AW139 Air Cond Training

Training DOCTR 039 AW 139LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 1 Training DOCTR 039 AW 139 This document must be used for training purpose only Training on Ventilation/Forced Ventilation/Heating and Air Conditioning System of the AB139 Helicopter Under no circumstances should this document be used as a reference It will not be updated LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 2 Training DOCTR 039 AW 139 TABLE OF CONTENTS: Table of Contents Abbreviations General description Ventilation System including Forced Ventilation: - Pilot Interfaces - System Control - Detailed System Operation - Low Pressure Ducting - Component description - Trouble shooting Heating and Ventilation System including Forced Ventilation: - Pilot Interfaces - System Control - Detailed System Operation - High Pressure Ducts - Component description - Trouble shooting LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 3 Training DOCTR 039 AW 139 TABLE OF CONTENTS: Air Conditioning System: - Pilot Interfaces - System Control - Detailed System Operation - Component description - Trouble shooting LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 4 Training DOCTR 039 AW 139 LIST OF ABBREVIATIONS A/C: Aircraft or Air Conditioning AC: Alternative Current ACCB: Air Conditioning Control Box AMM: Aircraft Maintenance Manual ANA: Analog ADTS: Air Duct Temperature Sensor AFT Cabin zone BAD: Bleed Air Duct BOB: Break Out Box CP: Cockpit Panel CMD: Command CTL/CONTR: Control CV: Check Valve DOTS: Over Temperature Switch EATS: External Air Temperature Sensor ECS: Environmental Control System EIRT: Evaporator Inlet Refrigerant Temperature ENG: Engine EORT: Evaporator Outlet Refrigerant Temperature FROB: Failure Read Out Box FV: Flapper Valve FWD: Cockpit zone GEN: Generator GND: Ground H/C: Helicopter HCB: Heating Control Box HP: High Pressure HTR: Heater LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 5 Training DOCTR 039 AW 139 LIST OF ABBREVIATIONS IP: In Process KW: Kilo watt L/H: Left Hand LPD: Low Pressure Duct LP: Low Pressure MAN: Manual MAU: Modular Avionic Unit MAX: Maximum NVG: Night Vision PAX: Passenger PWM: Pulls Wide Modulated REF: Reference R/H Right Hand SEL: Selection SIG: Signal SOV: Shut Off Valve TCV: Temperature Control Valve Temp: Temperature TEV: Thermostatic Expansion valve TS: Thermal Switch JP: Jet Pump LPD: Low Pressure Ducting LTS: LIEBHERR AEROSPACE Toulouse REF: Reference SOV: Shut Off Valve TCV: Temperature Control Valve VDC: Voltage Direct Current VIP: Very Important People LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 6 Training DOCTR 039 AW 139 Ventilation Enter Deleted LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 7 Training DOCTR 039 AW 139 Forced Ventilation Enter Deleted LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 8 . Training DOCTR 039 AW 139 Ventilation/Heating Enter LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 9 . Training DOCTR 039 AW 139 Forced Ventilation / Heating Enter LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 10 . Training DOCTR 039 AW 139 Ventilation / Heating Air Conditioning Cockpit + Cabin Enter compressor Cockpit condenser Fan L/H cockpit evaporator Cockpit HP-switch Cabin evaporator fans L/H cockpit evaporator Cockpit Panel Cabin condenser Fan R/H cockpit Cabin FV evaporator Cabin HP-switch Cabin LP switch Cockpit TS2 Cabin TS2 Cockpit LP switch Cockpit evaporator fans Cockpit TS1 EATS Cockpit FV’s CockpitTemp. Sensor LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 11 . Training DOCTR 039 AW 139 General Description LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 12 . Cooling is provided by two splitted vapour cycle systems dedicated respectively to the cockpit an cabin zones. . Training DOCTR 039 AW 139 GENERAL DESCRIPTION The Environmental Control System on the AB139 is divided in several subsystems which are the Ventilation and the Heating system optimised by an Air Conditioning System.Heating is generated by mixing bleed air from the engine with outside ram air flow in a jet pump and by diffusing it into the helicopter through a low pressure ducting system. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 13 .Fresh air is provided by outside Ram Air flow controlled by Flapper Valves and distributed into the helicopter trough a low pressure ducting system. . . P/N 3G2120 / 20204A01 . The heating* and forced ventilation system . The heating* and ventilation system .P/N 3G2141 / 20204D01 NOTE: Heating with Ventilation and Forced Ventilation are discribed in the same chapter. Training DOCTR 039 AW 139 The ECS system has 5 different versions: . The forced cabin ventilation system . . The cockpit and cabin ventilation system .P/N 3G2140 / 20204C01 . The AIR conditioning* / heating and Ventilation System . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 14 .P/N 3G2121 / 20204B01 NOTE: Ventilation and Forced Ventilation are discribed in the same chapter. .P/N 3G2150 / 20204E01 *High and low pressure ducts are provided for the heating and the air conditioning system. Training DOCTR 039 AW 139 Helicopter Ventilation System cut off view Ventilation Return Deleted LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 15 . Training DOCTR 039 AW 139 Ventilation system components: Item Components of the Cockpit ventilation P/N20204A010000 P/N Qty 91100A010000 Ventilation COCKPIT CONTROL PANEL 3G2120V00351 001 1 91100A010001 Ventilation COCKPIT CONTROL PANEL NVG 3G2120V00352 6034A010001 002 Ventilation Cockpit FLAPPER VALVE 2 3G2120V00651 8013A030000 003 Ventilation COCKPIT fan 2 3G2120V00553 6035A010001 004 Ventilation Cabin FLAPPER VALVE 3G2120V00851 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 16 . Training DOCTR 039 AW 139 Forced Ventilation (VIP Air cond. Option) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 17 . Training DOCTR 039 AW 139 Addional Forced Ventilation system parts: Components of the Cockpit/Cabin Forced ventilation system P/N Qty P/N 20204B010000 91102A010000 Forced ventilation COCKPIT CONTROL PANEL 3G2121V00351 1 91102A010001 Forced ventilation COCKPIT CONTROL PANEL NVG 3G2121V00352 8012A030000 CABIN fan 1 3G2121V00551 Forced ventilation CABIN CONTROL PANEL 91103A010000 1 Forced ventilation CABIN CONTROL PANEL .NVG 91103A010001 1 Forced ventilation CABIN CONTROL PANEL .NVG 91103A010001 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 18 . Training DOCTR 039 AW 139 Return VENTILATION SYSTEM LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 19 . The fans are manually-controlled by the crew in Off. Air is then distributed to the front face gasper outlets. Training DOCTR 039 AW 139 Ventilation LTS provides two different cockpit and cabin ventilation systems. Air is then distributed via a plenum to two separate lateral manifolds. Control of both flapper valves and both fans is effected by a common rotary switch. outside ram air enters the system through an air intake located in the forward pylon fairing on the cabin roof. similar (left and right) systems provide air for pilot and co-pilot ventilation. For the cabin. For the cockpit. Low Speed. Outside ram air flow is controlled by an electrically-actuated flapper valve. Outside ram air flow is controlled by two electrically-actuated flapper valves. Forced air for ventilation or defogging is provided by two 2-speed axial fans. two separate. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 20 . the main windshield diffusers and the side windows diffusers. called Ventilation and Forced ventilation. Outside ram air enters in each system through air intakes positioned under the nose section. or High Speed. FVs « Closed » and FANs « Off » (Closed means Ram Air opened) LOW .FVs « Closed » and FANs « Low speed » HIGH .the cabin (Qty 1) and cockpit (Qty 1) flapper valves VENT CREW 4 position switch: OFF .FVs « Closed » and FANs « High speed » VENT CREW FAN LOW FAN HIGH ON OFF PAX VENT CTRL CREW ON OFF PAX 91100A010000 or 91100A010001 (NVG) (Air conditioning option) Cockpit Control Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 21 .the cockpit fans (Qty 2) .FVs « Opened » and FANs « Off » (Open means Ram Air closed) ON .Training DOCTR 039 AW 139 Ventilation The Cockpit Control Panel (P/N 91100A010000/ 3G2120V00351) interfaces with: . Cabin FV “Opened” (Open means Ram Air closed) ON – Cabin FV “Closes” (Closed means Ram Air opened) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 22 . the control of the cabin area is done by the cockpit panel. The Cabin Control Panel (P/N 3G2120V00351) interfaces with: . When «PAX» is selected. When «CREW» is selected. the control of the cabin area is done by the passenger panel.the cabin flapper valve The VENT indication light on the Cabin panel is illuminated when “PAX” has been selected on the Cockpit panel.Training DOCTR 039 AW 139 Ventilation control (air conditioning option) CONTR 2-position switch control the availability of the passenger control panel. OFF . allows the direct control of two cockpit Upper Side fans (off/low/high) and two single cockpit flapper valves. PAX selected the cabin flapper valve is controled via the cabin panel (if installed). and the cabin Window Demister flapper valve. Cockpit ventilation Main winshield Demister Cabin ventilation Fan Side vents manifold Air intake Flapper valve To control panel Singular gaspers manifold Air intake Water Fan Air intake Flapper valve separation duct Plenum Main winshield Demister To control panel Singular gaspers manifold Upper Side Window Demister Lower Side Window Demister Side vents manifold Front face outlets LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 23 . Training DOCTR 039 AW 139 Ventilation System Control Front face outlets Lower Side Window Demister The cockpit panel CREW selected. Low Speed. The air is then routed through ducts which are installed above the cabin ceiling panels. provides outside/ram air for ventilation or defogging. outside ram air enters in the system through one air intake in the forward pylon fairing in the cabin roof. or High Speed mode.
