Safran PILATUS PC12 M19, Manual

Page 1: ...TEM DESCRIPTION AND OPERATION MANUAL WITH ILLUSTRATED PARTS LIST PILATUS PC12 M19 R 134a AIR CONDITIONING SYSTEM COMPONENTS DIRECT DRIVE COMPRESSOR MODULE 1150950 3 Supersedes 1150950 2 CONDENSER MODU...

Page 2: ...12037 N Highway 99 Seminole OK 74868 Phone 405 382 0731 www enviro ok com www safran passenger solutions com Copyright 2020 Original Release ATA 21 00 60 Page 2...

Page 3: ...OK 74868 Phone 405 382 0731 www enviro ok com www safran passenger solutions com Copyright 2020 Original Release ATA 21 00 60 Page 3 Table 1 Record of Revisions REV DESCRIPTION OF CHANGE DATE APPROVAL...

Page 4: ...ription and Operation 12 3 TESTING AND FAULT ISOLATION 15 3 1 General 15 3 2 System Leak Check Testing Procedure 15 3 3 Fault Isolation Trouble Shooting 17 4 SYSTEM PLUMBING DIAGRAM 20 4 1 R 134A Refr...

Page 5: ...rator Module Assembly Procedures 36 10 SPECIAL TOOLS EQUIPMENT 37 10 1 General 37 11 ILLUSTRATED PARTS LISTING 38 11 1 Introduction 38 12 SPECIAL PRODECURES 43 12 1 General 43 12 2 Tools Fixtures Equi...

Page 6: ...igure 2 1150900 2 Left 1150910 2 Right 1150910 2 Shown 39 Figure 3 1150970 1 Condenser Module 41 LIST OF TABLES Table 1 Record of Revisions 3 Table 2 Standard Torque Values 9 Table 3 Consumable Produc...

Page 7: ...skills shall perform the maintenance procedures in this manual 1 1 4 Although Enviro Systems tries to cover all conceivable issues that may arise there may be issues that are not covered in this manua...

Page 8: ...0 60 Page 8 1 2 Acronyms Abbreviations and Symbols CMM Component Maintenance Manual ATA Air Transport Association IPL Illustrated Parts Listing VCS Vapor Cycle System SDS Safety Data Sheet PSIG Pressu...

Page 9: ...90 IN LBS 5 8 18 PLUMBING CONNECTIONS RECEIVER DRYER INLET DISCHARGE PORT 132 156 IN LBS 7 8 14 PLUMBING CONNECTIONS COMPRESSOR SUCTION PORT 252 324 IN LBS 16 PLUMBING CONNECTIONS COMPRESSOR DISCHARGE...

Page 10: ...oid manufacturer s warranty 2 1 3 Inspections servicing and or maintenance schedules are presented in the following sections This will ensure component and or system reliability and performance are ma...

Page 11: ...d is rejected to the outside through the system condenser When the system is turned on the electric motor controller drives the R 134A compressor at a variable speed dependent upon current cooling req...

Page 12: ...Under this condition the current draw is limited to 105 AMPS at 28 VDC The Compressor Module Assembly is packaged to meet the aircraft installation requirements and contains the following major compon...

Page 13: ...oved without venting the system refrigerant charge 2 3 2 2 BINARY PRESSURE SWITCH The binary pressure switch performs two major functions The first function prevents the R 134A compressor from operati...

Page 14: ...ecirculation requirement and higher speed designed for maximum system cooling It was designed for continuous operation 2 3 3 3 BLOWER WHEEL The blower wheel is the component that is used in concert wi...

Page 15: ...em Leak Check Testing Procedure 3 2 1 A leak check of the refrigerant plumbing system is important to ensure the system maintains its charge to provide the designed performance and reduce damage to sy...

Page 16: ...ice ports are located on the compressor 3 2 3 6 Close all manifold gauge valves and verify hose connections are tight 3 2 3 7 Connect R 134A refrigerant charging manifold R 134A service gauges contain...

