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AirComm Corporation Airbus EC120 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual
AirComm Corporation Airbus EC120 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual
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AIR CONDITIONER SERVICE MANUAL EC120-200M-1 Revision 5 Page 21 5. Condenser Installation Figure 4-10 Condenser, Pre-Nov 2014 models
AIR CONDITIONER SERVICE MANUAL EC120-200M-1 Revision 5 Page 22 Figure 4-11 Condenser, looking inboard, Post-Nov 2014 models Figure 4-12 Condenser, Post-Nov 2014 models
AIR CONDITIONER SERVICE MANUAL EC120-200M-1
Revision 5 Page 23
6. Relay Panel, Single Evaporator Configuration
Figure 4-13 Relay Panel, Single Evaporator, Pre-Nov 2014 models shown,
Post-Nov 2014 models similar
AIR CONDITIONER SERVICE MANUAL EC120-200M-1 Revision 5 Page 24 7. Relay Panel, Dual Evaporator Configuration Figure 4-14 Relay Panel, Dual Evaporator, Pre-Nov 2014 models shown, Post-Nov 2014 models similar
AIR CONDITIONER SERVICE MANUAL EC120-200M-1 Revision 5 Page 25 Figure 4-15 – Cockpit A/C Control Panel
AIR CONDITIONER SERVICE MANUAL EC120-200M-1
Revision 5 Page 26
CHAPTER 5
PLACARDS AND MARKINGS
1. Placard and Marking Information
System Charging Instruction Placard
SYSTEM CHARGING INSTRUCTIONS
SYSTEM TO BE SERVICED BY QUALIFIED PERSONNEL
R134a Refrigerant- Polyester oil-XH9 Desiccant
System charge 2.4 lbs.
If exact weight of refrigerant charge is not known,
use following procedure:
º Charge system in .25 LB increments until minimum outlet
temperature & system suction pressure is achieved.
º Allow several minutes after each charge increment, to
allow temperature & pressure to stabilize.
NOTE: Refrigerant over charge or operation of the AC during low
Ambient temperature may cause tail rotor pedal feedback.
AIR COMM CORPORATION
BOULDER, COLORADO
Located on the transmission deck in the proximity of the charging ports
NOTE
Newer placards do not include the “BOULDER,
COLORADO” and may include the use of Ultra PAG oil.
Located on top surface of belt guard Located at center line on lower edge of
instrument panel
AIR CONDITIONER SERVICE MANUAL EC120-200M-1 Revision 5 Page 27 CHAPTER 6 SERVICING 1. Safety Precautions CAUTION Refrigeration servicing should be performed by qualified personnel only. Check all local and federal regulations before servicing any refrigerant system or storage device. The refrigerant used in the air conditioning system is the environmentally safe HFC R134a. This refrigerant is non-explosive, non-flammable, and non-corrosive, has practically no odor, and is heavier than air. However, certain precautions must me observed to ensure the safety of the equipment and any personnel servicing this system. HFC R134A is stored in a liquid state. It will rapidly evaporate or sublimate when exposed to normal temperature and atmospheric pressure. This rapid evaporation can causes a severe drop in temperature. If liquid refrigerant comes in contact with the skin or eyes it may cause severe frostbite or blindness. Care must be taken to prevent liquid refrigerant from contacting the skin or the eyes. WARNING Safety glasses must be worn at all times when servicing the air conditioning system. Should any liquid refrigerant come in contact with the skin or eyes seek medical attention immediately even if the irritation ceases. WARNING To avoid a potential explosion NEVER weld, solder, steam clean, use a flame type leak detector, blow torch, bake on aircraft finish, or use excessive heat on, or in the immediate area of refrigerant lines or supply tanks while they are closed to the atmosphere. WARNING Refrigerant servicing must be performed in a well-ventilated area to minimize inhalation of the refrigeration gas. 2. Servicing Information CAUTION Refrigeration servicing should be performed by qualified personnel only. NOTE A list of suggested servicing equipment is provided later in this chapter.
AIR CONDITIONER SERVICE MANUAL EC120-200M-1 Revision 5 Page 28 3. Servicing Procedure A. Connect the servicing manifold to the servicing ports located on the forward R/H side of the transmission deck. BLUE for low pressure or “Suction” and RED for high pressure or “Discharge.” B. After the quick disconnect fittings have been attached to the servicing ports, tighten the knobs on the back of the fittings to engage the schrader valves located inside the charging ports. NOTE The schrader valves inside the charging ports MUST be engaged to allow servicing of the air conditioner system. C. Connect the YELLOW line in the center of the manifold to the vacuum pump. Turn the vacuum pump on and open both valves on the charging manifold. Decreasing the pressure in the closed system to -29.40 InHg causes the moisture in the system to vaporize allowing it to be drawn out by the vacuum pump. Removal of all moisture is crucial to the operation of the A/C system. Any moisture left in the system will be turned into ice causing undesired operation or blockage of one or more expansion valve. Allow the vacuum pump to draw against the system for a minimum of ONE HOUR. NOTE Due to a drop in atmospheric pressure with an increase in altitude, the normal vacuum reading will drop 1” (1 kg/cm) for each 1000 ft of altitude gained e.g., Sea Lever Reading = 10 InHg, reading at 1000 feet above sea level = 9 InHg. D. After the system has been evacuated, turn both valves on the manifold assembly to the “OFF” position and switch the vacuum pump off. Allow the system to hold the vacuum for a minimum or ONE hour to check for vacuum leaks. If the system will not hold the vacuum, the system may have a fitting leak. It may be necessary to charge the system with one to two pounds of refrigerant and conduct a leak check using an electronic leak detector. CAUTION To ensure trouble free operation the system must be leak free. E. After the leak check has been performed evacuate the system for a minimum of ½ hour before charging with the required amount of HFCR134A as called out later in this chapter. NOTE Static charging is the most accurate and safest way to charge an air conditioning system. To accomplish this all of the refrigerant must be charged into the system without the compressor engaged or the system operating.