The cabin panel allows the direct control (open/close) of the cabin flapper valve with the VENT switch. Cabin ventilation system For the cabin. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 24 .Training DOCTR 039 AW 139 Cockpit ventilation system One 2-speed centrifugal fan on the L/H and one on the R/H side. the air flow is admitted by a flapper valve. They are manually controlled by the crew in Off. Training DOCTR 039 AW 139 FORCED VENTILATION LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 25 . Training DOCTR 039 AW 139 VENTILATION Forced Ventilation Return (VIP Air cond. Option) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 26 . LOW or HIGH speed mode when "CREW" selected or from the cabin panel by the passengers when "PAX" selected.Training DOCTR 039 AW 139 The Forced ventilation system comprises the basic ventilation installation with the addition of a single 2-speed axial fan for the cabin system. Nota: For Air Conditioning option. Control of the flapper valve and the fan is effected by a common rotary switch. The air conditioning option allows to run the cockpit and cabin fans in recirculation mode (override of the VENT Switch). The CABIN fan is controlled manually by the crew on the cockpit control panel VENT in OFF. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 27 . the air flow across the cabin evaporators is provided by the cabin fan and a second additional fan. Training DOCTR 039 AW 139 The COCKPIT panel for Forced Ventilation (P/N 91102A010000/3G2121V00351) interfaces with: - the cabin fan (Qty 1) - the cockpit fans (Qty 2) - the cabin (Qty 1) and cockpit flapper valves (Qty 2) Cockpit Control Panel P/N 91102A010000 The CABIN panel for Forced Ventilation (P/N 91103A010000) interfaces with (Air cond. Option): - the cabin fan (1) Cabin Control Panel - the cabin flapper valve (1) P/N 91103A010000 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 28 Training DOCTR 039 AW 139 Forced Ventilation System Control Front face outlets Lower Side When VENT CTRL "CREW" selected, the cockpit panel allows the direct Window Demister control of all fans (off/low/high), and flapper valves (open/close) in the Upper Side Window Demister cabin and cockpit zone. When VENT CTRL "PAX" selected, the cabin panel allows independently Main winshield the control of the cabin fan (off/low/high), and flapper valve (open/close). Demister Fan Cabin ventilation Side vents manifold Air intake Flapper valve To control panel Singular gaspers manifold Air intake Fan Air intake Flapper valve AFT Fan Plenum Main winshield Demister Cockpit ventilation To control panel Singular gaspers manifold Upper Side Window Demister Lower Side Window Demister Side vents manifold Front face outlets LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 29 Training DOCTR 039 AW 139 Forced Ventilation in air conditioning configuration: VENT CREW and PAX 4 position switch: OFF - FVs "Opened" and FANs "Off" = FV - in re-circulation position ON - FVs "Closed" and FANs "Off" = FV - in ram air position LOW - FVs "Closed" and FANs "Low speed" = FV - in ram air position HIGH - FVs "Closed" and FANs "High speed" = FV - in ram air position LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 30 Training DOCTR 039 AW 139 Ventilation / Forced Ventilation System Control : LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 31 Training DOCTR 039 AW 139 Ventilation and Forced ventilation System Logic : Fwd Ventilation :  If cockpit fans are operating, then the control panel sends the " Forward Ventilation On " discrete signal to the helicopter general displayer (MAU).  Aft Ventilation :  If cabin fan is operating, and cabin flapper valves are not fully closed, then the control panel sends the " After Ventilation On " discrete signal to the helicopter general displayer (MAU). Ventilation Failure:  If AFT-FAN-FAULT is active or FWD-FAN1-FAULT is active or FWD- FAN2-FAULT is active, then the control panel sends the " Ventilation Failure " discrete signal to the helicopter general displayer.  Ventilation Failure in air conditioning configuration COND NORMAL selected: The ‘‘A/C-FAILURE’’ signal blinks if one of the two evaporator fans is in default, but the system keeps functioning in damage mode. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 32 Training DOCTR 039 AW 139 Detailed Ventilation System Operation And Component Description LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 33 Training DOCTR 039 AW 139 Cockpit and Cabin Ventilation and Forced Ventilation Front face outlets Lower Side Window Demister The cockpit and the cabin ventilation systems are two different and separate sub-systems. Upper Side Window Demister Cockpit ventilation system (basic) Main winshield Demister For the cockpit, two separate systems provide air for pilot and co-pilot. Outside RAM air enters the systems Fan through two air intakes positioned on the helicopter Air intake nose section. Flapper valve To control panel Air for ventilation or defogging is provided by either ram air and/or (on ground) by two 2-speed axial fans Air intake installed near to the pilot and co-pilot pedestal (flapper valves open). Fan Air is then distributed to the different outlets, front faces Main winshield Demister outlets, main windshield and side windows diffusers. Upper Side Window Demister Lower Side Window Demister Front face outlets LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 34 Training DOCTR 039 AW 139 Cabin ventilation system (basic) For the Cabin. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 35 . The air is then routed through a duct to the flapper valve. each one being separated supplying fresh air via singular gaspers to the passengers. The outside Ram air flow is supplied by an Open/Close flapper valve controlled manually by the crew with a 2 position switch on the cockpit control Panel or by the cabin panel provided “VENT CONTR PAX” being selected. outside ram air enters in the system through one air intake in the forward pylon fairing in the cabin roof. VENT CREW FAN LOW FAN HIGH ON OFF PAX VENT CTRL CREW ON OFF PAX 91100A010000 or 91100A010001 (NVG) Cockpit Control Panel Air is then distributed via the plenum to both lateral manifolds. Training DOCTR 039 AW 139 FORCED ventilation for the cabin is provided by an additional two speed axial fan. Side vents manifold Singular gaspers manifold Water Air intake separation Flapper valve Fan duct Plenum To control panel Singular gaspers manifold Side vents manifold LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 36 . The fan and flapper valve control can be achieved by the crew through the cockpit panel or when VENT CTRL PAX selected by the passengers through the cabin panel. The cockpit gaspers are wide diffusers to provide comfortable diffusing with large air flow. Training DOCTR 039 AW 139 Distribution system description: The demisting outlets are composite diffusers with fins to control the air jet characteristics to perform the windscreen bay demisting. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 37 . The cabin and cockpit pedestals are composite outlets to diffuse air to crew and passengers feet. The cabin gaspers are standard airplane gaspers. Characteristics: The ventilation distribution system is designed to withstand pressure variations in a range of – 15 mBars and + 150 mBars. The maximum operating temperatures should be in-between – 40°C to + 85°C. Training DOCTR 039 AW 139 DISTRIBUTION SYSTEM DESCRIPTION LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 38 . Training DOCTR 039 AW 139 Ventilation Low Pressure Ducting Cockpit view: Fan Pluged Heating System connections Simple Flapper Valve LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 39 . we can distinguish 5 subsystems: • The LPD for Cockpit Ventilation Subsystem (basic) • The LPD for Cabin ventilation Subsystem (basic) • The LPD for Forced Cabin Ventilation Subsystem (kit) • The LPD for Heating Subsystem (kit) • The LPD for Air Conditioning Subsystem (kit) The ventilation system distribution ducting for cockpit and cabin is the basic version for the helicopter. front face outlets and a plenum. Training DOCTR 039 AW 139 Low Pressure Ducting The Low Pressure Ducting – LPD system consists of air distribution ducts. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 40 . cabin diffusors. window demister. pedestral outlets. manifolds. Depending on the configuration to be installed on the helicopter. Training DOCTR 039 AW 139 Low Pressure Ducting views (example): Cabin diffuser (example) Cabin ceiling plenum with diffuser LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 41 . Training DOCTR 039 AW 139 VENTILATION SYSTEM MAIN COMPONENT DESCRIPTION LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 42 . 3 mbar LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 43 . Pressure drop (valve full open) : With a nominal Cockpit flow of 125g/s = 0.2 mbar With a nominal Cabin flow of 350 g/s = 0. Installation: The valves are located after the ram air intakes of the ECS before fans. Training DOCTR 039 AW 139 Cockpit Flapper valves 6034A010001/3G2120V00651 General information: The pilot drives the Flapper Valves from the cockpit panel. The mounting brackets ensure bonding between the valve and the helicopter. to open or shut off the ram air intakes of cabin and cockpit low pressure distribution system. They are attached to the structure by metallic brackets and to the ducting with minox clips. : between 0.
a shaft which transmits the rotational movement by a tenon-mortise type drive
brushes direct current motor. Maximum opening/closing time: 5s Weight max.12 mdaN : <1.0A Normal operation temperature: -40°C to +70°C ( a max of 85°C during short time -valve not operating) Nominal operation pressure: 35 mBars rel.
a tangential gear box. Characteristics: Nominal power supply : 28 Vdc for a limit of 17 Vdc to 32 Vdc Current consumption at nominal torque of 0.
an aluminium flap. Training DOCTR 039 AW 139 Cockpit Flapper valve 6034A01000/3G2120V00651 (ventilation + heating) The two flapper valves are derived composed of :
a 3 inches cylindrical composite body.
one end of travel opening and one end of travel closing position switch.58 kg LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 44 .42 kg and 0. Training DOCTR 039 AW 139 Cockpit Flapper valve pin location : LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 45 . Training DOCTR 039 AW 139 Cockpit Flapper valve (6034A010001 ventilation + heating) general view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 46 . Inside the valve core an aluminium circular flap. Training DOCTR 039 AW 139 Cabin Flapper valve 6035A010001/ 3G2120V00851: The Ram air cabin valve is a 4 inches diameter. single cylindrical composite body butterfly valve. The flapper valve shaft is driven by an electrical actuator. Two end of travel micro-switches indicates the state of the valve: Open or Close.5 kg LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 47 . consists of an endless screw and an 28Vdc electrical motor. The electric actuator.0A Normal operation temperature: -40°C to +70°C ( a max of 85°C during short time -valve not operating) Nominal operation pressure: 35 mBars rel. Maximum opening/closing time: < 5 s Weight: 0. held by 2 half-shafts. perform the shut-off function.12 mdaN : <1. Characteristics: Nominal power supply : 28 Vdc for a limit of 17 Vdc to 32 Vdc Current consumption at nominal torque of 0. Training DOCTR 039 AW 139 Cabin Flapper Valve pin location : LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 48 . Training DOCTR 039 AW 139 Cabin Flapper valve 6035A010001/ 3G2120V00851 general view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 49 . select OFF/ON. current consumption: 7 A (start up 14 A) Weight: 0./heat.40°C to + 70°C Low speed flow rate at 30°C and at see level: 7350 rpm High speed flow rate at 30°C and at see level: 14200 rpm / 6. system only): There are 2 two speed brushless cockpit fans per helicopter on 2 symmetrical ventilation systems. Both fan sucks air from the ram air intake and generates ventilation air flow towards the cockpit outlets and are used for ground and flight operation. Training DOCTR 039 AW 139 Cockpit Fan 8013A030000/3G2120V00553 function (vent. Fan characteristics: Power supply: 28Vdc Normal working temperature range: . They are controlled by the ECS Cockpit panel at high and low speed and are equipped with a thermal switch and a under speed detection. To reset the fan.9 kg LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 50 .5 A Max. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 51 . With power supplied and OFF selection the under-speed pin detection shall be open circuit. Training DOCTR 039 AW 139 Cockpit Fan 8013A030000 /3G2120V00553 under speed detection: In ON mode. An under-speed fault is detected if the under-speed pin detection is ground after the start up phase. During the start up phase when ON selection is activated the under-speed pin detection is open circuit during 5 seconds. The under-speed detection level is the half off low speed and half off high speed ±15% (in tr/mn). In this case the fan will be stop and a OFF/ON selection is necessary for start again the fan. With no power supplied the under-speed pin detection shall be Open. a fault is indicated (Ground) only if the speed is inferior to the under speed limit during 3 to 5s. Training DOCTR 039 AW 139 Cockpit Fan 8013A030000/3G2120V00553 electrical logic: • ON/OFF selection : • Under-speed detection : o Ground → ON o Ground → Fault o Open Circuit → OFF o Open Circuit → No fault • High speed / Low speed selection : o Ground → Low speed o Open Circuit → High speed LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 52 . Training DOCTR 039 AW 139 Cockpit Fan 8013A030000 /3G2120V00553 Pin Location (idem for FAN 2): LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 53 . Training DOCTR 039 AW 139 Cockpit Fan 8013A030000 (ventilation/heating system only) general view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 54 . It is controlled either by the ECS Cockpit panel or Cabin panel. The fan sucks air from the ram air intake and generates ventilation air flow towards the cabin overhead outlets. Fan characteristics: Power supply: 28 Vdc Normal working temperature range: .40°C to max. Training DOCTR 039 AW 139 Cabin Fan 8012A030000/3G2121V00553 function (Forced vent./heating): In this configuration we will find one 2 speed brush less cabin fan per helicopter. + 85°C Low speed flow rate at 30°C and at see level: 7500 rpm / 5A High speed flow rate at 30°C and at see level: 13200 rpm / 17A Nominal current consumption: 16 A (start up 23 A) Weight: 1. The cabin fan is used for ground and flight operation.6 kg LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 55 . With power supplied and OFF selection the under-speed pin detection shall be open circuit. