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AirComm Corporation Bell 429 Air Conditioning 429EC200M1Rev9 User Manual
AirComm Corporation Bell 429 Air Conditioning 429EC200M1Rev9 User Manual
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AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 43 NOTE Maintaining the correct amount of refrigerant and refrigerant oil in the system is critical for ensuring the long life of the compressor. 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. 4. System Leak Check A. It is important to identify and eliminate refrigerant leaks at system connections to ensure trouble free operation of the air conditioning system. A new or empty system can be pressurized with R134a at 50 psi (3.5 kgcm) to conduct a leak survey. Do not pressurize the system with compressed air. Compressed air will introduce moisture into the system, which will degrade the operation of the system. The preferred method is to use an electronic leak detector in conjunction with a small charge of R134a refrigerant. All checks done in this manner should be conducted with the air conditioner off. Since the refrigerant is heavier than air, leaks are most likely to be detected on the underside of hoses and fittings. In some cases, leaking refrigerant gas may collect in low areas of the aircraft and provide erroneous leak detection. A stream of compressed air from a nozzle may be useful in clearing the area just prior to conducting a leak test. B. If a leak is detected at an O-Ring fitting, check to insure proper torque has been applied to the fitting. If the system continues to leak, reclaim the refrigerant and install a new O- Ring. NOTE Be sure that the O-Ring is lubricated with refrigerant oil prior to its installation. A small amount of leakage (approximately one ounce per year) past the compressor shaft seal is normal. Most leak detectors are sensitive enough to show a leak of this magnitude. 5. Suggested Equipment for Servicing Recovery / Recycling / Recharging Station (Example: Sun (Snap-on) Kool Kare QTech III, Robinair Model 34788, or equivalent) Note: new equipment should meet SAE standard J2788 Electronic Leak Detector (R134a compatible) (Example: Micro-Tech III, Robinair, Snap-on, or equivalent) Manifold and gauge set (R134a compatible)
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 44 (Example: Robinair, Snap-on, or equivalent) 6. Consumable Materials A. Refrigerant: This system is to be charged with Dupont (or equivalent) HFC R134a refrigerant. Lubricant: Lubricant: Ultra PAG refrigerant oil. See Lubrication information, pg. 39. B. O-Rings: This system utilizes the refrigerant HFC R134a. Consequently, the system must also utilize Highly Saturated Nitrile (HSN O-Rings) the insert O-Ring fittings (as previously described in this manual) require the use of Green HSN O-Rings while the TORQ LOK® Fittings (As previously described in this manual) require the use of the Black HSN O-Rings. C. Loctite thread sealer 554 (or equivalent). D. Torque-Seal Anti Sabotage Lacquer. 7. Suggested Spares List ITEM PART NUMBER Binary Pressure Switch ES57178-1 Drive Belt, Compressor ES35429-1 Bypass Valve ES26194-6 Receiver Drier Bottle ES43030-5 Compressor Assembly S-3038EC-1 Condenser Blower, pre-July 2015 S-6063EC-1 Condenser Blower, July 2015 & newer S-6085EC-2 Blower Motor Assembly (LH Fwd Evaporator) S-6029EC-11 Blower Motor Assembly (RH Fwd Evaporator) S-6029EC-12 Blower Motor Assembly (LH Aft Evaporator) 429EC-6302-11 Blower Motor Assembly (RH Aft Evaporator) 429EC-6302-12
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 45 HSN O-Rings; Insert Type (Green) # 6 O-Ring ES44010-2 # 8 O-Ring ES44010-3 # 10 O-Ring ES44010-4 HSN O-Rings; TORQ LOK® Type (Black) #6 O-Ring ES44012-2 #8 O-Ring ES44012-3 #10 O-Ring ES44012-4
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 46 CHAPTER 7 STANDARD PRACTICES AND INFORMATION 1. Fitting Torque Procedures and Values INSERT O-RING FITTINGS TORQ-LOK® FITTINGS Apply a thin coating of refrigerant oil to O-Ring and Female side of fitting. Confirm there is no damage (nicks, dirt, etc.) on fittings. Slide B-nut back away from the end of the tube so you can see the O-Ring as you slide the fitting together. Be careful not to pinch O-Ring during assembly. Engage the male end into the female fitting being careful to maintain alignment. The male flange should seat fully against the female fitting without the O-Ring being pinched. It is important to hold the fitting together while sliding the B-nut forward and engaging the threads. Tighten the B-nut by hand and then torque as follows: Tightening specifications CAUTION: ALWAYS USE BACK UP WRENCH. EXCESSIVE TORQUE WILL DAMAGE THE JOINT, COMPROMISING THE INTEGRITY OF THE SEAL. Insert O-Ring Fittings (regardless of size): Hand tighten, then turn an additional 60 deg. (one flat on the nut). TORQ-LOK ® fittings (regardless of size): Hand tighten, then turn an additional 30 deg. DO NOT OVER TORQUE ALWAYS USE BACK UP WRENCH INSERT O-RING FITTINGS TORQ-LOK® FITTINGS
