AirComm Corporation Airbus EC135 Cabin Air Conditioner Instructions for Continued Airworthiness User Manual

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8  February 23, 2015 
 1575 West 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 
AIRBUS EC135 
AIR CONDITIONING SYSTEM 
 
 
 
 
 
 
THIS HANDBOOK INCLUDES THE MAINTENANCE INFORMATION 
REQUIRED TO BE AVAILABLE BY FAR PART 27 
 
 
 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
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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. 
   
						

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LIST OF EFFECTIVE PAGES 
Title Page(s) Revision No. 
Record of Revisions iii 8 
List of Effective Pages iv 8 
Table of Contents v to vi 8 
Chapter 1 Introduction 1 to 6 8 
Chapter 2 Airworthiness Limitation Section 7 8 
Chapter 3 Inspections 8 8 
Chapter 4 Location and Access 9 to 19 8 
Chapter 5 Placards and Markings 20 8 
Chapter 6 Servicing 21 to 28 8 
Chapter 7 Standard Practices 29 to 41 8 
Chapter 8 Troubleshooting 42 to 45 8 
 
 
Appendix A 
Weight and Balance Information 47 8 
 
  
						

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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 ..................................................................................................... 2 
8. Units of Measure ............................................................................................. 2 
9. Information Essential to Continued Airworthiness ........................................... 3 
10. Reference Documents .................................................................................... 3 
11. Distribution ...................................................................................................... 3 
12. Changes to Instructions for Continued Airworthiness ..................................... 3 
13. Air Conditioner Features ................................................................................. 3 
14. Description of Vapor Cycle Air Conditioner and Installation ............................ 5 
15. Refrigeration Cycle Illustration ........................................................................ 6 
CHAPTER 2 .................................................................................................................... 7 
AIRWORTHINESS LIMITATION SECTION ................................................................ 7 
1. Airworthiness Limitations ................................................................................ 7 
CHAPTER 3 .................................................................................................................... 8 
INSPECTIONS AND OVERHAUL ............................................................................... 8 
1. Inspection Requirements ................................................................................ 8 
2. Inspection Of Blower Electrical Connectors (annual requirement) .................. 8 
3. Component Overhaul / Replacement Schedule .............................................. 9 
CHAPTER 4 .................................................................................................................. 10 
LOCATION AND ACCESS ........................................................................................ 10 
1. Location of Air Conditioner Components ...................................................... 10 
CHAPTER 5 .................................................................................................................. 21 
PLACARDS AND MARKINGS ................................................................................... 21 
1. Placard and Marking Information .................................................................. 21  
						

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CHAPTER 6 .................................................................................................................. 22 
SERVICING ............................................................................................................... 22 
1. Safety Precautions ........................................................................................ 22 
2. Servicing Information .................................................................................... 22 
3. Lubrication Information ................................................................................. 25 
4. System Leak Check ...................................................................................... 26 
5. Suggested Equipment for Servicing .............................................................. 27 
6. Consumable Materials .................................................................................. 27 
7. Suggested Spares List .................................................................................. 28 
CHAPTER 7 .................................................................................................................. 29 
STANDARD PRACTICES AND INFORMATION ....................................................... 29 
1. Fitting Torque Procedures and Values .......................................................... 29 
2. Torque Seal. ................................................................................................. 30 
3. General Information ...................................................................................... 30 
4. Removal and Replacement of Forward Evaporator Assembly (LH or RH) ... 30 
5. Removal and Replacement of Forward Evaporator Blower Motor Assembly 
(LH or RH, Figure 8 and Figure 9).......................................................................... 31 
6. Removal and Replacement of Aft Evaporator Assembly .............................. 32 
7. Removal and Replacement of Aft Evaporator Blower Motor Assembly ........ 32 
8. Removal and Replacement of Condenser Assembly (Figure 11) ................. 34 
9. Removal and Replacement of Condenser Blower Assembly (Figure 11) ..... 34 
10. Removal, Replacement and Adjustment of Compressor Drive Belt .............. 35 
11. Removal and Replacement of Compressor Assembly .................................. 36 
12. Removal and Replacement of Receiver Drier (Figure 13) ............................ 39 
13. Removal and Replacement of Bypass Valve (Figure 14) .............................. 40 
14. Removal and Replacement of Binary Switch (Figure 13) .............................. 41 
CHAPTER 8 .................................................................................................................. 42 
TROUBLESHOOTING ............................................................................................... 42 
1. System Troubleshooting ............................................................................... 42 
2. System Schematics ...................................................................................... 44 
APPENDIX A ................................................................................................................. 47 
WEIGHT AND BALANCE INFORMATION ................................................................ 47 
 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
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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 Airbus EC135 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 Bell Helicopter  models EC135,  P2,  T2,  P2+,  and  T2+ 
equipped  with  Air  Comm  Corporation  kit  number EC135-200  & EC135-202 air 
conditioner systems. 
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. 
Ambient air temperature: Temperature of the air surrounding a person or object. 
Charging  station: An  air  conditioning  system  service  unit  which  is  capable  of 
evacuating and charging an air conditioner. 
Condensation: The process of changing a gaseous phase into a liquid. 
Desiccant: Material  used  in a receiver/drier  bottle,  designed  to  absorb  moisture  from 
refrigerant. 
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. 
Pressure,  ambient: The  pressure  of  the  air  surrounding  a  body,  normally  measured  in 
pounds per square inch, 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.  
						