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 56 . In this case the fan will be stop and a OFF/ON selection is necessary for start again the fan. a fault is indicated (Ground) only if the speed is inferior to the under speed limit during 3 to 5s. Training DOCTR 039 AW 139 Cabin Fan 8012A030000/3G2121V00553 under speed detection: In On mode. During the start up phase when ON selection is activated the under-speed pin detection is open circuit during 5 seconds. With no power supplied the under-speed pin detection shall be Open. An under-speed fault is detected if the under-speed pin detection is ground after the start up phase. The under-speed detection level will be the half off low speed and half off high speed ±15% (in tr/mn). Training DOCTR 039 AW 139 Cabin Fan 8012A030000/3G2121V00553 electrical logic: • ON/OFF selection : • Under-speed detection : o Ground → ON o Ground → Fault o Open Circuit → OFF o Open Circuit → No fault • High speed / Low speed selection : o Ground → Low speed o Open Circuit → High speed LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 57 . Training DOCTR 039 AW 139 Cabin Fan 8012A030000/3G2121V00553 Pin Location : LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 58 . Training DOCTR 039 AW 139 Cabin Fan 8012A030000 (Forced ventilation/heating) general view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 59 . Training DOCTR 039 AW 139 VENTILATION SYSTEM TROUBLE SHOOTING PROCEDURE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 60 . Training DOCTR 039 AW 139 AB139 Forced ventilation trouble shooting guide Testing using LTS . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 61 .BOB: Break Out Box – BOB 92612A010000 (Ventilation/Heating/Air Conditioning) Caution: Before connecting the special tool to the electrical harness switch-off the 28Vdc helicopter power supply. Training DOCTR 039 AW 139 Forced Ventilation System test (in Air conditioning helicopter configuration) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 62 . Training DOCTR 039 AW 139 Forced Ventilation (VIP Air cond. Option) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 63 . Training DOCTR 039 AW 139 Note: In order to check ONLY the ventilation system the BOB 92612A010000 must be used. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 64 . Connector J03 Connector J02 (only used when only used in A/C configuration cabin panel installed) Connector J01 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 65 . Training DOCTR 039 AW 139 1) The BOB 92612A01000 must be connected between the Cockpit Panel J01 and the helicopter harness. The connector J02 on the Cockpit Panel back side must remain connected. CONTR in « CREW » position (if available) and TEMP CONTR in « Min » 3) Connect 28Vdc power to the helicopter and put GEN switch to ON. Training DOCTR 039 AW 139 2) Put all selection buttons on the cockpit panel in « OFF » position. Warning: In A/C configuration the Condenser fan might start for a couple of secondes. 4) The BOB initial configuration should be: AFT FV-CMD = yellow LED is «ON» AFT FAN-CTL = yellow LED is «ON» FWD FV-CMD = yellow LED is «ON» FWD FAN-CTL = yellow LED is «ON» Note: All other LEDs are « OFF » LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 66 . jumper 26 and 31 (lane 2). LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 67 .Confirm absence of 28VDC power supply to the cockpit panel between . Training DOCTR 039 AW 139 4-a) If the LED’s remain « off ».jumper 25 and 32 (lane 1) and . Refer to helicopter AMM electrical power supply. . Training DOCTR 039 AW 139 5) On the cockpit panel switch the VENT « CREW » selector to « ON » 6) The BOB configuration should be: AFT FV-CMD = yellow LED is «ON» AFT FAN-CTL = yellow LED is «ON» FWD FV FULL CLOSE = «GREEN» LED comes ON FWD FV-CMD = LED becomes «GREEN» FWD FAN-CTL = yellow LED is «ON» Reminder: FV in open position it’s « recirculation » position. FV in full close position it’s « ram air » position . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 68 . Training DOCTR 039 AW 139 6-a) If the FWD FV-CMD LED remains «YELLOW».To confirm a cockpit panel failure confirm absence of 28VDC between jumper 32 and 23 ⇒ replace cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 69 . . . disconnect FV1 .Check wiring and connection to both FV’s ⇒ if OK replace FV 1 (2) 6-c) If motor noise is audible. replace FV2. Training DOCTR 039 AW 139 6-b) If the FWD FV-CMD LED becomes «GREEN» but the FWD FV FULL CLOSE LED remains « off » (no electrical motor noise).FV2 0 VDC between jumper 51 and 32 ⇒ if not check wiring and connection and if O. disconnect FV2 .K. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 70 .K. replace FV1. 6-d) If motor noise is audible.FV1 0 VDC between jumper 51 and 32 ⇒ if not check wiring and connection and if O. if not replace corresponding fan LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 71 . Training DOCTR 039 AW 139 7) On the cockpit panel switch the VENT « CREW » selector to « FAN LOW » 8) The BOB configuration should be: AFT FV-CMD = yellow LED is «ON» AFT FAN-CTL = yellow LED is «ON» FWD FV FULL CLOSE = «GREEN» LED remains ON FWD FV-CMD = LED remains «GREEN» FWD FAN-CTL = LED becomes «GREEN» FWD FAN-ON = «GREEN» LED comes ON Note: Both fans are runing in LOW speed. Training DOCTR 039 AW 139 8-a) If the FWD FAN-CTL LED remains « Yellow » .replace cockpit panel Reminder: FAN automatically runs in « High Speed » 8-b) If the FWD FAN-ON LED remains « OFF » .Check resistance between jumper 15 and 32 .If open circuit ⇒ replace cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 72 . .Loss of FWD FAN-CTL order. if not replace corresponding fan LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 73 . Training DOCTR 039 AW 139 9) On the cockpit panel switch the VENT « CREW » selector to « FAN HIGH » 10) The BOB configuration should be: AFT FV-CMD = yellow LED is «ON» AFT FAN-CTL = yellow LED is «ON» FWD FV FULL CLOSE = «GREEN» LED remains ON FWD FV-CMD = LED remains «GREEN» FWD FAN-CTL = LED becomes «YELLOW» FWD FAN-ON = «GREEN» LED remains ON Note: Both fans should run in High speed. Training DOCTR 039 AW 139 10-a) If the FWD FAN-CTL LED remains «GREEN» ⇒Check resistance between jumper 16 and 32 .If continuity ⇒ replace cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 74 . Training DOCTR 039 AW 139 11) On the cockpit panel switch the VENT « CREW » selector to « OFF » and VENT « PAX » to « ON » 12) The BOB configuration should be: AFT FV FULL CLOSE = «GREEN» LED comes on AFT FV-CMD = LED becomes « GREEN » AFT FAN-CTL = yellow LED is «ON» FWD FV-CMD = yellow LED is «ON» FWD FAN-CTL = yellow LED is «ON» LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 75 . To confirm a cockpit panel failure confirm absence of 28VDC between jumper 21 and 32 ⇒ replace cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 76 . Training DOCTR 039 AW 139 12-a) If the AFT FV-CMD LED remains «YELLOW». . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 77 .K. .Check wiring and connection to AFT . replace AFT cabin .FV.FV ⇒ if OK replace AFT cabin .AFT FV 0 VDC between jumper 55 and 32 ⇒ if not check wiring and connection and if O. Training DOCTR 039 AW 139 12-b) If the AFT FV-CMD LED becomes «GREEN» but the FWD FV FULL CLOSE LED remains « off » (no electrical motor noise). .FV 12-c) If motor noise is audible. Training DOCTR 039 AW 139 13) On the cockpit panel switch the VENT « PAX » selector to « FAN LOW » 14) The BOB configuration should be: AFT FV FULL CLOSE = «GREEN» LED remains on AFT FV-CMD = LED remains «GREEN» AFT FAN-CTL = LED becomes «GREEN» AFT FAN-ON = «GREEN» LED comes on FWD FV-CMD = yellow LED is «ON» FWD FAN-CTL = yellow LED is «ON» Note: Both fans are runing in LOW speed. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 78 . if not replace corresponding fan. If open circuit ⇒ replace cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 79 .Check resistance between jumper 8 and 32 .Loss of FWD FAN-CTL order.replace cockpit panel Reminder: FAN automatically runs in « High Speed » 14-b) If the FWD FAN-ON LED remains « OFF » . . Training DOCTR 039 AW 139 14-a) If the AFT FAN-CTL LED remains « Yellow » . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 80 . if not replace corresponding fan. Training DOCTR 039 AW 139 15) On the cockpit panel switch the VENT « PAX » selector to « FAN HIGH » 16) The BOB configuration should be: AFT FV FULL CLOSE = «GREEN» LED remains on AFT FV-CMD = LED remains «GREEN» AFT FAN-CTL = LED becomes «YELLOW» AFT FAN-ON = «GREEN» LED remains on FWD FV-CMD = yellow LED is «ON» FWD FAN-CTL = yellow LED is «ON» Note: Both fans should run in HIGH speed. if O.K. ⇒ replace cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 81 . Training DOCTR 039 AW 139 16-a) If the AFT FAN-CTL LED remains «GREEN» -Check continuity between jumper 9 and 32. Training DOCTR 039 AW 139 17) Put both CREW and PAX VENT switches in « FAN LOW » position Reminder: A FAN FAILURE is indicated on the BOB when the internal electronic of the fan detects an underspeed. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 82 . ⇒ Check corresponding fan and if no foreign object blocking -replace fan Attention: If one FWD (AFT) FAN has failed the MAU «Ventilation failure » message is triggered. Training DOCTR 039 AW 139 18) System inputs/outputs in case of FAN FAILURE can be simulated by putting a shunt between the jumpers: AFT FAN1 FAILURE – shunt between 50 and 31 AFT FAN2 FAILURE – shunt between 43 and 31 FWD FAN1 FAILURE – shunt between 35 and 32 FWD FAN2 FAILURE – shunt between 44 and 32 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 83 . (fan running) – check connections of the distribution ductings.k. Cockpit gaspers fully open pedestral gaspers fully closed. – replace Cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 84 . Training DOCTR 039 AW 139 Further troubleshooting advises: On the Cockpit panel : Switch VENT CREW Fan in low and high speed mode (both FWD fans).k.
no 28Vdc power supply (BOB FWD-FAN-ON light «Off») – check wiring and power supply to the Cockpit Panel
wiring and power supply o. IMPORTANT: Loose of FWD FAN-CTL order result automatically into a Fan « High speed » order! 1) NO air flow on left or/and right side (both sides are completely independant): Check power supply to the fan (FWD-FAN-ON [to confirm remove jumper 15 – light goes «Off»]
if o. check High speed order (BOB: FWD Fan-Ctl light «Yellow/Red». to confirm signal remove jumpers. Fan-On light «Green»)
No High speed order – replace Cockpit panel Reminder BOB: Fan On (Jumper-15) + Fan CTL (Jumper-16).
High speed order o.K. – check wiring and 28Vdc on fan connector
If O.replace concerned fan LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 85 . .If not. Training DOCTR 039 AW 139 Ventilation System troubleshooting 2) Low flow at the cockpit gaspers with fan running 2-a) Check if left/right Fan is/are running in high speed mode (different noise level use flowmeter) .k. replace concerned FV
BOB FWD FV CMD light «Off » – check wiring and 28Vdc power supply to the Cockpit panel between jumper 25 and 32
If O.BOB FWD FV Full Close green light "OFF« [Jumper 51]. . .K. and valve still open . ram air open)
Confirm visualy the position of the FV on the indicator
If FWD FV-CMD o.k.K. .replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 86 .check wiring and 28Vdc on FV connector
If wiring and 28Vdc O. Training DOCTR 039 AW 139 Ventilation System troubleshooting 2-b) Low flow and Fan running in low and high speed mode
Check power supply order to the flapper valve(s) which should be fully close – BOB FWD FV CMD green light «On » (Jumper-23). (close = re-circulation close. k. (fan running) – check cabin distribution ducting connection downstream of the plenum. – check power supply to cockpit and/or cabin panel
Wiring o. select « CREW » Note: « PAX » selected – in ECS configuration Cabin panel provides order to cockpit panel which controls the cabin evaporator Fan.
If o. Training DOCTR 039 AW 139 Forced Ventilation System troubleshooting: On the Cockpit VENT PAX (or on the cabin panel VENT) switch fan in low and high speed mode (all 12 cabin gaspers open).
No 28Vdc power supply – check wiring and connection
Wiring o. 1) No flow at the cabin outlets:
Check power supply to the AFT fan.k. BOB-AFT FAN-ON « Green » light On (28Vdc between Jumper-8 and 25) and FAN CTL « Yellow/Red » light ON = High Speed order (28Vdc between Jumper-9 and 25). – replace cockpit or cabin panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 87 .k. Reminder: Fan-On green light (Jumper-8) and Fan-CTL Yellow/Red light (high speed Jumper-9)
Check wiring and 28Vdc on Fan connector.Check High speed order to the fan.replace fan. .k. .k.K.replace cabin panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 88 . if O.
« PAX » selected for Cabin panel check wiring and if o. . using break out box. Training DOCTR 039 AW 139 Forced Ventilation System troubleshooting 2) "Low" flow at the cabin outlets: 2-a) Fan not running in high speed mode .
No High speed order Fan CTL Green light « ON » (low speed) – Remove Jumper .9 from BOB and check if Fan CTL « Yellow/Red » light comes on (high speed) – Check helicopter wiring.
If o.replace Cockpit panel. Look for a leakage/disconnected duct located upstream of the plenum in the upper deck zone LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 89 . FV might be either in open (recirculation) or close (ram air) position. BOB AFT FV-CMD green light "On"[Jumper-21] and AFT FV Full-close green light « ON » (Jumper-55).. if o.Check power supply to the flapper valve which must be fully close.
For Cabin panel check wiring and if o. depending to the Cockpit panel selection (intermittend position is not allowed) .k. replace Cabin panel 2-c) Fan running in low and high speed mode and FV close Attention: In A/C configuration. visually check the Flapper Valve position indicator. and valve still open.k. BOB green light «OFF » [Jumper-55]) . Training DOCTR 039 AW 139 2-b) Low flow and Fan running in low and high speed mode .replace FV
No 28Vdc power supply (BOB between jumper 25 and 32) – replace Cockpit panel.
