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

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 15 
 
 
 
 
 
 
 
 
 
 
Figure 10:  Aft Evaporator Installation 
Beneath Cabin Floor 
(View Looking Down) 
  
EC135-6008-1 
Aft Evaporator Assy 
ES61142-3 
Blower Motor 
EC135-6844-1 
Blower Assy  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 16 
 
 
 
 
Figure 11:  Condenser Installation 
(View Looking Inboard, LH Side) 
 
  
EC135-7000-1 
Condenser Assy 
Tailboom (ref) 
Engine Exhaust 
(ref) 
ES73186-9 
Blower Assy 2X  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
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Figure 12:  Air Distribution Installation 
(View Looking Inboard, LH Side) 
 
  
ES39210-2 
Airbox Actuator 
EC135-6812-1 
Air Box Assy 
EC135-6800-1 
Headliner Duct Assy 
Cabin Floor (ref)   
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 18 
 
 
 
 
 
 
Figure 13:  Receiver Drier, Service Ports, and Pressure Switch Installation 
(View Looking Inboard, LH Side) 
  
ES43030-6 
Receiver Drier 
(located behind 
condenser assembly) 
Low Pressure 
Service Port 
ES57178-1 
Pressure Switch 
High Pressure 
Service Port 
Condenser Assy 
(ref)  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 19 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 14:  Bypass Valve Installation 
(View Looking Inboard, LH Side) 
 
 
  
EC135-6008-1 Aft 
Evaporator (Ref) 
ES26194-24 
Bypass Valve 
Note Arrow Flow Direction  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 20 
 
 
 
 
 
 
 
Figure 15:  Relay Panel Installation 
(View Looking Outboard)  
 
 
Relay Panel Assy 
EC135-8420-2 
LH Outside 
Skin Panel  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
Revision 8 Page 21 
CHAPTER 5 
PLACARDS AND MARKINGS 
1. Placard and Marking Information 
 
 
 
 
 
Figure 16:  System Charging Instruction Placard 
(Refrigerant charge shown for dual evap installation) 
 
NOTE 
Newer systems do not include the “BOULDER, COLORADO” annotation on the System 
Charging Instructions Placard. 
 
NOTE 
Systems shipped in 2015 or later include both “Polyester oil” and “Ultra PAG oil” in the 
annotation on the System Charging Instructions Placard. 
 
 
4.0 1.82  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
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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 be  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. 
 
   
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
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NOTE 
A  list  of  suggested  servicing  equipment  is  provided  later  in  this 
chapter. 
 
Servicing Procedure 
 
A. Connect  the  servicing  manifold  to  the  servicing  ports  located adjacent  to  the 
condenser  assembly (Figure 13). 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  Level 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. 
  
						

							INSTRUCTIONS FOR CONTINUED AIRWORTHINESS EC135-200M-1 
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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  refrigerant  must  be 
charged  into  the  system  without  the  compressor  engaged  or  the 
system operating. 
 
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 3.0 Lbs (1.82 Kg.). Open doors to the helicopter so 
that the evaporator inlet air remains stable during charging. 
 
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.