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AirComm Corporation Bell Air Conditioner 206L4 Installation Instructions with TORQLOK Plumbing
AirComm Corporation Bell Air Conditioner 206L4 Installation Instructions with TORQLOK Plumbing
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INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 35 7. REMOVE AND REPLACE COMPRESSOR DRIVE PULLEY (Figure 12) 7.1 REMOVE COMPRESSOR DRIVE PULLEY a Remove compressor drive belt per section 6 (Above). Retain all hardware and disc. (Page 30). b Remove cotter pin from fwd end of S-3014EC-1 bolt assembly and remove AN320-6 nut. c Remove drive pulley from 206-040-320 shaft assembly. 7.2 REPLACE COMPRESSOR DRIVE PULLEY a Apply anti seize lubricant to inside spline of drive pulley and install on 206-040-320 shaft assembly. b Torque AN320-6 nut to 40-60 in/lbs and install new AN380-3-3 cotter key. c Re-install belt and driveshaft per section 6 (Page 30). 8. REMOVE AND REPLACE FORWARD EVAPORATOR (Figure 14) 8.1 REMOVE FORWARD EVAPORATOR a. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station or equivalent. b. Remove instrument side panel just aft of evaporator. c. Remove Suction and Pressure hoses from evaporator. d. Install caps and plugs over outlets and hoses. e. Disconnect electrical connector. f. Disconnect air outlet duct from evaporator. g. Remove and retain evaporator mounting hardware. h. Remove evaporator. 8.2 REPLACING FWD EVAPORATOR a. Re-install the evaporator and its mounting hardware. b. Reconnect air outlet duct to evaporator. c. Reconnect electrical connectors. d. Remove caps and plugs over outlets and hoses. e. Replace the ES44012-2 and -4 O-Rings in hose fittings and install hoses per instructions on pg. 27. f. Reconnect suction and pressure hoses to evaporator. g. Re-install instrument side panel just aft of evaporators. h. Service with R134a refrigerant per CHAPTER 6.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 36 9. REMOVE AND REPLACE AFT EVAPORATOR (Figure 15) 9.1 REMOVE AFT EVAPORATOR a. Remove plastic Hat Rack from aft end of cabin. b. Open baggage door and remove oval ceiling panel. c. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station or equivalent. d. Remove Suction and Pressure hoses from evaporator. e. Install caps and plugs over outlets and hoses. f. Disconnect electrical connector. g. Disconnect air inlet and outlet ducts from evaporator. h. Remove and retain evaporator mounting hardware. i. Remove evaporator. 9.2 REPLACING AFT EVAPORATOR a. Reinstall the evaporator and mounting hardware. b. Reconnect air inlet and outlet ducts to evaporator. c. Reconnect electrical connectors. d. Remove caps and plugs over outlets and hoses. e. Reconnect suction and pressure hoses to evaporator. f. Replace the ES44012-2 and -4 O-Rings in hose fittings and install hoses per instructions on pg. 27. g. Service with R134a refrigerant per CHAPTER 6. h. Reinstall oval ceiling panel in baggage compartment. i. Reinstall plastic hat rack in aft end of cabin. Figure 14: Forward Evaporator – View G-G S-6106EC-1 Evaporator Air Outlet Ducting 5X AN525-10R12 Screw 5X NAS1149F0332P Washers Drain Tube
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 37 10. REMOVE AND REPLACE AFT EVAPORATOR BLOWER (Figure 15) 10.1 REMOVE AFT EVAPORATOR BLOWER a. Open baggage door and remove oval ceiling panel. b. Disconnect electrical connector on blower. c. Remove all three flex ducts from blower housing and adapter. d. Remove AN525-10R8 screws that support blower. e. Remove blower through access panel opening in baggage compartment ceiling. 10.2 REPLACING AFT EVAPORATOR BLOWER a. Open baggage door and remove oval ceiling panel. b. Install blower through access panel opening in baggage compartment ceiling. c. Install all three flex ducts to blower housing and adapter using CT21 cable ties. d. Install 6 ea. AN525-10R8 screws that support blower. e. Connect electrical connector on blower. f. Test blower to ensure blower wheel does not rub and turns the right direction. Figure 15: Evaporator Blower - VIEW E-E CT21 Tywrap Evaporator BlowerAft Evaporator 4X AN525-10R8 Screw4X NAS1149F0332P Washer No. 52 Clamp 6X AN525-10R8 Screw6X NAS1149F0332P Washer
