Acceptance (Major Change): N/A – Meets Minor Change Agreement MR-100-134 7/22/2013 Signature Date
11 11-18-2014 Pg 9,10,18,29: added alternate blower S-
6501EC-1. Pgs 41,42: updated elec
schematics to show relay box variances due
to condenser blower options. Pg 12: updated
p/n’s in views. Pg 19,20: added pressure
relief valve for new kits.
Prepared By:
J Byrnes 11/18/2014
Date
ACC Approval:
MJK 11/20/2014
Signature Date
FAA Acceptance (Major Change):
J. Cox Jan 5, 2015
Signature Date
AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 12 Page v TABLE OF CONTENTS Contents 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 ..................................................................................................... 2 8. Units of Measure ............................................................................................. 2 9. Information Essential to Continued Airworthiness ........................................... 2 10. Reference Documents .................................................................................... 2 11. Distribution ...................................................................................................... 2 12. Changes to Instructions for Continued Airworthiness ..................................... 3 13. Air Conditioner Features ................................................................................. 3 14. Description of Vapor Cycle Air Conditioner and Installation ............................ 5 CHAPTER 2 .................................................................................................................... 7 AIRWORTHINESS LIMITATION SECTION ................................................................ 7 1. Airworthiness Limitations ................................................................................ 7 CHAPTER 3 .................................................................................................................... 9 INSPECTIONS AND OVERHAUL ............................................................................... 9 1. Inspection Requirements ................................................................................ 9 2. Component Overhaul / Replacement Schedule ............................................ 10 CHAPTER 4 .................................................................................................................. 11 LOCATION AND ACCESS ........................................................................................ 11 1. Location of Air Conditioner Components ...................................................... 11 CHAPTER 5 .................................................................................................................. 23 PLACARDS AND MARKINGS ................................................................................... 23 1. Placard and Marking Information .................................................................. 23 CHAPTER 6 .................................................................................................................. 25 SERVICING ............................................................................................................... 25
AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 12 Page vi 1. Safety Precautions ........................................................................................ 25 2. Servicing Information .................................................................................... 25 3. Lubrication Information ................................................................................. 26 4. System Leak Check ...................................................................................... 27 5. Suggested Equipment for Servicing .............................................................. 28 6. Consumable Materials .................................................................................. 28 7. Suggested Spares List .................................................................................. 29 CHAPTER 7 .................................................................................................................. 31 STANDARD PRACTICES AND INFORMATION ....................................................... 31 1. Fitting Torque Procedures and Values .......................................................... 31 2. Removal and Replacement of Forward Evaporator Assembly ...................... 32 3. Removal and Replacement of Forward Evaporator RH Blower Assembly .... 32 4. Removal and Replacement of Aft Evaporator Assembly .............................. 33 5. Removal and Replacement of Aft Evaporator Blower Assembly .................. 33 6. Removal and Replacement of Air Box Assembly .......................................... 34 7. Removal and Replacement of Condenser Assembly .................................... 34 8. Removal and Replacement of Condenser Vane Axial Blower Assembly ...... 35 9. Removal and Replacement of Compressor Drive Belt .................................. 35 10. Removal and Replacement of Compressor Assembly .................................. 36 11. Removal and Replacement of Receiver Drier Bottle ..................................... 37 12. Removal and Replacement of Bypass Valve ................................................ 37 13. Removal and Replacement of Binary Switch ................................................ 38 CHAPTER 8 .................................................................................................................. 39 TROUBLESHOOTING ............................................................................................... 39 1. System Troubleshooting ............................................................................... 39 Figure 8-1 – Electrical Schematic (IDS Equipped Aircraft) ..................................... 41 Figure 8-2 – Electrical Schematic (Non IDS Equipped Aircraft) ............................. 41 APPENDIX A ................................................................................................................. 43 WEIGHT AND BALANCE INFORMATION ................................................................ 43
AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 12 Page 1 CHAPTER 1 INTRODUCTION 1. Scope The scope of this manual encompasses scheduled and unscheduled maintenance procedures for continued airworthiness of Air Comm Corporation air conditioning system installed in the Agusta A119 and Agusta Westland AW119 MKII series helicopter. 2. Purpose The purpose of this manual is to provide aircraft field mechanic 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 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 Agusta Helicopter models A119 & Agusta Westland AW119 MKII which are equipped with the Air Comm Corporation kit number A119-206 & A119- 208 & A119-210 & A119-212 & A119-214 air conditioner systems. The kit Serial Number is engraved on the compressor mount assembly. Mandatory Service Bulletin SB A119- 306 requires that all Agusta A119s equipped with ACC air conditioners require the use of this ICA. 5. Definitions The following terms are provided to give a ready reference to the meaning of some words contained within this manual. These definitions may differ from those given by a standard dictionary. a. Ambient air temperature: Temperature of the air surrounding a person or object. b. Charging station: An air conditioning system service unit which is capable of evacuating and charging an air conditioner. c. Cold: The absence of heat. d. Condensation: The process of changing a vapor into a liquid. e. Desiccant: Material used in a receiver/drier bottle, designed to absorb moisture from refrigerant. f. Evaporate: To change from a liquid into a vapor. g. Heat load: The amount of heat which the air conditioner is required to remove from the aircraft cabin. h. 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. i. Pressure, ambient: The pressure of the air surrounding a body, normally measured in pounds per square inch, or PSIG. j. 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. k. Relative humidity: The ratio of the amount of water vapor in the air to the
AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 12 Page 2 amount of water vapor required to saturate the air at the existing temperature. l. 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. m. Vacuum: A negative pressure, or pressure below atmospheric; it is usually expressed in inches of mercury. n. Vapor: The gaseous state of a material. 6. Abbreviations gm: Gram kg: Kilograms inHg: Inches of Mercury In-lbs: Inch pounds Kg/cm: Kilograms Per Centimeter lbs: Pounds ml: Milliliters mm: Millimeters Nm: Newton-meters oz: Ounces Psig: Pounds Per Square Inch (gauge) 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 Measure All measurements contained within this manual are given in United States standard measurement, followed by metric conversion in parentheses. 9. Information Essential to Continued Airworthiness This manual provides information which is required for operation and maintenance of the Air Comm air conditioning system installed in Agusta model A119 & Agusta Westland AW119 MKII 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 SR00463DE. 11. Distribution This document is to be placed with the aircraft maintenance records at the time of system installation.
AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 12 Page 3 Changes will be made to this document in response to safety-of-flight 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 and on the List of Revisions 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 or to correct the safety-of-flight issue. Replacement or revised copies of this manual can be obtained by contacting: Air Comm Corporation Service Department 3330 Airport Road Boulder, CO.80301 Phone No. 303-440-4075 Fax No. 303-440-6355 Email: [email protected] 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. 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. Air Conditioner Features The vapor cycle air conditioner features one forward mounted evaporator assembly (cockpit), one aft mounted evaporator assembly (above main cabin), one condenser assembly, and a compressor driven by the fan drive shaft just aft of the aft main transmission, aircraft left. These components and associated plumbing combine to provide conditioned air through the existing air distribution system when the engines are operating during both ground and flight operations. This system can be operated in either the air condition (A/C), or blower mode. In the A/C mode, conditioned air is provided by the forward and aft evaporator assemblies to the cockpit and main cabin areas respectively. In blower mode, the evaporator blowers are used to circulate and mix cabin air and fresh air, while the compressor clutch remains disengaged. When using the cabin heater it is acceptable to operate the air conditioner if desired, to defog the cabin windows. The air conditioning system is connected electrically to the aircraft’s DC Power Panel 28 VDC Bus. The control panel for the air conditioner system is located on the existing overhead switch panel between the pilot’s and copilot’s seats. The control panel consists of an A/C & Blower switch, two switches for the control of cockpit and cabin evaporator blower speed, and a temperature control rheostat. Temperature control is achieved by means of a refrigerant bypass valve, thus eliminating compressor cycling. The blower motors feature dual fan speed. This feature can be used in both the A/C or fan modes. A “COMP ON” light, located on the upper main instrument panel, provides a visual status of compressor operation. For aircraft equipped with an Interactive Display System (IDS), compressor engagement is displayed on the IDS as a green ECS ON annunciation. For aircraft equipped with a Garmin G1000, the indication will show on the screen.
AIR CONDITIONER SERVICE MANUAL A119-206M-1 Revision 12 Page 4 Figure 1-1 – Air Conditioning System Control Panel The compressor is mounted on the surface of the transmission drain pan, in the aft aircraft center portion of the transmission compartment and is driven by a Poly V-Belt and a pulley which is mounted to the oil cooler blower drive shaft. Access to the compressor is provided by the transmission compartment access doors. The condenser assembly is mounted below the baggage floor and features a blower assembly and a separate heat exchanger to reject system heat overboard. Airflow through the condenser heat exchanger is provided by two 28 volt DC high performance blowers. The forward evaporator is mounted on the left side of the instrument panel console. Conditioned air is delivered to the crew by means of air ducts, mounted to the sides of the instrument panel console. An optional RH mounted blower may be installed. The aft evaporator assembly is mounted above the cabin top and is enclosed by the transmission cowling. Cabin return air is ducted to the evaporator through a cutout in the cockpit closeout panel at fuselage station 2050. Conditioned air is pumped to the existing headliner ducting through the existing fresh air inlet in the cabin top. The aft evaporator assembly is equipped with a freeze switch. The freeze switch probe is located in the core of the evaporator heat exchanger. This unit prevents coil freeze-up by limiting the minimum coil temperature to 32º F (0º C).