Page 17: ...of R 134A refrigerant oil to flare and or O ring to prevent metal galling or O ring damage 3 2 3 15 Tighten joints as required to stop leaks refer to Table 1 Section 1 3 for torque values CAUTION VEN...

Page 18: ...2 Overcharged system cutout 2 Reclaim refrigerant as required 3 Failed Compressor 3 Replace Compressor Drive 4 Failed Drive Motor 4 Replace Compressor Drive 5 Failed expansion valve s 5 Replace 6 Eva...

Page 19: ...switch open 8 Allow unit to cool If switch still open replace Compressor Drive G No Evaporator Module Air Flow 1 Circuit breaker off 1 Energize or replace 2 Mode switch failed 2 Replace 3 Fan speed sw...

Page 20: ...Copyright 2020 Original Release ATA 21 00 60 Page 20 PLUMBING DIAGRAM 4 SYSTEM PLUMBING DIAGRAM 4 1 R 134A Refrigerant Flow Schematic 4 1 1 The following schematic shows an air conditioning system an...

Page 21: ...ed to the extent necessary to access any faulty subassembly 5 1 1 The condenser fan and compressor have no field replaceable items In the event of a failure or damaged component send the complete unit...

Page 22: ...igerant charge has been recovered refer to Servicing Section 13 5 2 1 2 Disconnect electrical wiring to binary pressure switch 5 2 1 3 Disconnect refrigerant plumbing connection from receiver dryer in...

Page 23: ...washers securing the motor mounting plate to the motor mount bracket CAUTION USE EXTREME CARE TO PREVENT DAMAGE OR BENDING OF BLOWER WHEEL DURING REMOVAL OF MOTOR AND WHEEL 5 3 1 3 Cut RTV between blo...

Page 24: ...IT WARNING SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY PRECAUTIONS SUCH AS WEARING SAFETY GLASSES GLOVES AND PROTECTIVE CLOTHING WHEN USING CERTAIN CLEANING SOLVENTS AND OR CHEMICALS IN...

Page 25: ...s essential that the assembly remain clean to ensure proper operation and optimal performance The coil fins will over time become clogged with dirt dust and other foreign matter It is essential that t...

Page 26: ...matter A small stiff brush such as a tooth brush can be used to break loose any caked on dirt 6 3 1 2 EVAPORATOR HOUSING ASSEMBLY The components that comprise the evaporator housing assembly are the s...

Page 27: ...chedule requires cleaning refer to Cleaning Procedure Section 6 7 1 2 If any component listed in this schedule requires repair and or replacement refer to Repair Section 8 Table 5 Condenser System Ins...

Page 28: ...or leaking cracks or damage 12 Months Evaporator housing Assembly Shroud Assembly Escutcheon Water Deflector Inspect seam between shroud assembly and escutcheon for signs of separation and condensate...

Page 29: ...l Release ATA 21 00 60 Page 29 returned for repair or overhaul Table 7 Compressor Inspection Component Type Inspection Required Times Electrical connections Inspect insulation for cracks or deteriorat...

Page 30: ...PERFORMING SERVICE TO THE UNIT CAUTION SERVICE TECHNICIANS MUST PREVENT CONTAMINATION OF INTERNAL SYSTEM PLUMBING DURING ANY SERVICING AND OR MAINTENANCE OPERATION THIS INCLUDES NOT ALLOWING THE RECEI...

Page 31: ...ormance If the shrouds are separating refer to Disassembly Section for removal Then refer to Cleaning Section After insuring that the seam between the shrouds and condenser have been cleaned according...

Page 32: ...il assembly must be removed and sent to Enviro Systems for repair Contact Enviro Systems customer service 8 3 1 2 Evaporator Housing Assembly The components that comprise the evaporator housing assemb...

Page 33: ...If the blower motor is damaged or is not operating to specifications motor will need to be removed and replaced 8 3 1 4 Condensate Drain The condensate drain part of the housing assembly can over time...

Page 34: ...RYER TO BE EXPOSED TO ATMOSPHERIC CONDITIONS FOR ANY LENGTH OF TIME ALL PLUMBING LINES SHOULD REMAIN CAPPED WHENEVER POSSIBLE DURING THE SERVICING OF THE SYSTEM CAUTION RECEIVER DRYER MUST BE REPLACED...