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 38 11. REMOVE AND REPLACE CONDENSER BLOWER ASSEMBLY (Figure 16 and Figure 17). 11.1 REMOVE CONDENSER BLOWER ASSEMBLY a. Deactivate Air Conditioner circuit breaker on overhead circuit breaker panel. b. Working under aircraft beneath baggage compartment floor, remove 13ea AN525- 10R12 screws. c. Swing blower assembly down and disconnect Molex electrical connector. d. Remove 6 ea. AN525-10R8 screws MS21042L3 nuts and NAS1149F0332P washers. Remove condenser blower assembly. 11.2 REPLACING CONDENSER BLOWER ASSEMBLY a. Install condenser blower assembly. b. Install the electrical connectors. For kits prior to 2015 that use the Molex connector refer to CHAPTER 7, Section 4, page 28 for installation information. c. Secure condenser blower with retained hardware. d. Under aircraft beneath baggage compartment floor, install 13 AN525-10R12 screws. e. Activate air conditioner circuit breaker on overhead panel. f. Turn air conditioner switch to “ON”. Ensure that scoop opens and blower draws air in through scoop and out through heat exchanger. 12. REMOVE AND REPLACE CONDENSER HEAT EXCHANGER (Figure 18). 12.1 REMOVE CONDENSER HEAT EXCHANGER a. Remove aft panel in baggage compartment. b. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station or equivalent. c. Remove Suction and Pressure hoses from condenser heat exchanger. d. Install caps and plugs over outlets and hoses. e. Remove condenser blower assembly per step 11 above. f. Remove heat exchanger retaining screws from under side of baggage compartment. g. When heat exchanger is loose, remove it through the blower assembly opening.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 39 Figure 17: Condenser Install - VIEW C-C Figure 16: Condenser Install VIEW LOOKING UP AN525-10R8 ScrewsMS21042L3 NutsNAS1149F0332P Washers 6 PlsS-7060EC-1Blower Assy FWD SECTION VIEW OF LEFT SIDE 155.8STA Lower contour ofbelly panel AN525-10R12 Screws 13 Pls
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 40 Figure 18: Condenser Install - View E-E
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 41 12.2 REPLACING CONDENSER HEAT EXCHANGER a. Replacing the heat exchanger is the reverse of removal. b. Insert heat exchanger through the blower assembly opening. c. Secure heat exchanger in place using original hardware. d. Replace the ES44012-2 and -3 O-Rings in hose fittings and install hoses per instructions. See section 12. e. Service with R134a refrigerant per CHAPTER 6. f. Reinstall condenser blower assembly per Step 11 of this section. 13. REMOVE AND REPLACE BYPASS VALVE (Figure 19). 13.1 REMOVE BYPASS VALVE a. Remove aft panel in baggage compartment. b. Recover refrigerant using Robinair Model 34700 Recover/Recycling/Recharge Station or equivalent. c. Remove 2X MS35275-240 Screws from valve mount bracket. d. Cut wires at splices. e. Disconnect tubing from valve and remove valve from aircraft. 13.2 REPLACE BYPASS VALVE a. Install valve in aircraft and connect tubing. b. Re-connect wires using new M81824/1-2 splices. c. Reinstall retained screws in valve mount bracket. d. Service with R134a refrigerant per CHAPTER 6. e. Always install new O-Rings in fittings. f. Always use back-up wrenches when tightening tube or hose fittings. g. Reinstall aft panel in baggage compartment. 14. REMOVE AND REPLACE BINARY SWITCH (Figure 19). 14.1 REMOVE BINARY SWITCH a. Remove aft panel in baggage compartment. b. Remove electrical connectors from switch. c. Remove switch from tube. NOTE Not Necessary to discharge system. d. Place cap over tube fitting. 14.2 REPLACE BINARY SWITCH a. Remove cap from tube fitting and install switch. NOTE Do not over tighten switch. b. Re-connect wires to Binary Switch. c. Reinstall aft panel in baggage compartment.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 42 Figure 19: Binary Switch – View F-F Binary Switch Solenoid Bypass Valve 2X MS35275-240 Screw Drier/Receiver
