instructions for continued airworthiness
Contents
1. Integrated Flight Systems Air Conditioning System Instructions for Continued Airworthiness For Eurocopter France AS355E AS355F AS355F 1 AS355F2 AS355N AS355NP Rev IR Te lf Document No ICA 355 00 011 Lm 7E Rev IR lt _ on Xx Date November 19 2008 zE Page 2 of 12 RECORD OF REVISIONS Revision Description Date Approval IR Initial Release 11 19 08 L Aday LIST OF EFFECTIVE PAGES REVISION DATE PAGE 1 IR 11 19 08 2 IR 11 19 08 3 IR 11 19 08 4 IR 11 19 08 5 IR 11 19 08 6 IR 11 19 08 7 IR 11 19 08 8 IR 11 19 08 9 IR 11 19 08 10 IR 11 19 08 11 IR 11 19 08 12 IR 11 19 08 S JE aLL LTO LA Document No ICA 355 00 01 1 LEDR p 77 Rev IR lt a gt Xe Date November 19 2008 a Page 3 of 12 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS FOR INTEGRATED FLIGHT SYSTEMS AS355 SERIES AIR CONDITIONING SYSTEM Aircraft Make Eurocopter France Aircraft Model AS355E AS355F AS355F1 AS355F2 AS355N AS355NP 1 Introduction Kit 355 00 011 is applicable to all models of the SA355 helicopter It is a system utilizing R 134a non CFC type refrigerant This kit is compatible with utility corporate and EMS configuration An Integrated Flight Systems unit is designated to be as maintenance free as possible It incorporates in the design components that have proven themselves to be highly reliable 2 Description The Integ2. Ama T Me Date November 19 2008 SS Page 12 of 12 9 Special Inspection Requirements No special inspections are required for this system 10 Application of Protective Treatments No special treatments are required after inspection and or maintenance 11 Data Torque values for all attachment hardware are listed in the Integrated Flight Systems Installation Instructions Document Number INST 355 00 011 12 List of Special Tools No special tools are required for inspection or maintenance of this system 13 Recommended Overhaul Periods No additional overhaul time limitations are required for this system 14 Airworthiness Limitation No additional Airworthiness Limitations are required for this system NOTE The Airworthiness Limitations section is FAA Approved and specifies maintenance required under 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA Approved 15 ICA Revision Any revisions to these instructions will be made available at the Production Approval Holders website www integratedflightsys com
3. is utilized The switch will automatically reset to the closed position as soon as pressure is applied in PSI greater than the cut in point Non adjustable switches are located under the cabin floor High Pressure Switch A High pressure switch is identified under P N 090004 It is a normally closed switch which opens on a rise in pressure that exceeds the switches upper limit Once the pressure has been reduced below the switches upper design point it will again close automatically System Operation Limitations A Below 60 degrees Fahrenheit it may be found that the air conditioning compressor will not come on line and remain in operation This is due to that fact that coolness of the air available across the condenser does not allow the refrigerant system to maintain sufficient low side pressure to keep the safety low pressure switch from tripping the compressor of line 7 Removal and Replacement Information The Integrated Flight Systems Air Conditioning Kit is installed and removed in accordance with Installation Instructions provided per Kit PN See Diagrams 8 Diagrams bof AFT EVAPORATOR C NEW WEMACS L H AIR OUTLET s Ci a ier ay AND 5 AMP C B Cay COMPRESSOR Se R LINZ CNS R H AIR OUTLET AND FWD CONTROL SWITCHES FWD EVAPORATOR CONDENSER BLOWER Kit PN 355 00 011 CORPORATE EMS CONFIGURATION Pa SN LA Document No ICA 355 00 01 1 MEIR Ly 77 w Rev IR
4. e warm IF one side is relatively warm and the other side is very cool or attempts to frost then blockage of the receiver drier has been determined The receiver drier should be removed and a new one installed in its place The P N is 090016 5 O ring type The charging instructions should be followed in recharging the system Expansion Valves A B Hoses The Expansion Valves are of O ring type Both expansion valves are identical O ring type P N 090002 0 NOTE THE EXPANSION VALVES OF THE ABOVE PART NUMBER CONTAIN A CHARGE IN THE HEAD OF THE VALVE CONTAINING R 134A It is EXTREMELY IMPORTANT that the sensing bulb be clamped tightly to the suction return line in the same manner as removed Also the line is to be clean so good contact takes place between the sensing bulb and the line This area must be re insulated as in the original manner Leak test and recharge Nylon barrier type hose with Bubble crimped ferrules are utilized with O ring fittings They are found at all fitting locations and should be inspected For security crimped fitting for leakage and obvious defects E LE pa LA Document No ICA 355 00 011 LAR n 7 Rev IR a ee ae Ng Date November 19 2008 e Page 11 of 12 Low Pressure Switch A This switch is a non adjustable type normally open and relocated to an area under the cabin floor P N 050107 set at 7 PSI out 22 PSI in
