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AirComm Corporation Bell 407 Air Conditioner Instructions for Continued Airworthiness User Manual
AirComm Corporation Bell 407 Air Conditioner Instructions for Continued Airworthiness User Manual
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AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 July 17, 2015 AIR COMM CORPORATION 1575 W. 124th Avenue WESTMINSTER, CO. 80234 PHONE: 303-440-4075 FAX: 303-440-6355 [email protected] INSTRUCTIONS FOR CONTINUED AIRWORTHINESS BELL HELICOPTER 407 AIR CONDITIONING SYSTEM
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page ii 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.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page iv LIST OF EFFECTIVE PAGES LIST OF EFFECTIVE PAGES Title Page(s) Revision No. Record of Revisions iii 11 List of Effective Pages iv 11 Table of Contents v-vii 11 Chapter 1 Introduction 1-7 11 Chapter 2 Airworthiness Limitation Section 8 11 Chapter 3 Inspections 9-13 11 Chapter 4 Location and Access 14-28 11 Chapter 5 Placards and Markings 29-30 11 Chapter 6 Servicing 31-39 11 Chapter 7 Standard Practices 40-61 11 Chapter 8 Troubleshooting 62-70 11 Appendix A Weight and Balance Information 71 11
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page v TABLE OF CONTENTS CHAPTER PAGE 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 MEASUREMENT ............................................................................... 3 9. INFORMATION ESSENTIAL TO THE CONTINUED AIRWORTHINESS OF THE AIR CONDITIONER ............................................................................................. 3 10. REFERENCE DOCUMENTS ............................................................................... 3 11. DISTRIBUTION .................................................................................................... 3 12. CHANGES TO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ........... 3 13. AIR CONDITIONER FEATURES ......................................................................... 4 14. DESCRIPTION OF THE VAPOR CYCLE AIR CONDITIONER AND ITS INSTALLATION ................................................................................................... 6 15. REFRIGERATION CYCLE ILLUSTRATION ....................................................... 7 AIRWORTHINESS LIMITATION SECTION....................................................................... 8 1. AIRWORTHINESS LIMITATIONS ....................................................................... 8 INSPECTIONS ................................................................................................................... 9 1. INSPECTION REQUIREMENTS ......................................................................... 9 2. COMPONENT OVERHAUL / REPLACEMENT SCHEDULE .............................. 9 LOCATION AND ACCESS .............................................................................................. 14 1. LOCATION OF AIR CONDITIONER FEATURES ............................................. 14 CHAPTER 1 .............................................................................................................................. 1 CHAPTER 2 .............................................................................................................................. 8 CHAPTER 3 .............................................................................................................................. 9 CHAPTER 4 ............................................................................................................................ 10
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page vi PLACARDS AND MARKINGS ........................................................................................ 29 1. PLACARD AND MARKING INFORMATION ..................................................... 29 SERVICING ...................................................................................................................... 31 1. SAFETY PRECAUTIONS .................................................................................. 31 2. SERVICING INFORMATION ............................................................................. 31 SERVICING PROCEDURE .................................................................................. 31 LUBRICATION INFORMATION ........................................................................... 37 SYSTEM LEAK CHECK ...................................................................................... 39 3. SUGGESTED EQUIPMENT FOR SERVICING ................................................. 40 4. CONSUMABLE MATERIALS ............................................................................ 40 5. SUGGESTED SPARES LIST ............................................................................ 40 STANDARD PRACTICES INFORMATION ..................................................................... 42 1. FITTING TORQUING PROCEDURES AND TORQUE VALUES ...................... 42 1. REMOVAL & REPLACEMENT OF CONDENSER BLOWER MOTOR & FAN ASSEMBLY ....................................................................................................... 43 2. REMOVAL, REPLACEMENT & ADJUSTMENT OF COMPRESSOR DRIVE BELT .................................................................................................................. 