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 47 Once the system is charged, check each fitting with an electronic leak detector. An electronic leak detector is the only reliable method of checking for refrigerant leaks. Once the fittings have been checked and are found to be free of leaks, torque seal as appropriate. 2. Removal and Replacement of Forward Evaporator Blower Motor Assembly Removal CAUTION It is recommended that battery and external power be disconnected before starting work. Care should also be taken to protect the chin bubble area from scratches while performing this task using a foam sheet or other protective measure. A. Disconnect Molex connector located on motor controller from aircraft wiring. CAUTION Be sure to support blower motor assembly while removing attaching hardware to prevent damage to blower assembly, evaporator assembly, or the aircraft. B. Remove and retain six (6) screws from blower motor base (five (5) size 12 and one (1) size 8 screws). C. Remove blower motor assembly from evaporator housing. Installation/Replacement CAUTION It is recommended that battery and external power be disconnected before starting work. Care should also be taken to protect the chin bubble area from scratches while performing this task using a foam sheet or other protective measure. A. Install new blower motor assembly in the appropriate location. B. Ensure the blower motor assembly is supported while installing attachment hardware. C. Reinstall six (6) mounting screws to the blower motor base. D. Reconnect Molex connector located on motor controller to aircraft wiring. E. After re-applying power, perform an operational check by switching the air conditioning control switch to the “BLOWER” position and operating the forward evaporator blower fan through its entire range of speed to ensure motor does not bind, chafe, or drag.
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 48 3. Removal and Replacement of Forward Evaporator Assembly Removal A. It will be necessary to discharge (evacuate) refrigerant from the system to remove or replace the forward evaporator assembly. Instructions on servicing and evacuating this system can be found in Chapter 6 of this manual. CAUTION Refrigerant servicing should be performed by qualified personnel only. CAUTION It is recommended that battery and external power be disconnected before starting work. B. Remove the panel located on the underside of the aircraft nose to gain access to the fwd evaporator plumbing. CAUTION Always use a backup wrench when removing, or installing refrigerant line fittings. C. Disconnect the aircraft plumbing from the forward evaporator assembly and cap to prevent oil leakage. D. Disconnect all ducting attached to forward evaporator blower outlet. E. Disconnect drain hoses from bottom of evaporator assembly. F. Disconnect evaporator assembly from aircraft wiring at the existing Molex connector located on the evaporator motor controller. G. Remove attaching hardware from the forward evaporator assembly located on the forward and aft side of evaporator. CAUTION Be sure to support the evaporator assembly during removal to prevent damage to the aircraft or evaporator assembly. H. Once attaching hardware has been removed the evaporator may be removed from the aircraft. Installation/Replacement CAUTION It is recommended that battery and external power be disconnected before starting work.
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 49 CAUTION Refrigerant servicing should be performed by qualified personnel only. A. Install evaporator assembly in the appropriate location. B. Ensure the evaporator assembly is supported while installing attachment hardware. C. Reinstall attachment hardware to attach the forward evaporator assembly on to the forward and aft side of the evaporator. D. Reconnect Molex connector located on evaporator motor controller. E. Reconnect the drain hoses to the bottom of the evaporator assembly. F. Reconnect all ducting attaching the forward evaporator blower outlet. CAUTION Always use a backup wrench when removing, or installing refrigerant line fittings. G. Reconnect the aircraft plumbing to the forward evaporator assembly. H. Replace all O-Rings before connecting refrigerant plumbing to evaporator fittings using a back-up wrench. Torque refrigerant line connections to 30–35 inch-lbs (3.4-4.0 Nm) for the #6 fitting and 40–45 inch-lbs (4.6-5.1 Nm) for the #8 fitting. I. Reinstall the panel on the underside of the aircraft nose. J. Service air conditioning in accordance with Chapter 6 of this manual. 4. Removal, Replacement and Adjustment of Compressor Drive Belt Removal A. It is necessary to access the upper transmission compartment to remove, replace, or adjust the compressor drive belt. B. Cut safety wire on the compressor belt tensioning link and jam nuts, and loosen the respective jam nut(s). C. Before attempting to adjust drive belt tension, ensure that compressor mounting / attaching bolts have been loosened to allow free movement of compressor body on the compressor mount. D. Adjust belt tension by turning the barrel portion of the tension link until enough slack has been achieved to pull the belt off of the compressor pulley.