5. eled A C OFF and FAN Selecting the A C position turns on the system s dual evaporator fans and condenser blower and belt driven compressor The second rocker switch is HIGH MED LOW evaporator fan speed selection for the forward cockpit The aft evaporator has a separate fan speed 2 position switch HI LOW located in aft cabin LE Say SN LA Document No ICA 355 00 011 a Rev IR R Date November 19 2008 is Page 4 of 12 4 Servicing Information All components are readily accessible for inspection or servicing Major components are accessed as follows A Compressor Remove transmission cowling in accordance with DGAC Maintenance Manual B Condenser Condenser Blower Remove baggage compartment floor in accordance with DGAC Maintenance Manual C Forward Evaporator Evaporator Blower Remove co pilot s rudder pedals accordance with DGAC Maintenance Manual D Aft Evaporator Evaporator Blower Located above left baggage compartment Open right hand transition cowl compartment door E Service Ports Sight Glass Located in left baggage compartment Open baggage compartment door Charging Refrigerant R 134a Into System A DANGER R 134a practically liquid R 134a should never be allowed to come in contact with the eyes or skin Under normal conditions R 134a as a gas or vapor is in inert substance and non poisonous A flame type leak detector should never be used becau
6. it temperature difference may be recorded at humidity of 30 or more This is due to less dense air moving more rapidly through the evaporators If the system is found to be completely empty of R 134a a set of charging gauges should be connected to both high and low side service ports and to a cylinder of R 134a Purge the charging hoses from the cylinder to the service ports with R 134a vapor Open both the low and high side charging valves and allow pressure from the cylinder to equalize through the system until at least 50 PSI is noted Utilizing an electronic leak detector check all fittings on the system to determine the point of leakage Any fitting indicating an oily or dirty condition is a prime suspect 5 Maintenance Instructions An Integrated Flight Systems unit is designated to be as maintenance free as possible It incorporates in the design components that have proven themselves to be highly reliable It is suggested that at each periodic inspection whether at 50 or 100 hour intervals at least a visual inspection be accomplished to the following items to fulfill with inspection criteria per Appendix D Far 43 Para A Para B 2 Para C 1 7 Para D 2 7 9 and Para F G I 2 3 J Compressor Compressor Clutch Bearing Compressor Mount Refrigerant Hose and Fittings Evaporator Fans and Mountings Condenser Blowers and Mountings Condense Evaporator Coils QSAR gt Compressor i ii iii iv In addition t
7. o the above inspection the compressor should be inspected for a true turning and free clutch One mechanic should turn the main rotor blade while another observes the belt and clutch faceplate Turn system to A C and check magnetic operation of clutch plate An independent 14 wire may be necessary from the compressor to an airframe ground in order to ensure that the clutch engages in a positive manner If clutch plate and pulley show signs of excessive heat replace clutch pulley assembly bearing and coil The compressor mounts should be inspected for possible cracks deterioration and that all bolts are firmly attached Check condition of belt Inspect for cracks deterioration separation worn or flat spots Change belt whenever any of these conditions exist Change every one year or one thousand hours which ever comes first a J oe a LA Document No ICA 355 00 011 MIR p 77 Rev IR ee oe lt Date November 19 2008 a Page 8 of 12 Hoses i Inspect hoses for general condition cuts or swelling Replace as required Security of clamps and Anti chaff material Evaporators i Forward evaporator blower motor is a permanent magnetic type No repair can be made motor must be discarded il Aft evaporator blower motor is a permanent magnetic blower motor It has removable brushes If brush length is 5 16 or less replace Inspect every 200 hours iii Run both of the evaporator blowers in the FAN position and