Check 28Vdc power supply on connector. (Fan running in low and high speed mode. Note: FV position explanation Vent OFF selected means FV open = Ram Air closed (Recirculation open) Vent ON selected means FV close = Ram Air open (Recirculation closed) Vent Low/High speed selected means FV close = Ram Air open (Recirculation closed) Vent Low/High speed + Cond Recircule selected means FV open = Ram Air closed (Recirculation open) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 90 . Do Not check the upper deck zone. Flapper valve open) -Look for a leakage located either on the plenum connection or on the manifold and lateral diffusers. Training DOCTR 039 AW 139 Forced Ventilation System troubleshooting 3) Flow misbalance between left and right side. Training DOCTR 039 AW 139 Return HEATING AND VENTILATION SYSTEM LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 91 . Training DOCTR 039 AW 139 Helicopter Heating System cut off view LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 92 . Training DOCTR 039 AW 139 Helicopter Heating/Ventilation System components: Heating system Components (ventilation) 20204C010000 P/N Qty 91104A010000 HEATING COCKPIT CONTROL PANEL + Crew switch 3G2140V00351 1 91104A010001 HEATING COCKPIT CONTROL PANEL .NVG 3G2140V00352 14422A030001 TEMPERATURE CONTROL VALVE 1 3G2140V00751 FACIAL E-SEAL JOINT 3475 4 1'' HP Check valve 3G2140V00651 2298A020000 2 12771A010001 HIGH PRESSURE DUCT Left 1 12773A010001 12772A010000 HIGH PRESSURE DUCT Right 1 12774A010001 HP Duct 12760A020001 2 HP Duct 12761A020001 1 Duct Overheat Thermal Switch 3G2140V01051/3G2140V01351 92252A01/92244A01 1 Composite Jet Pump 3G2140V00851 428B010000 1 Shut off valve 3G2140V00551 6916A020000 2 Heating control box 3G2140V00252 92177A020000 1 Air Duct Temperature sensor 3G2140V00951 93260A010000 1 HEATING COCKPIT CONTROL PANEL basic 91104A010001 1 3G2140V00354 91129A010000 HEATING COCKPIT CONTROL PANEL + FV 3G2141V00353 91108A010000 HEATING COCKPIT CONTROL PANEL + FV NVG 3G2141V00354 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 93 . Training DOCTR 039 AW 139 Return DOTS + ADTS SOV’s Jet Pump TCV Check valves HCB LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 94 . Training DOCTR 039 AW 139 Return LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 95 . Training DOCTR 039 AW 139 Helicopter Heating / Forced Ventilation System components: Components of the Heating + Cockpit/Cabin Forced ventilation P/N Qty system P/N 20204D010000 91106A010000 Heating + Forced ventilation COCKPIT CONTROL PANEL 3G2141V00351 1 91106A010001 Heating + Forced ventilation COCKPIT CONTROL PANEL NVG 3G2141V00352 8012A030000 CABIN fan 1 3G2121V00551 Forced ventilation CABIN CONTROL PANEL 91103A010000 1 Forced ventilation CABIN CONTROL PANEL .NVG 91103A010001 1 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 96 . Training DOCTR 039 AW 139 Heating System The heating system consists of the elements described on the following schematic and a distribution system. AMBIANT AIR ENG1 SOV1 (1) CV1 (2) TCV (4) BAD (3) JP (5) ADTS (7) DOTS (8) CV2 (2) SOV2 (1) ENG2 HCB (6) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 97 . Training DOCTR 039 AW 139 Heating System Jet Pump Distribution ducting: Front cabin diffusor Rear cabin diffusor Fan Pedestral outlets From cockpit ventilation From cockpit ventilation Fan Pedestral outlets Front cabin diffusor Rear cabin diffusor LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 98 . Training DOCTR 039 AW 139 Low Pressure Ducting (Vent/Heating) Cockpit view: Fan From Heating System Flapper Valve LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 99 . An overheat protection (DOTS: Duct Overheat Temperature Switch ) is provided to shut off the system if required. in case of automatic mode failure The Cockpit Control Panel for Heating and Ventilation System interfaces with: .the Temperature Control Valve ( TCV ) (Qty 1) .the cabin (Qty 1) and cockpit flapper valves (Qty 2) .
Manual mode to insure the safety defogging mode. Training DOCTR 039 AW 139 The Heating Control Box and the Cockpit Panel controls and monitors the Heating System according to the pilot demand.the Shut Off Valves (SOV1 & SOV2) . Two modes are basically proposed for the system :
Semi-automatic mode where the control box controls the blowing temperature in accordance with the selected temperature set by the crew on the cockpit panel.the Heating Control Box ( HCB ) (Qty 1) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 100 .the cockpit fans (Qty 2) . Training DOCTR 039 AW 139 High Pressure Ducts and Insulation Jackets The different Shut Off Valves of the Heating system are supplied with hot engine air by HP-ducts which are equipped with insulation jackets in order to keep the skin temperature below 200°C. HP Duct 12771A020000 HP Duct 12761A020000 HP Duct 12772A020000 HP Duct 12760A020000 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 101 . Training DOCTR 039 AW 139 HEATING Return PILOT INTERFACES LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 102 . Training DOCTR 039 AW 139 "Heating and Ventilation system" Cockpit Control P/N91104A010000 HTR VENT HTR CREW TEMP FAN AUTO Man CONTR MAN LOW FAN HIGH AUTO Auto ON MIN MAX OFF OFF PAX CONTR SOV MAN HTR 1 Normal 2 CREW CLOSE ON NORMAL Close OFF PAX 91104A010000 or 91104A010001 (NVG) Cockpit Control Panel AUTO 1 potentiometer MIN MAX 2 switches VENT MAN HTR Toggle switch ON OFF VENT 91101A010000 or 91101A010001 (NVG) Cabin Control Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 103 . « CLOSE » the SOV is closed for safety reason by the crew. Note: The switch can moved back to the ‘’ NORMAL ‘’ position after turning HTR switch to “OFF” or by cutting off the 28VDC to the control panel. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 104 . Training DOCTR 039 AW 139 Cockpit Control Panel "Heating and Ventilation system" P/N91104A010000/ 3G2140V00351 Enter VENT part : please refer to "Ventilation" chapter HEATER part : Two 2-positions toggle switches control the SOV 1+2 : « NORMAL » the SOV is opened or closed. « MAN » selected. Auto” switch allows to select the control mode : « OFF » selected. and the HCB controls the blowing temperature by modulating the TCV according to temperature demand. that means ram air “Open and cold air is mixed with the warm air from the heating system. the HCB is switched "On". the Heating Control Box is switched “Off” (no automatic overheat protection anymore). both SOV’s are closed. Therefore. which is set by the pilot using the rotary potentiometer. the Heating System is in automatic mode. Training DOCTR 039 AW 139 A 3-positions “Off. Both SOVs are open. and the control of the Heating System is done by direct TCV motor command from the TEMP CONTR in rotary toggle switch position (up-side down). do activate carefully the toggle switch to not move the TCV to full open position. The pilot can choose ventilation mode. Both SOVs are open. For proper selection. that means ram air “Open and cold air is mixed with the warm air from the heating system. « AUTO » selected. The pilot can choose ventilation mode. which allows to adjust manually the blowing temperature. The pilot can choose ventilation mode. it takes about 5 seconds to move the TCV in full open position. the Heating Control Box is switched “Off”. Note: When ventilation mode is selected along with heating the FV’s are in “Close” position. Man/Demist. and controls automatically the blowing temperature (only if at least one of the SOV is open). Note: In “MAN” mode. Note: When ventilation mode is selected along with heating the FV’s are in “Close” position. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 105 . to avoid any system overheat. the control panel sends a discrete signal. The manual control of the TCV with the HMV rotary toggle switch is hence inhibited. Training DOCTR 039 AW 139 “TEMP CONTR” A rotary potentiometer/toggle switch is provided to either adjust in “AUTO” mode the temperature demand or to act as a “Toggle switch” in “MAN” mode. Rotary Potentiometer (switch in top position): When HTR ”AUTO” is selected, the potentiometer controls via the Heating Control Box the Temperature in cabin and cockpit. When « OFF » or « MAN » is selected, the potentiometer has no function. Rotary Toggle Switch (switch in upside down position): When “OFF” is selected the Rotary Toggle Switch controls directly the TCV but no heating is obtained because both SOV’s are in closed position. When « AUTO » is selected, the Rotary Toggle Switch must be in potentiometer position between “min and max” (top position). When « MAN » is selected, the Rotary Toggle Switch controls directly the TCV, left position (-) for closing (less heating) and right position (+) for opening (more heating). LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 106 Training DOCTR 039 AW 139 Heating and Forced Vent. system Cockpit Control P/N 91106A010000/3G2141V00351 HEATER VENT HTR CREW CLOSE TEMP CONTR OFF CREW MAN FAN HIGH ON AUTO FAN OFF LOW MIN SOV - + MAX PAX 1 NORMAL 2 OFF FAN HIGH ON FAN LOW CLOSE 91129A010000 Cockpit Control Panel 1 potentiometer 2 switches LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 107 Training DOCTR 039 AW 139 Cockpit Control Panel « Heating and Forced » Cabin Ventilation system VENT part : please refer to "Ventilation" description Enter HEATER part : please refer to previous “Heating and Ventilation system“ description Enter LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 108 Training DOCTR 039 AW 139 SYSTEM CONTROL LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 109 Training DOCTR 039 AW 139 Cockpit panel functions, Ventilation/Heating system: (VENT CTRL "CREW" selected)
Control Cockpit fans (off/low/high),
Control Cockpit and Cabin Flapper Valves*,
Control Shut Off Valve – SOV 1+2 opening/closing (in Man and Auto mode),
Control Temp Control Valve – TCV opening/closing (in Man mode by the Temp. Contr. Rotary Toggle Switch),
Control Heating system Control Box – HCB on/off,
Provides Cockpit/Cabin zone temperature demand signal to the HCB (potentiometer). *With VENT CTRL "PAX" selected on the cockpit control panel the cabin panel controls the cabin flapper valve. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 110 Training DOCTR 039 AW 139 Cockpit panel functions, Heating and Forced Ventilation system: (VENT CTRL "CREW" selected) Control Cockpit fans (off/low/high),
Control Cockpit and CABIN fan (s) (off/low/high)*
Control Cockpit and Cabin Flapper Valves*,
Control Shut Off Valve – SOV 1+2 opening/closing,
Control Temp Control Valve – TCV with toggle switch ("MAN" mode)
Control Heating system Control Box – HCB On/Off,
Provides Cockpit/Cabin zone temperature demand signal to the HCB (potentiometer). *With VENT CTRL "PAX" selected on the cockpit control panel the cabin panel controls the cabin flapper valve and the cabin fan. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 111 Training DOCTR 039 AW 139 Cockpit panel pin location: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 112 Training DOCTR 039 AW 139 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 113 .
Monitoring the Shut Off Valves .
Triggering HTR-Failure.
Monitoring of the Duct Overheat Thermal Switch – DOTS. DOTS and the Temp. Training DOCTR 039 AW 139 Heating system Control Box – HCB functions:
Monitoring of the External Air Temperature Sensor – EATS (Agusta responsability)
Monitoring of the Air Duct Temperature Sensor – ADTS.