Page 35: ...1 1 After insuring that the shroud coil mating surfaces have been cleaned in accordance with section 6 apply a 1 8 inch bead of RTV to outlet shroud coil mating surface 9 2 1 2 Attach fan outlet shro...

Page 36: ...efrigerant oil to the O rings to prevent damage 9 3 1 4 Connect expansion valve to coil header fitting Refer to table 1 Section 1 for torque specifications 9 3 1 5 Leak check per Testing and Fault Iso...

Page 37: ...meets the listed equipment specifications Regulated Shop Air 40 PSIG Fin comb SK1250101 13 Miscellaneous hand tools and socket set Shop vacuum with soft utility brush Vacuum pump air or electric 0 30...

Page 38: ...parts This IPL includes Illustrations of the Condenser Module and Evaporator Module Assemblies to be used during the procedures outlined previously Figures and item numbers to call out specific compon...

Page 39: ...ighway 99 Seminole OK 74868 Phone 405 382 0731 www enviro ok com www safran passenger solutions com Copyright 2020 Original Release ATA 21 00 60 Page 39 Figure 2 1150900 2 Left 1150910 2 Right 1150910...

Page 40: ...MOTOR ASSEMBLY USED ON RIGHT EVAPORATOR ASSEMBLY PART NUMBER 1150910 2 2 4 NAS1801 08 10 SCREW 8 32 X 625 HEX HEAD 3 4 MS35333 38 WASHER LOCK 8 FLAT INTERNAL TOOTH 4 4 NAS1149FN816P WASHER FLAT 174 X...

Page 41: ...12037 N Highway 99 Seminole OK 74868 Phone 405 382 0731 www enviro ok com www safran passenger solutions com Copyright 2020 Original Release ATA 21 00 60 Page 41 Figure 3 1150970 1 Condenser Module...

Page 42: ...com Copyright 2020 Original Release ATA 21 00 60 Page 42 Table 9 Condenser Module Parts Listing ITEM QTY PART NUMBER DESCRIPTION 1 1 1134275 23 RECEIVER DRYER ASSEMBLY 2 2 QS100M36H CLAMP 2 50 DIA WO...

Page 43: ...CAUTION SERVICE TECHNICIANS MUST PREVENT CONTAMINATION OF INTERNAL SYSTEM PLUMBING DURING ANY SERVICING AND OR MAINTENANCE OPERATION THIS INCLUDES NOT ALLOWING THE RECEIVER DRYER TO BE EXPOSED TO ATMO...

Page 44: ...laimed and recycled apply a vacuum on the system for a minimum of 30 minutes The vacuum should attain 25 27 in hg in 10 15 minutes Allow pump to hold a vacuum for at least an additional 15 minutes CAU...

Page 45: ...NG THAT ALL THE SOLVENT HAS BEEN REMOVED FLUSH AGENTS REMAINING IN THE SYSTEM RESULY IN POOR COMPRESSOR LUBRICATION AND PREMATURE COMPONENT FAILURE IT HAS BEEN FOUND THAT RESIDUAL AMOUNTS OF FLUSH AGE...

Page 46: ...charge 12 5 18 Verify system performance Table 10 Typical Operating Pressures Ambient Temp C Ambient Temp F Suction Pressure Min PSIA Suction Pressure Max PSIA Discharge Pressure Min PSIA Discharge Pr...

Page 47: ...ould be performed at 12 months from MFG date on unit and every 6 months thereafter for a maximum of 36 months NOTE When installing unit with MFG date in excess of 12 months prior to installation date...

Page 48: ...stem should be operated for 10 15 minutes every two weeks to maintain a thin oil film on the compressor output shaft dynamic seal to prevent shaft leakage 13 3 2 Prior to turning on the air conditioni...

Page 49: ...l packaging is not available for repackaging ensure that the component is packaged in the following manner 13 4 1 5 Ensure duct or refrigerant openings are capped to further protect the component from...