AirComm Corporation Cabin Air Conditioner A119 Instructions for Continued Airworthiness User Manual

							AIR CONDITIONER SERVICE MANUAL A119-206M-1 
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The system is also equipped with a Binary switch. This switch is designed to protect the 
system  against  over-pressure  situations,  or  under-pressure  in  the  event  of  refrigerant 
loss from the system. The switch also prevents the system from operating in low ambient 
temperatures below 50º F (10º C). 
 
The switch operating pressures are: 
 
Low Pressure Function: 
Cut-out at 28 +/- 2.8 psig (1.97 +/- .2 kg/cm2) 
Cut-in at 29 +/- 4.3 psig (2.04 +/- .3 kg/cm2) 
 
High Pressure Function: 
Cut-out at 384 +/- 30 psig (27.0 +/- 2.1 kg/cm2) 
Cut-in at 298 +/- 43 psig (20.95 +/- 3 kg/cm2) 
 
14. Description of Vapor Cycle Air Conditioner and 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 
(See Figure 1-2). 
 
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 insures that the liquid refrigerant leaving this component is free of any water or 
other contaminants. 
 
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 psig (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. 
 
 
 
 
 
 
 
  
						

							AIR CONDITIONER SERVICE MANUAL A119-206M-1 
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Figure 1-2 – Refrigeration Cycle Illustration 
(NOTE: This illustration is provided as a reference only and may not match actual installation) 
 
 
  
High pressure liquid 
Low pressure vapor 
Low pressure liquid 
High pressure vapor 
Compressor 
Condenser 
Aft Evaporator 
Receiver- 
Drier 
Bypass 
Valve 
Expansion 
Valves 
Fwd Evaporator  
						

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CHAPTER 2 
AIRWORTHINESS LIMITATION SECTION 
 
1. Airworthiness Limitations 
 
The  Airworthiness limitations  section  is  FAA approved  and  specifies  inspections  and 
other  maintenance  required  under  Sections  43.16  and  91.403  of  Federal  Aviation 
Regulations unless an alternative program has been FAA approved. 
 
“No airworthiness limitations associated with this type design change.” 
 
 
 
FAA approval: 
       
ACO Representative                                                                             Date 
						

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CHAPTER 3 
INSPECTIONS AND OVERHAUL  
1. Inspection Requirements 
 
PERIODIC INSPECTIONS 
(Hours are aircraft time) 
 Item Annual Every 100 Hours of  Operation Every 400 Hours of Operation Special Inspection Information  
Evaporator Blower Hi/Lo Operation  X   X Check for operation   
 Condenser   Blowers   X    X Check for operation      
Forward Evap Blower  Motor ES61064-1   FASCO Aft Evap Blower Motor  ES61142-1 
X    X 
 X     X 
Check for operation in Hi and Lo settings   Check for operation in Hi and Lo settings 
    
Compressor Drive Belt    X  X  X Check belt tension, and for signs of excessive wear (example: Glazing, Cracks, and exposed fibers) 
 
Air Conditioner Placards & Markings (see chapter 5) 
X   X Check for security and legibility  
Air Conditioner Compressor Assembly  
 X  X  X Check for operation, security of attaching hardware, and signs of oil or refrigerant leaks.  
 
Air Conditioner Compressor Mount  
 X  X  X Check for cracks on compressor lugs, support doubler, WL1156.6 engine deck area, and rivet condition and cracks on lower surface of WL1156.3 engine deck. No cracks allowed. Check for condition and security of pivot and belt tension arm bolts. 
 
Plumbing and Fittings X  X Check for security and signs of oil or refrigerant leaks 
 
Air Conditioner Compressor drive pulley (mounted to oil cooler shaft) 
X  X Check for security of attaching hardware.   
 
Compressor Isolator Mounts X X X Check for security, and condition  
Aft Evaporator mounting brackets & upper deck area 
X   Check for security and condition of attaching hardware & mounting brackets. No chaffing is allowed between aft evaporator brackets and upper deck of aircraft. 
 
Forward Evaporator  mounting brackets & isolators 
X  X Check for security, and condition   
						

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2. Component Overhaul / Replacement Schedule 
 
 Description Part Number Overhaul / Replacement Hours Condenser Blower (deployable scoop intake) & Forward / Aft Evaporator Blower Motor   
ES73190-1(Condenser Blower) ES73192-1 (Condenser Blower)  ES61064-1 (Fwd Evap Motor)  ES61142-1( FASCO Aft Evap Motor)  
The blower manufacturer recommends TBO is 500 hrs. At the discretion of the operator it is acceptable to operate the blower until failure. A blower failure will result in a reduction in cooling, but no safety-of-flight issues are involved. 
Compressor Isolator Mounts ES36096-1 Isolator The manufacturer requires replacement of the compressor isolators every two (2) years Condenser Blower (High Output) (Fixed intake grille) A119-7008-1 Blower S-6501EC-3 Blower (alt.) The blower manufacture recommends a TBO of 1000 hrs. At the discretion of the operator it is acceptable to operate the blower until failure. A blower failure will result in a reduction in cooling, but no safety-of-flight issues are involved. 
 
 
 
 
 
   
						

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CHAPTER 4 
LOCATION AND ACCESS 
1. Location of Air Conditioner Components 
 
 
 
Nomenclature Description of Location 
 Air Conditioner Circuit Breaker & Relay Panel  Right side forward bulkhead of baggage compartment 
 Air Conditioner Control Panel  Existing overhead circuit breaker / switch panel 
 Forward (Cockpit) Evaporator and Blower  
LH side center console below instrument panel in chin bubble area – blower is integral to forward evaporator 
 Forward Evaporator Blower Assembly  RH center console below instrument panel in chin bubble area 
 Aft (Main Cabin) Evaporator, Blower Assembly, and Air Box Assembly  
Main cabin roof area just forward of main rotor transmission 
 Condenser Assembly and Blower Assembly  Aircraft belly below aft baggage compartment 
 Compressor  Aft center section of engine compartment drain pan 
Refrigerant Plumbing 
Routes from compressor, to area below baggage compartment, and forward to nose area (As refrigerant plumbing connects compressor, condenser, and evaporators, it may be necessary to access these components through several panels and cabin headliner  Hi & Lo Service Ports  Aft of compressor in engine compartment, RH side 
 Receiver Drier Bottle  
Adjacent to condenser assembly in aircraft belly below aft baggage compartment 
 Bypass Valve  Aft of compressor in engine compartment, RH side 
 Binary Switch  Aft of compressor in engine compartment, RH side 
  
						

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SIDE VIEW 
Figure 4-1 – Layout of A119 Air Conditioning System 
 
 
 
TOP VIEW 
Figure 4-2 – Layout of A119 Air Conditioning System 
  
A119-706-1,-2 Condenser Installation 
A119-606-1 thru -6 Forward Evaporator Instl 
A119-606-1 thru -6 Forward Evaporator Instl 
A119-706-1,-2 Condenser Installation    
						

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Figure 4-3 – Compressor Installation 
(Engine Deck – View Looking Down) 
 
  
A119-3040-1 
Compressor Assembly 
3X ES36096-1 
Isolator 
ES35119-2 
Belt 
A119-3042-11-1 
Drive Pulley   
						

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Figure 4-4 – Forward Evaporator Air Outlets 
Non IDS Equipped Aircraft 
(Instrument Panel – View Looking Fwd) 
 
  
COMP ON Light 2X A119-6800-1 
Air Outlet Assembly 
LH & RH 
S-2500EC-4 
Mag Compass Deviation 
Placard