8. om their electrical source which are 20 amp condenser blower circuit breakers C Always check system R 134a pressure first as leaking unit may have caused the low pressure switch to open This switch is set to open at 8 PSI and close at 22 PSI It requires that pressure or greater to close ote LA Document No ICA 355 00 011 LAR 7 Rev IR an oa XR Date November 19 2008 SS SS Page 9 of 12 D Failure of the condenser blower or coil blockage could result in high side switch opening Both switches are designed to reset automatically E NOTE Internal blockage of the high pressure side of the refrigerant system can cause a very low pressure reading at the low side service gage and may also cause a low pressure reading at the high side service gage This can occur when either or both of the two 2 expansion valves in the system closes the receiver drier were clogged Compressor A The compressor installed is a Model SD 505 manufactured by Sanden International B A copy of Sanden Service Manual can be found on the Sanden website at www sanden com C No maintenance other than clutch bearing or coil replacement should be attempted in the field Evaporators A If either the forward evaporator fan or aft evaporator blower fails to run confirm that the Aircraft Master Switch is in the ON position and the Air Conditioning control Switch is placed to FAN IF the fan blower still does n
9. ot run determine that electrical power is available to the aircraft from an outside power source such as a GPU or the aircraft power source Inspect the circuit breakers in the Master Air Conditioning Electrical Panel Determine if electrical power is being supplied to the wire which is the power source to each motor If power is available it will be necessary to test with a voltmeter that electrical power is being supplied directly to the motor by the appropriate wire If power is being supplied and the motor is properly grounded then it can be assumed that the motor has failed B On the forward motor P N 050052 the evaporator assembly needs to be removed to allow removal of the motor The motor may be obtained from Integrated Flight Systems and installed in the same manner C Always check system R 134a pressure first as a leaking unit may have caused the low pressure switch to open This switch is set to open at 8 PSI and close at 22 PSI It requires that pressure or greater to close D On the aft motor P N 050143 the screws in the motor support loosen to allow removal of the motor The motor may be obtained from Integrated Flight Systems and installed in the same manner E NOTE The Aft Evaporator Blower SHOULD NOT BE DISASSEMBLED other than to inspect the brushes The Motor is ordered as a UNIT oe a LA Document No ICA 355 00 011 MEIR p 77 Rev IR Aaa n N lt Date November 19 2008 a SS Page 10 of 12 Conden
10. perform visual inspection of the assemblies to see that foreign materials have not been ingested into the blowers which might cause blade damage The blowers should also be run at the various speeds available to check motor operation iv The fins of the evaporator coils should be checked for cleanliness and that they are straight If damage has occurred to the fins a fin comb should be utilized to put them in like new condition v Condenser i The two 2 brushes are located under caps on each side of the blower motor Inspect remove replace and check brushes every 200 hours for wear If brush length is 5 16 or less replace brushes ii NOTE TAKE CARE WHEN INSTALLING BRUSHES THAT BRAIDED POSITIVE LEAD DOES NOT CONTACT HOUSING CAUSING SHORT iii The fins of the condenser coil a well as the evaporator coil should be checked for cleanliness and that they are straight If damage has occurred to the fins a fin comb should be utilized to put them in like new condition 6 Troubleshooting Information General A Should the system not perform as expected either because of unreasonably erratic pressure readings total lack of cooling or reduced cooling it will be necessary to use the trouble shooting information if the A amp P mechanic is unfamiliar with corrections B The high and low pressure switches should be checked if electrical power is lost to the compressor clutch These are in series and they should be checked fr