Control of the Temperature Control Valve – TCV (in Auto mode)
Memorizing the EATS. ADTS.SOV 1 + 2 which are controlled by the Cockpit Panel. Control fault message. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 114 . Training DOCTR 039 AW 139 Detailed Operation Heating System LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 115 . The bleed air is routed from each engine port to a Shut-Off Valve (1) Check valve (2) avoids any back flow from one engine to the opposite engine. AMBIENT AIR ENG1 SOV1 (1) CV1 (2) TCV (4) BAD (3) JP (5) ADTS (7) DOTS (8) CV2 (2) SOV2 (1) ENG2 HCB (6) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 116 . Training DOCTR 039 AW 139 Heating system operation: Added to the cockpit and cabin ventilation system. The basic heating system uses bleed air from the compressor discharge port of each engine. The Heating Control Box and the Cockpit Control Panel control the proper function of the heating system and provides alarm and overheat protection. this configuration includes the heating functions which consists of the elements shown here below. The bleed flow is limited down to 2% of the total air flow of each engine by restrictions. hot engine air under high pressure is routed to the Temperature Control Valve (4) which controls the quantity of bleed air to be mixed in the Jet Pump (5) with the air outside ambient air. In case of overheat non-detected by this sensor. The Shut-Off Valves and the Temperature Control Valve can also be controlled manually by the pilot via the Cockpit Panel (9). given by the Cockpit Control Panel potentiometer(9). the Duct Overheat Temperature Switch (8) closes directly the shut-off valves. The mixed air is ducted to the delivery distribution ducts (10). An additional injector which by-pass the TCV in case of TCV malfunction. The mixed airflow is controlled by the Heating Control Box (6) by comparison between the blowing temperature measured by the Air Duct Temperature Sensor (7) and the selected temperature. enables a minimum heating system operation. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 117 . Training DOCTR 039 AW 139 Heating system operation: Via the Bleed Air Tubes – BAD (3). Training DOCTR 039 AW 139 Heating System Architecture: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 118 . Training DOCTR 039 AW 139 Temp -CTL1-SIG Temp -CTL1 -SUP 11 7 43 HTR Failure HELICOPTER Temp -CTL1-REF 12 HCB + 28 Vdc1 AUTO -HTR-SEL Heating System Architecture: 28 AFT -FAN-ON AFT FAN1 B Selection and Speed Control D J01 AFT-FAN-CTL C A 12 10 11 41 8 9 M F TEMP_CONTR AFT FAN2 0 Vdc1 B Selection and Speed Control D A C M VPWR2 HTR MAN F AUTO FWD-FAN-ON FWD FAN 1 0 Vdc1 OFF Selection and Speed PAX E Control HIGH B VPWR1 LOW FWD-FAN-CTL D ON A OFF M HIGH F LOW ON OFF J01 E Selection and Speed 55 Control CREW B HIGH F VPWR1 LOW 15 A ON M OFF D HIGH 16 LOW ON FWD FAN 2 OFF 51 PAX/CREW AFT-FV-CMD-H AFT FV VPWR1 HIGH 21 4 LOW AFT-FV-CMD-L M ON OFF 22 3 HIGH LOW 5 6 ON OFF 6 FWD FV1 FWD-FV-CMD-H 4 VPWR1 PAX/CREW FWD-FV-CMD-L M HIGH 23 LOW 24 3 ON OFF 5 6 HIGH LOW ON FWD FV2 OFF 7 4 M 3 5 6 49 48 EATS 3 45 +28 Vdc2 4 2 46 3 HCB 44 0 Vdc2 HELICOPTER LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 119 . AUTO 39 M 2 TCV-CMD-CLOSE-IN 3 TCV-CMD-OPEN. Training DOCTR 039 AW 139 ADTS TCV -FC 1 5 8 3 HCB Heating System Architecture: 2 6 40 34 14 15 36 9 TCV -FO VPWR2 J01 TCV -REF TCV HTR 37 MAN/OFF 5 + TCV-CMD-OPEN-OUT Speed AUT O 38 3 - option MAN/OFF 1 + TCV-CMD-CLOSE-OUT .IN 4 2 TCV -FC SOV1 36 HTR CLOSE VPWR2 AUTO/MAN SOV1-ON NORMAL 53 OFF CLOSE SOV1-CMD SOV1 AUTO/MAN A NORMAL 29 SOV 1 OFF B SOV2 AUTO/MAN CLOSE SOV2-ON A DOTS NORMAL 54 OFF CLOSE AUTO/MAN SOV2-CMD SOV2 SOV 2 NORMAL 30 A OFF B SOV1 -ON B SOV2 -ON FWD-VENTILATION 48 VENT-FAILURE 34 AFT -VENTILATION LOGICS 49 FWD-FAN1-FAULT 35 C FWD-FAN1 FWD-FAN2-FAULT 44 C FWD.FAN2 AFT -FAN1-FAULT 50 E AFT -FAN 1 43 CASE GND 33 * Forced ventilation configuration +28 Vdc1 VPWR1 25 E AFT -FAN 2 0 Vdc1 32 + 5 Vdc * ECS configuration 0 .5v 40 DIMMING VPWR2 0 Vdc LAMPS DIMMING 47 J01 cc protection 26 31 20 Heater on HELICOPTER 0 Vdc2 +28 Vdc2 17 18 26 10 37 50 38 39 8 9 13 7 5 4 6 12 MAINTENANCE CONNECTOR LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 120 . The error thus obtained via un internal logic drives the Temperature Control Valve.. thermal loads in the cabin.Control Principale: System control is achieved by an analog closed loop. Training DOCTR 039 AW 139 HCB . taking care to avoid excessive overheating of the Heating Ducts. The comfort in the cabin is adjust by the pilot who adapts the blowing temperature as a function of outside conditions. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 121 .. The loop controls the temperature by comparing a reference which is set by the pilot with the real temperature measured by the Temperature Sensor. etc. Training DOCTR 039 AW 139 Heating/Ventilation System Logic LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 122 . and cabin flapper valves are not fully closed. Training DOCTR 039 AW 139 Heating/Ventilation System Logic Description: Forward Ventilation : If cockpit fans are operating. then the control panel sends the " After Ventilation On " discrete signal to the helicopter general displayer (MAU).FAN2-FAULT is active . then the control panel sends the " Forward Ventilation On " discrete signal to the helicopter general displayer (MAU). then the control panel sends the " Ventilation Failure " discrete signal to the helicopter general displayer. After Ventilation : If cabin fan is operating. Ventilation Failure: If AFT-FAN-FAULT is active or FWD-FAN1-FAULT is active or FWD. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 123 . After Ventilation On and NO Ventilation Failure). then the HCB sends the " Heater Failure " discrete signal to the helicopter general displayer. Heater Failure:  If DOTS is open ( T°³ 85°C ) . then the control panel sends the " Heater On " discrete signal to the helicopter general displayer. Potentiometer defect (open circuit). LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 124 . Heater On: If SOV1 open command is active or SOV2 open command is active. or others electronic conditions as EATS broken (open circuit) and Temp. Training DOCTR 039 AW 139 Heating/Ventilation System Logic Description: Ventilation Failure: The Cockpit and cabin flapper valves even failed closed are NOT triggering the Ventilation failure. Nota: Air COND selection is associated to three additional signals (Forward Ventilation On. or regulated temperature is incorrect and ‘’HTR’’ selected.  if { [HTR is selected and (SOV1 is open or SOV2 is open)] and [(Duct temperature sensor is in open circuit or External temperature sensor is in open circuit or potentiometer is in open circuit)] } then the " Heater Failure " discrete signal shall be sent to the helicopter general displayer (MAU). Training DOCTR 039 AW 139 HCB Logic Functions: ‘’HEATER-Failure’’signal is sent to Modular Avionic Unit (MAU): if [(SOV1 is open or SOV2 is open) and (Duct Overheat Thermal Switch (DOTS) is active then the " Heater Failure " discrete signal shall be sent to the helicopter general displayer (MAU). LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 125 . Training DOCTR 039 AW 139 HCB . The HCB close Flapper Valves with following logic: .AFT FV and FWD FV power stages are activated during at least 15 seconds to close both Flapper Valves after HTR selection (independently of SOV status) Reminder: Closed flapper valve means = ram air open.TCV control logic: . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 126 .if { [HTR is selected and (SOV1 is open or SOV2 is open)] and [fault conditions are all inactive] then (TCV power stage is controlled according to PWM signal and error sign signal) else wise (TCV power stage is activated at maximum speed to close TCV). Air Duct Temperature Sensor (ADTS) has been during 15 seconds in open state permanent condition in automatic heater mode.Agusta) has been during 15 seconds in open state permanent condition in automatic heater mode. .Temperature selection potentiometer (CTL1 FAULT) has been during 15 seconds in open state permanent condition in automatic heater mode. . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 127 . Training DOCTR 039 AW 139 HCB Failure Logic: To memorized following failures for maintenance operation: . NOTA : Memorized fault signals must be read and reseted using Special Failure read- out Box 92599A010000. Duct Overheat Thermal Switch (DOTS) has been activated more than 8 seconds in automatic heater mode.External Air Temperature Sensor (EATS. . . Complete potentiometer range is corresponding to -10°C/90°C including failure analysis.To make temperature reference acquisition on 10 KΩ potentiometer with +/.HCB failure detection logic for temperature sensor and potentiometer: Potentiometer open circuit: temperature reference > 85°C Sensor open circuit: external temperature > 45°C or duct temperature > 80°C LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 128 . .2% accuracy. Regulation law: T regulation=T external + alfa (Tselected) + (40°C +/-5°C) if T regulation < T max .5°C +/.2.To regulate duct air at selected temperature ± 5°C in normal automatic conditions.To limit maximum duct air temperature to T max : 72. in function of External Air Temperature Sensor ( EATS ) using PWM motor drive on TCV actuator.To make temperature acquisition on EATS (-50°C to 50°C) and on ADTS (-10°C to 90°C) including failure analysis.5°C. . Training DOCTR 039 AW 139 HCB – ANALOG FUNCTIONS . 5 TCV OPEN TEMPERATURE CONTROL1 + TCV CLOSE EATS PID PWM ADTS .Training DOCTR 039 AW 139 FV AFT-FV- CONTROL CLOSE MODUL FWD-FV- CLOSE AUTO-HTR-SEL AND TCV SOV1 ON SOV2 ON OR CONTROL MODUL TCV-FC . MODUL EATS EATS FAULT MODUL DOTS FAULT HTR-FAILURE DOTS FAULT MODUL MODUL ADTS ADTS FAULT FAULT MODUL MEMORY CTL1 FAULT-READ TEMPERATURE FAULT-RESET FAULT CONTROL1 MODUL FAULT-TEST LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 129 .0. Training DOCTR 039 AW 139 Heating System Main Component description LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 130 . Training DOCTR 039 AW 139 92177A020000 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 131 . Cockpit Control Panel (ventilation/air-conditioning selected/available). The Electronic Control Box is an analog & logic array card fitted inside a metallic housing. . .Temperature Control Valve control via Cockpit Control Panel . . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 132 .Modular Avionic Unit ( MAU for failure triggering). The following equipments are interfacing with the HCB: -Temperature Sensors ADTS (PT1000) and EATS (PT500 supplied by Agusta) .10 KΩ ). It monitors the sensors and warns the crew when a fault occurs. .Thermal Switch DOTS.Potentiometer (Cockpit Panel . . Training DOCTR 039 AW 139 Heating Control Box 92177A020000/3G2140V00252: The HCB drives the Heating system. The FROB allows to read out the failure(s) memorised in the HCB and to get real time system information in « SCAN » mode. Enter Another function of the FROB is to SET / RESET the memory stage of the HCB. Training DOCTR 039 AW 139 Helicopter harness–Maintenance connector using Test box 92599A010000: Reminder: The FROB should be used during trouble shooting to help to identify quickly the faulty component. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 133 . Training DOCTR 039 AW 139 Heating Control Box – HCB general view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 134 . Training DOCTR 039 AW 139 Heating Control Box Pin Location: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 135 . / MAX WIRE FROM / TO CURRENT 2 EATS.SIG Analog Input 5 / 10 mA TWO TW From EATS 3 EATS.REF Analog Input 5 / 10 mA SH CORE 17 ADTS-FAULT 5v / OC 2 / 10 mA SINGLE CORE 18 CTL1-FAULT 5v / OC 2 / 10 mA SINGLE CORE 26 TS-FAULT 5v / OC 2 / 10 mA SINGLE CORE To 10 EATS-FAULT 5v / OC 2 / 10 mA SINGLE CORE Maintenance 37 FAULT-RESET 5v / OC 2 / 10 mA SINGLE CORE Connector 50 FAULT-TEST 5v / OC 2 / 10 mA SINGLE CORE 38 FAULT-READ 5v / OC 2 / 10 mA SINGLE CORE 39 ENABLE 5v / OC 2 / 10 mA SINGLE CORE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 136 . Training DOCTR 039 AW 139 Heating Control Box Pin Location: PIN ITEM TYPE NOM. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 137 . A piston acting as a valve displaces inside a cylinder. The valve is a fail safe component (in close position). compressed air through a filter pushes piston against the seat to close position. Piston rings avoid too large internal leakages. When solenoid is de-energized. thus causing piston to open. Training DOCTR 039 AW 139 Shut Off Valve – SOV 6916A020000/3G2140V00551: Function: The valve shuts off the engine hot air supply of the high pressure bleed ducting when heating is not selected by the pilot or forbidden for safety reasons. When energized. machined in a “1” inch diameter body. puppet valve shuts vent port and opens pressure port. The piston is kept at rest against its seat by a spring. Description: The shut-off valve is a solenoid operated in-line valve. Valve remains open as long as solenoid is energized. the solenoid vents air from the valve servo-chamber. 180°C Storage temperature: -55°C to + 85°C Weight: 1100 g LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 138 .SOV 6916A020000/ 3G2140V00551 Characteristics: Nominal power supply: 28 Vdc Current consumption: ≤ 0. Training DOCTR 039 AW 139 Shut Off Valve .4 A Opening /closing time ≤3s/≤4s Operating pressure min/max: 0. 