AIR CONDITIONER SERVICE MANUAL EC120-200M-1 Revision 5 Page 29 CAUTION Operating the air conditioning system with a low refrigerant charge may cause severe damage to the compressor assembly. F. If a charging station is not available, charge the A/C system as follows: 1) After vacuum and leak check have been performed (Steps A through E) and the system has been proven to be “Leak Free,” charge the system with an initial charge of 2.0 Lbs. 2) Engage the compressor and add the remainder of the required charge in .2 lb. increments allowing two minutes to elapse between each addition of refrigerant. WARNING If charging is to be accomplished with the compressor engaged it must be accomplished through the LO (BLUE) side only. Never Charge through the Discharge or “HIGH” (RED) side of the system while the compressor is running. This may cause severe damage to the servicing equipment and may cause personal injury or death. Care should be taken to ensure the HIGH (RED) side valve stays closed during this procedure and any time the system is operating. G. After charging, perform a test run to ensure proper function of the Air Conditioning System. CAUTION When reclaiming refrigerant, be sure to note any oil that is removed from the system, and replace the lost oil before or during re-servicing. Maintaining a proper oil and refrigerant charge is critical to the life of the compressor assembly. 4. Lubrication Information SYSTEM DESCRIPTION REFRIGERANT CHARGE OIL CHARGE EC120 air conditioning system, single (aft) evaporator 2.4 lbs 1.1 Kg 8.0 fl oz. 238 ml EC120 air conditioning system, dual evaporator system (1 fwd, 1 aft) 2.4 lbs 1.1 Kg 8.0 fl oz. 238 ml NOTICE Prior to mid-2015 this system used polyolester base (POE) 100 grade refrigerant oil. Systems after mid-2015 use Double End Capped Polyalkylene Glycol (DEC PAG, also known as ULTRA PAG). It is acceptable to mix these oils so conversion from polyolester to DEC PAG is permissible without flushing the existing installed system. Note also that regular PAG oil is not compatible with Polyolester and is not to be used, even for new installed systems.
AIR CONDITIONER SERVICE MANUAL EC120-200M-1 Revision 5 Page 30 If oil is spilled during installation / maintenance, or is lost due to a leak in the system, it is necessary to approximate the amount of lost oil and add this amount to the system. See paragraph B. Component Replacement below. This oil, if required, should be added to the compressor discharge line prior to system charging. This system may be serviced with either Polyolester (POE) or Double End Capped Polyalkylene Glycol (DEC PAG). Polyalkylene Glycol is preferred due to its superior lubricating properties and improved compressor service life. There are several types of PAG available. Only the “Double End Capped” type is permissible in Air Comm Corporation air conditioning systems. Double End Capped PAG oil is available from Air Comm Corporation in 8 ounce bottles (P/N ES94006-13). Mixing of POE and PAG is acceptable. Disregard previous statements to the contrary. They referenced PAG oil that was not “Double End Capped”. Current versions of compressors are designed to be operated using PAG oil. Testing by Air Comm Corporation has shown that “Double End Capped” PAG is compatible with POE and can therefore be mixed. “Double End Capped” is a reference to the chemical structure of the molecule and not to the container. (Do not use Mineral oil in this system with R134a refrigerant. Do not use any refrigerant oil other than Double End Capped Polyalkylene Glycol (also known as “ULTRA PAG”) or Polyolester (also POE)). Containers of DEC PAG or POE will absorb moisture if left open (hygroscopic). Keep containers tightly capped when not in use and keep all system components capped while servicing system. The quantity of lubrication in the system is critical. If too little lubrication is in the system the compressor life may be reduced. No other component in the A/C system requires lubrication. Too much lubricant in the system will retard heat transfer in the evaporator and condenser coils and reduce the cooling capacity of the system. The Service Ports for this system are located in the forward transmission deck area adjacent to the compressor. CAUTION This system is serviced with either Polyester Based Refrigerant Oil (POE) or Double end capped Polyalkylene oil (DEC PAG, aka Ultra PAG). The use of Mineral Oil or Polyalkylene (PAG) in this system will cause damage to the air conditioner compressor and expansion valves. A. New Installations - The total system oil charge is 8.0 fl oz. (238 ml.) of Double End Capped Polyalkylene Glycol (DEC PAG). The oil is initially contained within the compressor as shipped from the factory so no additional oil is required when installing a new system. B. Component Replacement - Once a system is in operation the lubrication is circulated through the system along with the refrigerant. The refrigerant becomes saturated with the oil and carries it throughout the system, lubricating the compressor internal parts. No other component in the air conditioning system requires lubrication. Excessive oil in the system causes a reduction in heat transfer and will result in poor air conditioning performance.