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 43 CHAPTER 8 TROUBLESHOOTING 1. System Troubleshooting Prior to troubleshooting a defective system, it is advisable to conduct a visual inspection for general condition and obvious signs of damage or failure. The following matrix lists the easiest checks and the most likely problems. Problem Cause Solution Premature Belt Failure a. Belt too loose b. Compressor misalign. c. System over charged a. Adjust belt tension b. Re-install/align compressor c. Adjust system charge Condenser blower motor Circuit Breaker “Pops” a. Probable cause- Overheating of condenser blower motor a. Check for loose or rubbing of fan blade, or possible replacement of motor Water (Condensate) in area of the aft evaporator a. Condensate drain fitting on evaporator not sealed b. Evaporator housing not sealed c. Drain line / check valve not installed properly d. Condensate forming on plumbing fittings a.b.c. Verify that installation conforms to drawing requirements. (remove evaporator inlet duct, and pour 1/2 ltr. Of water into housing assy. To check for leaks & drainage. d. apply cork insulation to all exposed refrigerant lines. Water in chin bubble area of forward evaporator a. Forward evaporator housing not sealed b. Condensate drain line fittings not secure at evaporator connection. c. Drain line check valve not installed a. Same as above. Conditioned air outlet louvers broken / loose a. Replace Louvers Evaporator Coil freeze up a. System suction pressure (temperature) too low. System suction pressure should not be below 20 psi. a. Adjust system charge to obtain 25 – 32 psi. System not Cooling a. Loss of refrigerant b. Water in system a. Leak check, evacuate system and recharge. b. Evacuate system, replace receiver drier bottle, & recharge System with Poor Cooling a. By-pass Valve a. Check to ensure the temperature control knob is in the full cold position, and the temperature control circuit breaker has not tripped. If the valve remains open (by-passing refrigerant) the valve will need replacement. 2. ELECTRICAL With the engine off turn switch to “Blower” and make sure all evaporator blowers operate in both Hi and Low modes. Pull evaporator circuit breaker in battery compartment, and turn switch to A/C. Check that the condenser blower and actuator assembly is working, and the compressor clutch is engaging.
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS - 206EC-270M-1 Revision H Page 44 3. SYSTEM CHARGE See page 24 “Charging Procedures”. 4. EXPANSION VALVE MALFUNCTION If the cooling loss is limited to only one evaporator, it is most likely a defective expansion valve. Loss of cooling in all evaporators (assuming that there were no problems identified during steps 1 or 2) could be caused by refrigerant flow blockage at the expansion valves. This blockage could be due to ice or dirt. Replacement of the drier bottle and a thorough system evacuation might be a fix (remove the possibility of ice at the expansion valve nozzles). 5. COMPRESSOR MALFUNCTION If the system will not maintain the pressures and there are no system leaks, the problem could be a failed compressor. The compressor must then be replaced. 6. SYSTEM LEAK CHECK The system should be leak tested using an electronic leak detector. Initial leak check can be accomplished with a refrigerant charge of .5 lbs and the electronic leak detector. Each fitting should be checked and repaired prior to the final charging process. Do not use compressed air for the pressure check! Compressed air can introduce moisture in the system which will cause it to operate poorly or not at all. Take your time, and check all around each fitting. A little extra time during the leak check will save a significant amount of time later during servicing or troubleshooting. All leak checks should be conducted with the air conditioner “off”. Since the refrigerant is heavier than air, leaks are most likely detected on the underside of hoses and fittings. Also the refrigerant will collect in low areas and provide an erroneous leak indication. A stream of “shop air” through a nozzle is useful in clearing an area just before checking for leaks. If a leak is detected at an O-ring fitting, reclaim the system and install a new O-ring. Lubricate the O-ring with refrigerant oil prior to installation. A small amount of leakage (one ounce per year) past the compressor seal is normal. Most leak detectors are sensitive enough to show a leak of this magnitude.