11. performed on the flight line with engine at 100 As soon as the A C Master Control Switch is turned to A C all 28 VDC evaporator blowers will immediately begin operation If after the system has been in the A C mode for at least 2 minutes and cooling is not being accomplished then check all circuit breakers Determine that 28 VDC power is available for control circuitry Check the operation of the relays and contacts D If after the system has been in the A C mode for at least 2 minutes and cooling is not being accomplished then check all circuit breakers Determine that 28 VDC power is available for control circuitry Check operations of the relays and contacts E After the compressor has come on line the entire system is operational with the manifold valve closed on the high side The R 134a cylinder valve should be closed initially in order to get an accurate reading on the low side gauge of the system pressure The reading on the gauge should not be allowed to go below 10 PSI as this will indicate that the low pressure safety switch is possibly set to low It will disconnect the electrical power to the compressor clutch if allowed to open Open of close the cylinder valve as required to monitor the flow of R 134a from the cylinder into the low side of the system if additional R 134a is needed Should additional charging be required do so with the cylinder in the upright position Charging the system if requi
12. rated Flight Systems Air Conditioning System is a vapor R134 refrigerant recovery system The compressor uses existing mounting points on the transmission case To improve efficiency two evaporators are used for this system one mounted forward of the co pilot the other in the aft right hand cargo compartment Also two 24 volt fan motors are used to circulate the cabin air through the evaporators Air distribution for the aft evaporator is accomplished through the ducts in the cabin The ducts are equipped with directional valves The condenser is mounted in the right handside baggage area A single 27 volt fan motor circulates air through the condenser The air enters through the intake screen on the side baggage door of the aircraft and exits at a second hole through the outlet air screen The system is activated by an On Off switch in the pilot s compartment and a selector switch to provide high or low air velocity distribution options 3 Operation The air conditioning installation consists of a belt driven vapor cycle air conditioning system using R 134A as the refrigerant The air conditioning system provides for cabin comfort during all operations both on the ground and in flight During ground operations when the engines are running cooling may be provided Controls for the air conditioning system are located on or near the instrument panel Three switches are provided The Master Control Selector consists of a rocker type switch lab
13. red until the system reads 28 PSI on low side if O A T is 80 degrees Fahrenheit or lower It should be noted that pressure on the low side with the R 134a cylinder valve closed F At this point the minimum amount of R 134a is in a system and charging should cease If the outside air temperature is 85 degrees Fahrenheit or more you should check the high side pressure if it is 295 PSI or higher you should remove a small amount of Freon to bring the system down to 290 PSI THE REFRIGERANT CHARGE SHOULD NOT EXCEED 2 5 POUNDS G The optimum method of determining the correct charge using at least two digital thermometers and place them near the return air and the discharge air of each evaporator R 134a can then be added or deleted as required until the highest T D is noted per the paragraph below At that time the correct amount of refrigerant is installed but do not exceed 290 PSI gt ae LA Document No ICA 355 00 011 Rev IR Date November 19 2008 See Page 7 of 12 H A test should be completed noting the average cabin temperature the temperature on the return or entering air to all evaporators and the discharge air form the evaporators at the nearest point If a Temperature Differential T D of less than 20 degrees Fahrenheit with a humidity of 30 or less at sea level the system should be considered as having possible defects which will need investigation At altitudes above sea level less than 20 degrees Fahrenhe
14. s is located in the 6 line in the ceiling of the baggage compartment Seay a la Document No ICA 355 00 011 LLM lt 3 3 77 u Rev IR Date November 19 2008 P Page 5 of 12 Oil Charging R 134a Refrigerant A Prior to the use of R 134a refrigerant R 12 refrigerant was used in all IFS systems The PROPERTIES OF R 134A REFRIGERANT AND THE VARIOUS TYPES OF OIL USED WITH THIS REFRIGERANT ARE COMPLETELY DIFFERENT The oils with R 134a DO NOT dissolve into the R 134a For this reason additional oil other than that in the compressor should NOT be added to a new system This is particularly true when Abarrier type hose is utilized The Sanden compressor uses a 500 viscosity SP 20 type oil ISO 100 100 O A T or higher ISO 68 100 or lower or an AESTERG type oil yellow label No other type oil can be utilized especially APAG types Initial Charging A Tighten any leaking connections or make repairs as necessary to eliminate leaks Shut off and disconnect hose from the refrigerant cylinder Connect the hose to a refrigerant mounted on a cylinder of dry nitrogen Purge the regulator to center manifold hose Close low side valve left at manifold Failure to do so can cause pressure to flow to the low side left gauge Failure of gauge can result Pressurize system to 250 PSI minimum 300 PSI maximum After the system has been rechecked with the leak detector and it is determined that no leaks exi