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 50 E. Gain access to the lower drive pulley in accordance with BELL service manual to remove belt from the hydraulic pump quill pulley. Installation/Replacement A. Install the drive belt on the compressor pulley and hydraulic pump quill pulley. CAUTION Care should be taken to ensure that the new belt is not damaged (nicked or cut) during installation. B. Adjust belt tension (See adjustment below). C. Tighten the belt tensioning link jam nuts and safety wire using .032 safety wire. D. Torque the compressor mounting bolts to 160 to 190 inch lbs. (18.08 – 21.47 Nm). Adjustment NOTE Proper belt tension is important to insure a long belt service life and to avoid excessive loads on the compressor, and bearing assemblies. A. The correct belt tension is achieved when the belt deflects .18” when a 5lb load is applied as shown below. This can be achieved with the aid of a belt tensioning tool (Gates 7401-0076 Belt Tension Gauge or equivalent). This is the preferred method of obtaining proper belt tensioning. B. An alternate method is to observe a .10” belt deflection when 5 lbs of force is applied at the midpoint of the belt. NOTE The belt tension should be checked, and adjusted, if necessary after the first two hours of operation for a newly installed belt.
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 51 5. Removal and Replacement of Compressor Assembly Removal A. It is necessary to access the upper transmission compartment to remove, replace, the compressor assembly. B. See Removal, Replacement, & Adjustment of Compressor Drive Belt prior to the removal of the air conditioner compressor assembly. C. It will be necessary to evacuate (discharge) the refrigerant from the system to remove and replace the air conditioner compressor. Instructions for servicing of the system are found in Chapter 6 servicing of this manual. CAUTION Refrigerant servicing should be performed by qualified personnel only. D. Disconnect the refrigerant hoses from the suction and discharge ports located on the aft top of the compressor housing. E. Remove attaching hardware for safety straps. F. Remove the attaching hardware from the top of the belt tensioning link and the compressor mount assembly. CAUTION Before removing the compressor attaching hardware it is necessary to seek assistance in supporting the compressor, due to the weight and position of this component. Failure to do so may result in damage to the aircraft. G. Remove the mounting bolt that attach the compressor body to the top of the compressor mount, and remove compressor assembly. Installation/Replacement A. Install the compressor assembly in the appropriate location. B. Ensure the compressor assembly is supported while installing attachment hardware. C. Reinstall the attaching hardware to the top of the belt tensioning link and the compressor mount. D. Torque attaching hardware to 160 to 190 inch lbs. (18.08 – 21.47 Nm). Reinstall the attaching hardware for the safety straps.
AIR CONDITIONER SERVICE MANUAL 429EC-200M-1 Revision 9 Page 52 E. Replace the O-Rings on the refrigerant hoses, and re-connect the hoses to the compressor housing. Torque the #10 hose fitting to 50 – 55 inch lbs (5.7-6.3 Nm) and torque the #8 hose fitting to 40 – 45 inch lbs (4.6-5.1 Nm). F. Install the belt tension bolt and attaching hardware to the compressor, and torque to 160 to 190 inch lbs. (18.08 – 21.47 Nm). G. Adjust the belt adjustment per the procedure shown on page 41. CAUTION Refrigerant servicing should be performed by qualified personnel only. NOTE An electronic leak detector should be used any time a component is replaced or the system has been opened, to insure trouble free operation of the air conditioner system. H. Recharge the refrigerant per the servicing instructions in Chapter 6 of this manual. I. Reinstall all cowlings removed to access the compressor assembly. 6. Removal and Replacement of Aft Evaporator Assembly Removal CAUTION It is recommended that battery and external power be disconnected before starting work. A. It is necessary to access the upper transmission compartment to remove, replace, the aft evaporator assembly. CAUTION Refrigerant servicing should be performed by qualified personnel only. B. It will be necessary to evacuate (discharge) the refrigerant from the system to remove and replace the aft evaporator assemblies. Instructions for servicing of the system are found in Chapter 6 servicing of this manual. C. Disconnect blower outlet ducting from the evaporator assembly. CAUTION Always use a backup wrench when removing, or installing refrigerant line fittings. D. Disconnect the aircraft plumbing from the evaporator assembly and cap to prevent oil leakage.