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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 gas formed by boiling or evaporating a liquid.  A gas at a temperature below 
its critical temperature. 
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 
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 generally given in the United States 
standard measurement, with metric conversions in parentheses as needed. 
   
						

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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 the Airbus model  EC135 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 
SR00565DE. 
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  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 
1575 West 124th Ave. 
Westminster, Colorado 80234 
Phone No. 303-440-4075 Fax No. 303-440-6355 
[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 two forward (optional single forward evaporator) 
mounted  evaporator  (cockpit),  one  aft  mounted  evaporator  assembly  (below  main 
cabin),  one  condenser,  and  a  compressor  driven  by  the  accessory  drive  pad  just  aft  of 
the  aft  main  transmission.  These  components  combine  to  provide  “conditioned  air” 
through  sections  of  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 Fan  mode.  In the A/C 
mode,  conditioned  air  is  provided  by  the forward  and  aft  evaporators  to  the  cockpit and 
main  cabin  areas  respectively.  In  the  Fan  mode,  the  evaporator  blowers  are  used  to 
circulate  cabin  air,  while  the  compressor  clutch  remains  disengaged.  When  using  the  
						

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cabin  heater  it  is  acceptable  to  operate  the  air  conditioner  if  desired,  to  assist  in 
defogging 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 center console 
between  the  pilot’s  and  co-pilot’s  seats.  This  panel  consists  of  the  A/C  &  Fan  switch, 
two  switches,  for  the  control of  the  Cockpit  &  Cabin  evaporator  blower  fan  speeds,  a 
“FRESH”  /  “RECIRC”  switch  which  opens  and  closes an air  inlet  box  located  above  the 
main  cabin  overhead  air  outlets,  a  Temperature  control  rheostat  knob,  and  compressor 
on annunciator. 
 
 
Figure 1:  Cockpit A/C Control Panel 
 
The Fan motors feature dual speed operation (Hi or Lo), and this feature can be used in 
both the air conditioner or fan modes. 
The  compressor  is  mounted  to  the  surface  of  the  Main  Gear  Box  Drive  Pad, in  the  aft 
aircraft center portion of the transmission compartment. It is driven by a Ploy V-belt and 
a pulley which is mounted to a splined drive shaft. Access to the compressor is provided 
by  transmission  compartment  access  doors.  Airflow  through  the  condenser  heat 
exchanger is provided by two 28 volt DC high performance blowers. 
The  aft  evaporator  is  equipped  with  a  Freeze  Switch.  The  Freeze  Switch  probe  is 
located  in  the  core  of  the  evaporator  heat  exchanger.  This  unit  performs  two  functions; 
1. It acts to prevent coil freeze-up by limiting  the minimum coil temperature to 32º F (0º 
C),  and  2.  It  acts  in  conjunction  with  the  cabin  air  temperature  control  system,  by 
controlling  the  bypass  of  refrigerant  through  the  evaporator  coil  in  response  to 
adjustment of the thermostat switch located on the control panel assy. between the pilot 
and co-pilots seats. 
The  refrigerant  plumbing  for  this  system  installation  incorporates  insert O-Ring and 
TORQ LOK® fittings: 
A. INSERT  O-RING  FITTINGS:  These  fittings  have  formed ends  that  along  with  an O-
Ring create a seal. Caution when assembling these fittings; care should be taken not 
to  damage  the O-Ring (i.e.  nicking,  splitting,  or  crushing,  etc.).  These  fittings  are 
signified  by  a  green  band  placed  around  the  outside  diameter  of  the  hose  or  tube 
they  are  utilized  on. Black O-Rings  must  not  be  used  on  these  fittings.  (See 
CHAPTER 7 for torqueing procedures).