15. se of the danger of fire or explosion around an aircraft Several electronic leak detectors are available on the market Never heat a cylinder of R 134a to produce additional pressure or to squeeze that last bit of refrigerant from the cylinder If the cylinder has become cooled to the point where additional refrigerant cannot be obtained from it The only approved method is to place the entire cylinder in a container of warm water Do Not Exceed 120 Degrees Fahrenheit Never attempt to repair a leak requiring brazing or soldering within the aircraft structure as fire or explosion can result Remove the entire assembly from the aircraft to a safe location before attempting such a procedure Should R 134a come in contact with the eyes or skin DO NOT attempt first aid beyond the immediate washing of the eye or skin with clear water A doctor should be contacted immediately for diagnosis and treatment even though the injury may be considered slight REPEAT DO NOT attempt first aid for this condition The refrigerant used in this system is R 134a and no other refrigerant is to be considered Normal safety practices such as wearing of gloves and the use of goggles should be utilized Charging of the system is a simple procedure whether on initial or recharging after leakage repair A set of refrigerant gauges with a minimum of three hoses should be connected to the high side and low side service ports provided The sight glas
16. ser A The condenser blowers may be checked by placing the Aircraft Master Switch in the ON position and then placing the Air Conditioning Control Switch to the A C position If one or both 25 amp circuit breakers are not open then power should be supplied directly to the condenser blower which is mounted in the right side baggage area B If air is not being exhausted from both fans a voltmeter should be utilized to determine if the power is being supplied through the switch and relay to the appropriate wire Check that all electrical terminals are secure and that power is directed to the motor s terminals Inspect ground If it is determined that the motor or motors have failed the screws holding the blower assembly in place should be removed The blower assembly must be removed as an entire assembly Receiver Drier A The receiver drier may be replaced if required by discharging the R 134a from the system through a refrigerant hose or set of charging gauges Again all R 134a refrigerants MUST BE CAPTURED Normally the receiver drier will not need replacement unless one of two factors is present i The system has been left open for sometime and may be contaminated by air and or moisture ii The receiver drier has become plugged which is evident by a large temperature differential on either side of the receiver drier Normally the liquid line to and from it would be of approximately equal temperature and will be quit
17. st disconnect the charging hose from the manifold set to the cylinder of nitrogen Open the valves allowing the R 134a and nitrogen within the system to be collected into an EPA approved recycling until expelling of refrigerant is not allowed Connect a vacuum pump to the center manifold hose Open both valves and evacuate the systems for a minimum of twenty minutes After twenty minutes of vacuum at seal level NOTE For each 1 000 foot rise in altitude above sea level a decrease below 30 of vacuum of 1 per one thousand feet rise in altitude will occur Adding R 134a Refrigerant to System A Close both the manifold valves and connect the center charging hoses to a cylinder of R 134a Open the valves of the cylinder Purge the charging hose by loosening it at the charging manifold s center hose ONLY THE HIGH SIDE VALVE OF THE CHARGING MANIFOLD MAY NOW BE OPENED The combination of the vacuum still existing and the pressure in the R 134a cylinder transfers the R 134a from the cylinder into the system on the high side only without the compressor running Ifa scale is available the cylinder may be pre weighted and 2 0 pounds of refrigerant R 134a added to the system No additional refrigerant should be added after the system is in operation Close manifold ay LE Document No ICA 355 00 011 Pia ae 7 77 Rev IR Date November 19 2008 SS Page 6 of 12 C The system is now ready for operation This must be
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