44 3. REMOVAL, INSTALLATION / REPLACEMENT OF COMPRESSOR ASSEMBLY ....................................................................................................... 45 4. REMOVAL, INSTALLATION / REPLACEMENT OF COMPRESSOR DRIVE PULLEY ............................................................................................................. 46 5. REMOVAL, INSTALLATION / REPLACEMENT OF FORWARD EVAPORATOR ASSEMBLY ....................................................................................................... 49 6. REMOVAL, INSTALLATION / REPLACEMENT OF AFT EVAPORATOR ASSEMBLY ....................................................................................................... 50 7. REMOVAL, INSTALLATION / REPLACEMENT OF CONDENSER ASSEMBLY51 8. REMOVAL, INSTALLATION / REPLACEMENT OF RECEIVER DRIER BOTTLE ............................................................................................................. 52 9. REMOVAL, INSTALLATION / REPLACEMENT OF BINARY SWITCH ........... 53 10. REMOVAL, INSTALLATION/ REPLACEMENT OF BY-PASS VALVE ASSEMBLY ....................................................................................................... 54 CHAPTER 6 ............................................................................................................................ 31 CHAPTER 7 ............................................................................................................................ 42
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page vii 11. REMOVAL, INSTALLATION / REPLACEMENT OF AFT EVAPORATOR BLOWER ASSEMBLY ...................................................................................... 55 12. REMOVAL, INSTALLATION / REPLACEMENT OF THE CONDENSER SCOOP ASSEMBLY. ...................................................................................................... 55 TROUBLESHOOTING ..................................................................................................... 64 1. SYSTEM TROUBLESHOOTING ....................................................................... 64 WEIGHT AND BALANCE INFORMATION ...................................................................... 73 CHAPTER 8 ............................................................................................................................ 64 APPENDIX A ........................................................................................................................... 73
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 1 CHAPTER 1 INTRODUCTION 7. SCOPE The scope of this manual encompasses the scheduled and unscheduled maintenance procedures for the continued airworthiness of the Air Comm Corporation air conditioning system installed in the Bell 407 series helicopter. 8. PURPOSE The purpose of this manual is to provide the aircraft field mechanic the necessary information to maintain the air conditioning system. 9. ARRANGEMENT This manual is arranged by chapters which are broken down into paragraphs and sub-paragraphs. All of the 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. 10. APPLICABILITY This manual is applicable to Bell Helicopter models 407 that are equipped with the Air Comm Corporation kit number 407EC-201, 407EC-202 and 407EC-203 air conditioner systems. 11. DEFINITIONS The following terms are provided to give a ready reference to the meaning of some of the words contained within this manual. These definitions may differ from those given by a standard dictionary. Ambient air temperature: The 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 vapor into a liquid. Desiccant: A material used in the receiver/drier bottle, designed to absorb moisture from the 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.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 2 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. 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 gaseous state of a material. 12. 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 13. 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.
AIR CONDITIONER SERVICE MANUAL 407EC-200M-2 Revision 11 Page 3 14. UNITS OF MEASUREMENT All measurements contained within this manual are generally given in the United States standard measurement, with metric conversions in parentheses as needed. 15. INFORMATION ESSENTIAL TO THE CONTINUED AIRWORTHINESS OF THE AIR CONDITIONER This manual provides information which is required for operation and maintenance of the Air Comm air conditioning system installed in the Bell model 407 series helicopter. After completion of the air conditioner installation this document must be placed with the appropriate existing aircraft documents. 16. REFERENCE DOCUMENTS The approval basis of the system covered by this ICA is Supplemental Type Certificate SR0033DE 17. 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”, and 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 (page i), and on the List of Revisions (page ii) 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, and or to correct, the “Safety of Flight” issue. Replacement, and or revised copies of this manual maybe acquired by contacting: Air Comm Corporation Service Department 1575 W. 124th Ave STE 210 Westminster, CO.80234 Phone No. 303-440-4075 Fax No. 303-440-6355 [email protected] 18. 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, while 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).