436°C for a short time Surrounding temperature: -40°C to +150°C up to max.7 bar/15 bar Normal operating temperature: 403 °C up to max. Training DOCTR 039 AW 139 Shut Off Valve .SOV Pin Location (idem for SOV2): (GND) Overall view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 139 . This is a double flap stainless steel check valve. Characteristics: Normal operating temperature (short time): 231°C (270°C) up to 403°C (436°C) max. Tornado and Eurofighter Aircraft. Similar check valves are already used on Jaguar. The check valve with a 1 inch diameter. is a non return valve connected to the bleed ducting branch close to the engine port. Ambient temperature: -40°C to +130°C Storage temperature: -55°C to + 85°C Weight: 50g Internal leakage closed in non return position: <1 g/mn at 8 bar LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 140 . lower engine rate) between the 2 engines. Training DOCTR 039 AW 139 High Pressure Check Valve 2298A020000/ 3G2140V00551: It prevents the potential one engine discharge towards the other in case of strong pressure misbalance (one engine off. Check Valve general view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 141 . Training DOCTR 039 AW 139 HP . is a cylindrical carbon plug valve with stainless "1" inch steel body. It is driven by an electric actuator mounted on an insulated base to limit the thermal conduction towards the actuator. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 142 . It modulates the amount of hot air to be injected in the jet pump to control the heating temperature for the cockpit and cabin zone. Training DOCTR 039 AW 139 Temperature Control Valve TCV 14422A030001/3G2140V00751 Function: The temperature control valve is driven either by the pilot in “Manual” or by the HCB in “Auto” mode. Description: The temperature control valve body. Training DOCTR 039 AW 139 Temperature Control Valve – TCV: Description: The valve is composed of : · a stainless steel body with machined female ports · a cylindrical carbon plug · a shaft which transmits the rotational movement of the plug by a tenon-mortise type drive · a spring washer which pushes the plug and the shaft onto the seal · a cap to maintain the spring The tightness at the bearing is ensured by a seal The tightness on the cap is ensured by the lip which is an integral part of the cap An electrical heating muff covers the valve body and is automatically supplied by 28Vdc in case of sub-zero temperatures. Two thermo switches control the electrical supply of the heater LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 143 . 6 Amp (1.7 bar Maximum operating temperature : 436 °C Ambient operation temperature : . closing time : ≤4s Internal leakage under 12 bar rel. Training DOCTR 039 AW 139 Temperature Control Valve TCV 14422A030001 Characteristics: Nominal supply voltage : 28 VDC (limit 17 Vdc to 32 Vdc) Current consumption : < 0.8 Amp with heating) Maximum operating pressure : 12. pressure: < 12 l/mn Weight: 700 g LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 144 .40°C to + 130°C Opening. Training DOCTR 039 AW 139 Temperature Control Valve 14422A030001 – TCV general view LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 145 . Training DOCTR 039 AW 139 Temperature Control Valve Pin Location : LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 146 . Bleed flow Outside fresh air Mixed air LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 147 . It produces a hot air flow using temperature and pressure of engine bleed air. Training DOCTR 039 AW 139 Jet Pump 428B010000/3G2140V00851: Function: The jet pump is the heating system hot air generator. The expansion of bleed air at high pressure and temperature through the injector sucks and warms up a large amount of outside fresh air. The generated hot air flow is therefore a mixture of extremely hot engine bleed air and external fresh air. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 148 . External temperature [-40. A tube directly connected to the injector of the Jet Pump. Training DOCTR 039 AW 139 Jet Pump 428B010000/3G2140V00851 : Description : The main components of the Jet Pump are:
A Composite Mixing Unit (a venturi and a mixing chamber in one assy)
A twin stainless steel Injector
An insulation plate installed between Mixing unit and Injector The jet pump provides sufficient heat to cockpit and cabin using HP engine bleed air (maximum 2% of each engine). This ensures a minimum temperature of 18°C and prov ides comfort to the cockpit and cabin within the full flight envelop: Altitude [0-20000ft] . by-passes the TCV if failed closed.+50°C] The calculated heat power of the jet pump is 13 kW . 40°C to + 85°C Weight: 0. short time operation temperature: 436°C Mixing Unit flow rate: 500 g/s Injector flow rate: 170 g/s Ambient operation temperature : .Mixing Unit: 85°C (short time 120°C) Maximum operating temperature .9 Kg LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 149 .Injector: 12.0 bar Maximum operating temperature . Training DOCTR 039 AW 139 Jet Pump: Characteristics: Maximum operating pressure .Mixing Unit: 0.Injector: 403 Max.1 bar above atmosphere Maximum operating pressure . Training DOCTR 039 AW 139 Jet Pump general view: By-pass tube Injector Mixing Unit ADTS location DOTS location LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 150 . the check valves and the temperature control valve. The ducting crosses the upper deck firewall and 2 different parts of the helicopter: .the tail rotor compartment for P/N 12760A020000 and 12761A020000 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 151 . Training DOCTR 039 AW 139 HP – Ducts & Insulation Jackets: Functions: The high-pressure ducting is used to supply air from the two engines bleed ports to the jet pump. It interfaces with the shut off valves.the engine compartment for P/N 12758A020000 and 12759A020000 NEW P/N 12773A010001 and 12774A010001 . to the engine ports with an orifice plate to limit the bleed flow to 2% of the total engine flow . Training DOCTR 039 AW 139 HP – Ducts & Insulation Jackets: Description: • P/N 12758A020000 & 12579A020000 Flexible hoses located in the engine compartment.to the shut off valves • P/N 12760A020000 Rigid duct located underneath the engine department connected to the shut off valves through a SM coupling and including the support flange of the check valve. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 152 . The duct is connected . The hose will compensate engine displacement and vibration. The duct is connected to the Temperature control valve and includes the check valves supporting flanges.7 bar at 436°C HP Duct 12759A020000 HP Duct 020000 12761A010001 HP Duct 020000 12758A010000 HP Duct 020000 12760A010001 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 153 . Maximum operating condition: 12 bar at 230°C or sho rt time 11. Training DOCTR 039 AW 139 HP – Ducts & Insulation Jackets cont'd: Description: • P/N 12761A010001 Rigid duct located underneath the engine compartment including a Tee junction and a flexible hose to compensate thermal growth and pressure loads. Training DOCTR 039 AW 139 HP – Ducts & Insulation Jackets: The ducts located underneath the engine compartment (P/N 12760A01 & 12761A01) are insulated to limit their skin temperature at 200°C. made of :  Nomex fabric coated on one side with viton  Long needled glass fibers  Glass fabric impregnated of viton product    LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 154 . The ducting is covered with Velcro fastenings insulation jackets. under fuel flammability. The EATS (supplied by Augusta) measures the external air temperature upstream from the Jet Pump. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 155 . Training DOCTR 039 AW 139 ADTS – Air Duct Temp. The HCB use the temperature information from both sensors and compares it with the temperature demand coming from the Cockpit Panel potentiometer. . Thus to adjust the TCV flap position to obtain the desired ambient temperature in the cockpit and cabin zone of the helicopter.The ADTS measures the output temperature of the Jet Pump. Sensor 93260A010000/3G2140V00951: Function: The sensors are providing a temperature information to the HCB (Heating Control Box): . 40°C to + 125°C Storage temperature range: . The ADTS is installed on the jet- pump. Training DOCTR 039 AW 139 ADTS – Air Duct Temp. Sensor 93260A010000/3G2140V00951: Description: Single Sensitive element allowing air to be circulated directly to the measurement component housing whit an optimum response time and accuracy. Characteristics Operating temperature range: .55°C to + 125°C Type : PT1000 Accuracy: 0°C to +85°C ± 1°C Response Time with flow 5 m/s: 15 seconds for 50 m/s: 6 seconds Weight: ≤ 100 g LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 156 . Training DOCTR 039 AW 139 ADTS – Air Duct Temperature Sensor Pin Location: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 157 . Air Temperature Sensor Pin Location (under Agusta responsability): The EATS installed in the helicopter front section under the cockpit/cabin and of the PT500 type. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 158 . Training DOCTR 039 AW 139 EATS – Ext. normally closed • Nominal current: < 0. In case of duct temperature overheat.Duct Overheat Thermal Switch 92244A010001/3G2140V01351: Description and operation It is composed of a housing.5°C) an d close the shut off-valve.7A • Weight: 68 g • Operating range -40 °C to +204 °C LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 159 . the thermal-switch opens the contact at a preset threshold of 85°C +/. Training DOCTR 039 AW 139 DOTS . a bimetallic thermal switch and an electrical connector welded on the housing.2 °C (close at 70°C +/. Characteristic • 28Vdc .Single contact switch. The thermal-switch is installed downstream of the jet pump. Training DOCTR 039 AW 139 DOTS .Duct Overheat Thermal Switch Pin Location: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 160 . please refer to Ventilation chapter Enter LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 161 .Training DOCTR 039 AW 139 Cockpit and Cabin fans. Training DOCTR 039 AW 139 HEATING SYSTEM IN FLIGHT RESET PROCEDURE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 162 . ”HEATING-Failure’’ signal is sent to Modular Avionic Unit (MAU): .if [(SOV1 is open or SOV2 is open) and (Duct Overheat Thermal Switch (DOTS) is active) then the "Heater Failure“ discrete signal shall be sent to the helicopter general displayer (MAU). LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 163 . . Training DOCTR 039 AW 139 Heating +SOV in flight reset procedure: Reminder: Heating system failure logic In “AUTO” mode.if { [HTR is selected and (SOV1 is open or SOV2 is open)] and [(Air Duct temperature sensor ADTS is in open circuit or External air temperature sensor EATS is in open circuit or potentiometer is in open circuit CTL1)] } then the " Heater Failure " discrete signal shall be sent to the helicopter general displayer (MAU). The heating system will re-start provided that the failure (Overheat event or other) is no longer present. the «TEMP CONTR» switch must be used as potentiometer (between the MIN and MAX position) to avoid any false «Heating failure» triggering to the MAU.Heating Control Box .In the event of a system overheat with a «DOTS» and «ADTS» malfunction the system must be cut off manually by the pilot (put the SOV1 + 2 switches in the « CLOSED » position).Both SOV are automatically closed by the HCB .Reset the system by turning HTR switch to «OFF» . Normal «AUTO» system behaviour: . Training DOCTR 039 AW 139 A Heating failure message appears on the MAU during flight with «HTR AUTO selected»: Caution: HTR AUTO selected.In the event of a system overheat along with a «DOTS» malfunction (does not open) the ADTS reacts as back up and the ACCB will cut off both SOV’s automatically. Abnormal «AUTO» system behaviour: .Turn the HTR switch back to «AUTO». . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 164 . The heating system will re-start provided that the failure (Overheat event or other) is no longer present.Move both SOV 1 + 2 switches back to «NORMAL» . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 165 .Turn the HTR switch back to «AUTO». to unlock: .Reset the system by turning HTR switch to «OFF» . Training DOCTR 039 AW 139 Important: Both SOV switches are blocked in the close position. Recommendation: To avoid any « OVERHEAT » conditions.The TCV is manually controlled with the toggle switch.The heating system will re-start provided that the failure (Overheat event) is no longer present. Normal «MAN» system behaviour: . . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 166 . close first the Temperature Control Valve – TCV by turning the toggle switch to « . the « TEMP CONTR » switch must be used as toggle switch (up side down position). Training DOCTR 039 AW 139 An overheat event occurs during flight with « HTR MAN selected »: Caution: HTR MAN selected.» position (left side) during 15-20 seconds and then open slowly « + » position (turn to right) 2-3 seconds then wait for the system to respond.If the system runs in overheat conditions the DOTS will automatically shut off both SOV’s. . Turn the HTR switch back to « MAN » (or AUTO).Move both SOV 1 + 2 switches back to « NORMAL » .In the event of a system overheat with a «DOTS» malfunction (does not open) the system must be cut off manually by the pilot (put the SOV1 + 2 switch in the «CLOSE» position). The heating system will re-start provided that the failure (Overheat event) is no longer present. to unlock: . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 167 . Training DOCTR 039 AW 139 Abnormal «MAN» system behaviour: . Important: Both SOV switches are blocked in the «CLOSE» position.Reset the system by turning HTR switch to « OFF » . Training DOCTR 039 AW 139 Return HEATING SYSTEM TROUBLE SHOOTING PROCEDURE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 168 . Training DOCTR 039 AW 139 Air Conditioning/Heating configuration DOTS Jet Pump Check valve Return TCV SOV SOV LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 169 . Training DOCTR 039 AW 139 Heating System Architecture: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 170 . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 171 .FROB’s and BOB’s: Break Out Box – BOB 92612A010000 (Ventilation/Heating/Air Conditioning) Failure read Out Box – FROB 92599A010000 (Heating) Caution: Before connecting the special tool’s to the electrical harness switch-off the 28Vdc helicopter power supply. Training DOCTR 039 AW 139 AB139 Heating trouble shooting guide Testing using LTS . HEATING LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 172 .Training DOCTR 039 AW 139 Note: In order to check the Heating/Ventilation system the FROB 92599A010000 and the BOB 92612A010000 must be used. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 173 . located in the L/H side of the luggage compartment ( just behind the main access door). Training DOCTR 039 AW 139 1) Connect the FROB 92599A010000 to the helicopter maintenance connector J144. The FROB allows to read out the failure(s) memorised in the HCB and to get real time system information in « SCAN » mode. Reminder: The FROB should be used during trouble shooting to help to identify quickly the faulty component. Another function of the FROB is to SET / RESET the memory stage of the HCB. Training DOCTR 039 AW 139 FROB 92599A010000 (Heating) Note: Used for Heating system trouble shooting only LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 174 . an "In Progress" message will be indicated on the display. Training DOCTR 039 AW 139 2) Heating and Ventilation System troubleshooting: Possible memorised failures: • EATS fault • TS fault (= DOTS) • ADTS fault • CTL 1 fault (= Cockpit potentiometer failure) Note: Press  "IP means: Press on the push button part of each program. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 175 . *Reason for the message "Reset Memory Faulty": 1) Failure is still present 2) MAU failure message still illuminated. do reset the message (cut off 28VDC) 3) No failure present and reset not possible – replace HCB. or Reset Memory Faulty* LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 176 . Training DOCTR 039 AW 139 2 a) Failure read out «flow chart»: FAILURE READ OUT Memory Scan Return Press  "IP" Press EATS-Fault/ADTS-Fault/CTL1-Fault/TS.K.K.fault or No Memorised Failure Press SELECT Read out Set/Reset Press SELECT Press  Set Reset "IP" Press Press SET MEMORY Memory Reset Start Abort Start Abort Press  Press "IP" Set Memory O. Press  Press  "IP" "IP" Reset Memory O. FAILURE READ OUT Memory Scan Press Press EATS-Fault/ADTS-Fault/CTL1-Fault/TS. Training DOCTR 039 AW 139 2 b) Failure read out «flow chart» in « SCAN MODE »: Scan: This function permit to detect immediately (in real time) a failure as soon as it occurs during ground run or testing. which allows failure confirmation. * If no failure is present the indication will be : SCAN Failure – « Press » push button to go back to initial menu.fault or No Memorised Failure Press SELECT Read out Set/Reset To continue refer to previous page LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 177 . Training DOCTR 039 AW 139 BOB 92612A010000: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 178 . Connector J03 (only used when cabin panel Connector J02 installed) Connector J01 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 179 . The connector J02 on the Cockpit Panel back side must remain connected. 4) Connect the BOB 92612A01000 between the Cockpit Panel J01 and the helicopter harness. Training DOCTR 039 AW 139 3) Once the ventilation system components have been found correct. continue with the heating system components check. HTR in « AUTO » and TEMP CONTR in « Min » position 6) Connect 28Vdc power to the helicopter and put GEN switch to ON. Warning: In A/C configuration the Condenser fan might start for a couple of secondes. 7) The BOB configuration should be: TCV FULL CLOSE = LED remains OFF TCV-CMD = Flushing «GREEN» LED SOV1-ON = «GREEN» LED comes ON (auditable click) SOV2-ON = «GREEN» LED comes ON (auditable click) AUTO-HTR SEL = «GREEN» LED comes ON Initial configuration LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 180 . Training DOCTR 039 AW 139 5) Put all selection buttons on the cockpit panel in « OFF » position. CONTR in « CREW ». LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 181 . Training DOCTR 039 AW 139 7a) If the SOV 1 or 2 LED remains « off » check ⇒ for SOV1 presence of 28VDC between jumper 29 and 31. wiring and connection and if O. replace the faulty SOV 7c) If the AUTO-HTR SEL LED remains «off » ⇒ change cockpit panel. ⇒ for SOV2 presence of 28VDC between jumper 30 and 31. if not change cockpit panel 7b) If the SOV 1 or 2 LED comes « on » but no auditable click check ⇒ DOTS.K. if not change cockpit panel. . ⇒ if TCV does not work in « MAN » mode . ⇒ if no voltage picks measured – replace cockpit panel and if O.K. if no voltage picks measured .K. ⇒ if O.K.change cockpit Panel.K.K. replace the TCV LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 182 .check wiring and connection. Training DOCTR 039 AW 139 7d) If the TCV-CMD LED remains « off » check ⇒ correct TCV functioning in « MAN » mode. check voltage picks between jumper 37 and 38/39. .check voltage picks between jumper 2 and 3. – check wiring/connection between cockpit panel and HCB. ⇒ if O. ⇒ if O. ⇒ if O.change HCB. Training DOCTR 039 AW 139 8) Put the HTR switch in « MAN » and TEMP CONTR selection button in «Toggle switch » position 9) The BOB configuration should be: SOV1-ON = «GREEN» LED remains ON SOV2-ON = «GREEN» LED remains ON LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 183 . Training DOCTR 039 AW 139 9a) If SOV1 or/and SOV2-ON «GREEN» LED goes OFF ⇒ Replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 184 . the BOB configuration should be: TCV FULL CLOSE = «GREEN» LED is flushing when TCV full close position is reached TCV-CMD = Flushing «YELLOW» LED becomes « GREEN » when TCV full close position is reached SOV1-ON = «GREEN» LED remains ON SOV2-ON = «GREEN» LED remains ON LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 185 . Training DOCTR 039 AW 139 10) Hold the toggle switch in « .» position. » position and if the BOB TCV-CMD «YELLOW» LED is NOT flushing: ⇒ Replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 186 .» position and if the BOB TCV FULL CLOSE «GREEN» LED is NOT flushing when TCV full close position is reached: ⇒ Check wiring and if O.Replace TCV 10b) With the toggle switch in « .K. Training DOCTR 039 AW 139 10a) With the toggle switch in « . . the BOB configuration should be: TCV FULL CLOSE = LED is « OFF » TCV-CMD = «GREEN» LED is flushing SOV1-ON = «GREEN» LED remains ON SOV2-ON = «GREEN» LED remains ON LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 187 . Training DOCTR 039 AW 139 11) Hold the toggle switch in « + » position. Training DOCTR 039 AW 139 11a) With the toggle switch in « + » position and if the BOB TCV-CMD «GREEN» LED is NOT flushing: ⇒ Replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 188 . Training DOCTR 039 AW 139 12) HTR switch in « MAN ». LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 189 . put the SOV 1 switch in «CLOSE» position. To reset turn HTR switch to « OFF » and put SOV switch back to the « NORMAL » position. the BOB configuration should be: SOV1-ON = LED goes « OFF » SOV2-ON = «GREEN» LED remains ON Note: Once the SOV is closed the switch is « BLOCKED » for safety reasons. Training DOCTR 039 AW 139 12a) HTR switch in « MAN ». if the SOV1-ON « GREEN » LED does NOT go « OFF »: ⇒ Replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 190 . put the SOV 1 switch in «CLOSE» position. Training DOCTR 039 AW 139 13) HTR switch in « MAN », put the SOV 2 switch in «CLOSE» position, the BOB configuration should be : SOV1-ON = «GREEN» LED is ON SOV2-ON = LED goes « OFF » Note: Once the SOV is closed the switch is « BLOCKED » for safty reasons. To reset turn HTR switch to « OFF » and put SOV switch back to the « NORMAL » position. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 191 Training DOCTR 039 AW 139 13a) HTR switch in « MAN », put the SOV 2 switch in «CLOSE» position, if the SOV1-ON « GREEN » LED does NOT go « OFF »: ⇒ Replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 192 Training DOCTR 039 AW 139 14) HTR switch in « AUTO », put the SOV 1 switch in «CLOSE» position, the BOB configuration should be : TCV-CMD = «GREEN» LED is flushing SOV1-ON = LED goes « OFF » SOV2-ON = «GREEN» LED is ON AUTO-HTR SEL = «GREEN» LED is ON Note: Once the SOV is closed the switch is « BLOCKED » for safty reasons. To reset turn HTR switch to « OFF » and put SOV switch back to the « NORMAL » position. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 193 Training DOCTR 039 AW 139 14a) HTR switch in « AUTO », put the SOV 1 switch in «CLOSE» position, if the SOV1-ON « GREEN » LED does NOT go «OFF»: ⇒ Replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 194 Training DOCTR 039 AW 139 15) HTR switch in « AUTO », put the SOV 2 switch in « CLOSE » position, the BOB configuration should be: TCV-CMD = «GREEN» LED is flushing SOV1-ON = «GREEN» LED is ON SOV2-ON = LED goes « OFF » AUTO-HTR SEL = «GREEN» LED is ON Note: Once the SOV is closed the switch is « BLOCKED » for safty reasons. To reset turn HTR switch to « OFF » and put SOV switch back to the « NORMAL » position. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 195 Training DOCTR 039 AW 139 15a) HTR switch in « MAN », put the SOV 2 switch in «CLOSE» position, if the SOV1-ON « GREEN » LED does NOT go « OFF »: ⇒ Replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 196 Training DOCTR 039 AW 139 16) Check the correct functioning of the cockpit panel potentiometer using voltmeter between jumper 11 and 12: ⇒ TEMP CONTR switch in « MIN » position ~ 0.2 Vdc (or ~4 Ohm jumper removed) ⇒ TEMP CONTR switch in « Middle » position ~ 1.5 Vdc ⇒ TEMP CONTR switch in « MAX » position ~ 3.0 Vdc (or ~8 KOhm jumper removed) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 197 Training DOCTR 039 AW 139 16a) If the measured voltage is +/.0.5 Vdc out of range: ⇒ Replace Cockpit Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 198 . Training DOCTR 039 AW 139 17) Connect the BOB between the HCB and the helicopter harness located in the L/H forward side of the luggage compartment (requires removal of the rack AHRS – A9). Note: In this position the BOB allows to check the EATS. ADTS and/or DOTS to confirm or not the failure memorised in the FROB 92599A010000 (see page 29). 18) Re-installed/re-connected the Cockpit Panel. Connection HCB LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 199 . K.2 Vdc out of range: ⇒ Check wiring and connection and if O. Note: On the EATS connector itself the . Training DOCTR 039 AW 139 19) To check the correct functioning of the EATS measure a voltage between jumper 2 and 3: 500 + (1.Pin location is 3 and 4.925 per 1°C) + 4640] Example for 27°C : = 532 mV . replace if 5 Vdc is mea sured.0.replace EATS (under Agusta responsability) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 200 .925 per 1°C) V= 5x V=[500 + (1. . 19a) If the measured voltage is +/. Training DOCTR 039 AW 139 EATS – LOOKUP TABLE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 201 . Note: On the ADTS connector itself .Pin location is A and B.0.85 per 1°C) + 4020] Example for 24°C: = 1068 mV. – replace ADTS LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 202 .85 per 1°C) V= 5x V=[1000 + (3. replace if 5 Vdc is meas ured.K. 20a) If the measured voltage is +/.2 Vdc out of range: ⇒ Check wiring and connection and if O. Training DOCTR 039 AW 139 20) To check the correct functioning of the ADTS measure a voltage between jumper 5 and 6: 1000 + (3. Training DOCTR 039 AW 139 ADTS – LOOKUP TABLE In mV °C In mV °C 1161 56 1164 57 1167 58 1169 59 1172 60 1175 61 1178 62 1181 63 1183 64 1186 65 1188 66 1191 67 1194 68 1197 69 1199 70 1203 71 1205 72 1208 73 1211 74 1214 75 1217 76 1219 77 1222 78 1225 79 1227 80 1230 81 1233 82 1235 83 1238 84 1241 85 1243 86 1246 87 1249 88 1252 89 1255 90 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 203 . using ohmmeter between BOB jumper 36 and 44 : No overheat detected = close circuit between 20 Ohm to 30 Ohm Note: The resistance can be measured on the DOTS connector between pin Pin A and B LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 204 . check electrical continuity between HCB and DOTS. Training DOCTR 039 AW 139 21) To check the correct functioning of the DOTS. K. – replace DOTS LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 205 . Training DOCTR 039 AW 139 21a) Measure resistance and if open circuit (value >1 KOhm): ⇒ Check wiring and connection and if O. Heater mode « Man » and « Auto » selected SOV’s are «Open »)
HTR AUTO – MIN
VENT Crew Fan – OFF
VENT Pax Fan – OFF
SOV 1 + SOV 2 – CLOSE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 206 . 1) Make sure that Heating Outside Air Intake is not fully or partially blocked by any foreign objects 2) Make sure that the Cockpit Panel is in correct initial selection:
HEATER mode – OFF (SOV – NORMAL: SOV’s are closed as long as Heater Mode « OFF » selected. Training DOCTR 039 AW 139 Heating and Ventilation System operational test during Ground Run (break out and failure read out box connected) WARNING : DO NOT OPERATE BLEED AIR HEATING SYSTEM WHEN OUTSIDE AIR TEMPERATURE IS ABOVE 45°C. K. ♣ SOV 1 does not open (no warm air flow): Check 28Vdc between jumper 53 and 32. check DOTS in close position . If O.if O.K. check wiring. repair as necessairy (search for a false contact). If O.continuity Check correct power supply to Cockpit panel (search for a false contact . 5)Switch to MAN on the Cockpit Control Panel 6)Set SOV 1 to Normal position (BOB [Jumper-53] Green led "ON").K. Training DOCTR 039 AW 139 3)Pedestral cockpit gaspers fully open.. -replace Cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 207 . connection between Cockpit Panel and SOV 1 (28Vdc between pin 1 and 2). 4)Start engines and operate them at 75% thrust.K. - replace SOV 1 ♣ No power supply to Cockpit panel Check wiring and connection if O. Check Heating "On" advisory legend comes in view on MAU. front face gaspers fully closed. 9)Using HTR MAN Rotary toggle switch. drive TCV to full close position (BOB TCV-CMD [Jumper-39] Yellow led "ON« and TCV Full Close [Jumper-36] Green led « ON »).replace SOV 1 (stucked open) 8)Repeat above steps with SOV 2 (28Vdc between jumper 54 and 32). Check the TCV closing: TCV – turn the HTR MAN Rotary toggle switch to – (close) on cockpit panel a) TCV break out box green led remains "OFF" – check TCV-CMD green led flushing on BOB (Jumper – 39) as long as toggle switch is activated (light is «OFF » when toggle switch not activated) b)If not flushing. Training DOCTR 039 AW 139 7) Set the SOV 1 to OFF position and VENT CREW FAN to LOW (warm air flow must stop). connection and correct 28Vdc power supply to the valve (pin 2 + 5) . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 208 .replace faulty element c) Check break out box BOB-TCV Full Close green led "ON" (18Vdc between Jumper 39 and 37). check wiring. ♣ If warm air flow does not stop . if O.K. connection between Cockpit panel and TCV. connection between Cockpit Panel and TCV. Training DOCTR 039 AW 139 ♣ TCV does not close (despite to TCV-CMD green led flushing) : Check wiring.replace TCV ♣ TCV does not open (No -TCV CMD) Check correct power supply to Cockpit panel.K. . . . . TCV Full Close green led still « ON » despite TCV-CMD Green led flushing (Hot air flow does not increase): Check wiring.replace Cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 209 .K.K.replace TCV ♣ TCV does not close (No -TCV CMD) Check correct power supply to Cockpit panel. repair as necessairy. repair as necessairy. if O. if O.replace Cockpit panel 10) Open gradually the TCV with toggle switch ( BOB TCV-CMD [Jumper-38] green led flushing ). ♣ TCV does not open. if O. Training DOCTR 039 AW 139 11) Switch VENT CREW to FAN HIGH . starting with the main duct upstream the Y-connection assy (behind fuel tanks) b) Flow misbalancing between left and right side Check for leakages downstream the Y-connection assy (behind fuel tanks) 12) Full open the TCV (activate for at least 10 seconds the toggle switch) Check for the cut "Off" of the heating system when the blowing temperature at the rear cabin diffusor exceed 85+/-5°C Note: In manual mode the DOTS fault is not memorized in HCB. check for presence of warm air flow from the cockpit diffusors: a) Not enough warm air flow
Check ventilation and heating distribution ductings on connections and flexible hoses for leakages. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 210 . Check wiring. if not replace Cockpit Panel. Training DOCTR 039 AW 139 Heating System Operational test in « AUTO » mode 1) Set the SOV 1 + SOV 2 selection in « Normal » position 2) Select the heating system to «AUTO» ♠ Heating « HTR failure » advisory legend comes in view on MAU . Check that DOTS is physically closed.check if SOV selection switch is in Normal position . ♠ If CTL 1 fault is triggered on HCB. if O.K. connection between HCB and DOTS. if not replace DOTS.check if failure is memorised in HCB. EATS + ADTS fault⇒ ⇒ Enter Check correct power supply to SOV 1+2. repair as necessairy.⇒ Enter LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 211 .K. ♠ If DOTS fault memorised in the HCB. Check that NO EATS and ADTS failure is memorized in the HCB. if O. connection between HCB and Cockpit Panel. – check wiring between Cockpit Panel and TCV. if O.replace TCV LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 212 . If power supply O. Training DOCTR 039 AW 139 3)Turn HTR AUTO button clockwise to MAX position ♠ Check for presence of warm airflow from the diffusors. ♠ Check correct power supply to TCV (BOB – TCV-CMD green or yellow led). if O. .K. repair as necessairy. No warm air flow from the diffusor (TCV does not open): ♠ Check if failure is memorised in HCB.K. If EATS or ADTS is memorized in the HCB ⇒ if not Enter ♠ Check wiring. if not replace Cockpit panel or/and HCB.K. Training DOCTR 039 AW 139 4)Select Auto Mode "OFF" and SOV 1 + SOV 2 to close position.  Warm air flow from the diffusors stops and heating advisory legend on MAU goes off 5)Shutdown engines LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 213 . Training DOCTR 039 AW 139 AIR CONDITIONING HEATING AND VENTILATION SYSTEM LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 214 . Training DOCTR 039 AW 139 Helicopter Air Conditioning System cut off view Return Cockpit + Cabin compressor Cockpit condenser Fan L/H cockpit evaporator Cockpit HP-switch Cabin evaporator fans L/H cockpit evaporator Cockpit Panel Cabin condenser Fan R/H cockpit Cabin FV evaporator Cabin HP-switch Cabin LP switch Cockpit TS2 Cabin TS2 Cockpit LP switch Cockpit evaporator fans Cockpit TS1 EATS Cockpit FV’s CockpitTemp. Sensor LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 215 . Training DOCTR 039 AW 139 AIR CONDITIONING SYSTEM The air conditioning system consists of two splitted vapour cycle systems dedicated respectively for the cockpit and the cabin zones.
Evaporator.50g.
Condenser
Air Conditioning Control Box Two identical Air Conditioning Control Boxes – (ACCB) are installed. of refrigerant R134a in the cabin loop is 1000g +/. of refrigerant R134a in the cockpit loop is 1200g +/. Each vapour cycle loop can be divided into 4 different main components :
Compressor. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 216 . The qty.50g. one per zone to be cooled (cockpit/cabin) . The qty. The new flapper valve has inlets dedicated to recirculated air which are used when RECYCLE mode is selected. Each evaporator S/A cools the re-circulated air before being distributed in the dedicated Cockpit/Cabin zone. The Condenser S/A consists of two identical subassemblies on each side of the pylon fairing. 2 for the cockpit and 1 for the cabin zone are different and only some of their parts are interchangeable. Training DOCTR 039 AW 139 AIR CONDITIONING SYSTEM Compressor S/A is composed of two compressors which are mechanically driven via a drive shaft by the accessories gear box. The basic ventilation cockpit flapper valves and fans are replaced by other valves and fans and the air has to pass through an evaporator on each side. The air has to pass through an evaporator assembly. one per zone cockpit/cabin. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 217 . The three Evaporator S/A. The cabin flapper valve is replaced by another valve and a second fan is added. Two identical Air Conditioning Control Boxes – (ACCB). The new flapper valves have an inlet dedicated to recirculated air which is used when RECYCLE mode is selected. Training DOCTR 039 AW 139 Air Conditioning System/Heating/Forced Ventilation components: Item Component P/N Qty COND / HEATER VENT 8020A010000 001 CABIN Fan 2 3G2150V02251 14422A030001 TEMPERATURE CONTROL VALVE 3G2140V00751 1 002 2298A020000 003 1'' Check valve 2 3G2140V00651 428B010000 004 Composite Jet Pump 1 3G2140V00851 6916A020000 005 Shut off valve 2 3G2140V00551 92177A020000 006 Heating control box 1 3G2140V00252 COND HTR 93260A010000 007 ADTS Temperature sensor 1 3G2140V00951 92252A01/92244A01 008 Overheat thermal switch 1 3G2140V01351 3521B010000 009 Cockpit evaporator right 1 3G2150V00853 3522B010000 010 Cockpit evaporator left 1 3G2150V00753 8028A010001 010 Condenser Fan 2 93036A010001 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 218 . NVG 3G2150V00352 91130A010000 019 NEWHTR COCKPIT CONTROL PANEL without PAX COND 3G2150V00353 1 91130A010001 020 NEW COCKPIT CONTROL PANEL Syst 5 – without PAX NVG (OPTION) 3G2150V00354 92183A020000 021 AIR CONDITIONING CONTROL BOX 2 3G2150V00252 4577B010000 022 New cabin flapper valve for ecs .includes two 2303A010000 1 3G2150V01352 Dryer filter 20204-061 2 050 052 High pressure switch (29 bar) (NEW P/N 20204-071 + 20204-072) 20204-062 2 060 Low pressure switch (NEW P/N 20204-073 + 20204-074) 20205-010 1 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 219 .Training DOCTR 039 AW 139 Air Conditioning System/Heating/Forced Ventilation components: 1758D010000 011 Cabin evaporator assy 1 3G2150V00953 3520B01/3520C01 012 Condenser assy 1 COND / HEATER VENT 3G2150V02351 1768B010000 013 COMPRESSOR PACK ASSY 1 3G2150V01153 92279A010000 014 VENTILATED TEMPERATURE SENSOR 2 3G2150V01251 6039B010000 015 Cockpit double flapper valve for ECS 2 3G2150V00652 8011A030000 016 Cockpit ECS fan 2 3G2150V00553 91108A010000 017 NEW COCKPIT CONTROL PANEL Syst 5 3G2150V00351 1 91108A010001 018 NEW COCKPIT CONTROL PANEL Syst 5 . Training DOCTR 039 AW 139 PILOT INTERFACES LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 220 . Training DOCTR 039 AW 139 PILOT INTERFACES The cockpit control panel allows the pilot to control the Environmental Control System.the cockpit fans (2 qty) .the Shut Off Valves (SOV1 & SOV2) (total 2 qty) .the Heating Control Box (HCB) (1 qty) .the Temperature Control Valve (TCV) (1 qty) .the cabin fans (2 qty) .the Cockpit & Cabin Air Conditioning Control Boxes (2 qty) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 221 . It interfaces with : .the cabin (1 qty) and cockpit flapper valve (2 qty) . four (4) discrete signals:
AFT-VENTILATION
FWD-VENTILATION
VENT FAILURE
HEATER-ON LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 222 . Training DOCTR 039 AW 139 PILOT INTERFACES It sends to the Helicopter general displayer (Modular Avionic Unit .MAU ) depending on the system status. Each ACCB control the cockpit and cabin temperature by comparison of the measured VENT temperature in each zone to the desired temperature adjusted by the crew with the TEMP CONTR potentiometer. CREW COND / HEATER VENT TEMP CONTR CREW COND HTR 91108A010000 Cockpit Control Panel TEMP CONTR OFF COND / VENT RECYCLE MAN FAN HIGH ON NORM AUTO MIN FAN OFF LOW OFF FAN MIN ON SOV - HIGH FAN + MAX PAX CONTR LOW 1 CLOSE 2 CREW OFF TEMP CONTR VENT FAN HIGH ON FAN LOW NORMAL PAX 91108A010000 Cockpit Control Panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 223 . both cockpit and cabin zones are controled . Training DOCTR 039 AW 139 When CREW is selected on the cockpit control panel. + MAX PAX 1 CLOSE 2 MIN NORMAL PAX LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 224 .Training DOCTR 039 AW 139 VENT CREW COND / HEATER VENT TEMP CONTR CREW COND HTR TEMP CONTR MIN SOV . Training DOCTR 039 AW 139 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 225 . Training DOCTR 039 AW 139 When PAX selected the Cabin temperature control can be directly adjusted on the Cabin panel by the passenger. The air conditioning system has been sized for re-circulation air in both cockpit and cabin zone. The temperature regulation is realised by On/Off cycles of the compressors. FV in recirculation FV in ram air position COND / HEATER VENT COND HTR CREW 91108A010000 Cockpit Control Panel TEMP CONTR OFF RECYCLE MAN FAN HIGH ON NORM AUTO FAN OFF LOW SOV MIN . + MAX PAX CONTR 1 COND NORMAL / HEATER 2 VENT CREW OFF FAN HIGH ON FAN LOW CLOSE PAX 91108A010000 Cockpit Control Panel 3 potentiometers 2 switches COND HTR LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 226 . Training DOCTR 039 AW 139 COND/HEATER COND HTR 5 position switch: OFF selected: The Cockpit and Cabin Air Conditioning Control Box as well as the Heating Control Box is switched "Off". The flapper valves are suppling outside ram air. The ACCBs will adjust the temperature in the respective zones according to the pilot cockpit panel potentiometer temperature demand. both SOV are closed. The pilot can choose ventilation mode. ♦ MAN and AUTO position and all other switches: Idem to Heating Cockpit panel ⇒ ⇒ Enter LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 227 . using Cabin Control Panel potentiometer. ♦ NORM and PAX selected selected: The passenger can adjust the temperature in the cabin himself. ♦ NORM and CREW selected: The ACCB 1 for the cockpit and ACCB 2 for the cabin zone are switched « ON » and the HCB is switched « OFF ». providing the dedicated fans are running (Low or High speed). ♦ RECYCLE selected: Cabin and Cockpit flapper valves are closed – the VENT 4 position switches on the Cockpit and Cabin panel are no longer active with regard to the flapper valve position. The potentiometer is considered as faulty when open circuit or a temperature reference > 45°C.0 Vdc LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 228 .5 Vdc TEMP CONTR switch in « MIN » position ~ 3. Control: TEMP CONTR switch in « MIN » position ~ 0. Complete potentiometer range is corresponding to (+5°C/+45°C) range including failure analysis. Using BOB: Voltage between jumper 11 and 12 Temp.Training DOCTR 039 AW 139 Note: The ACCB monitors the temperature reference acquisition on 10 KΩ potentiometer with +/.2% accuracy.2 Vdc TEMP CONTR switch in « MIN » position ~ 1. Training DOCTR 039 AW 139 SYSTEM CONTROL LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 229 . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 230 . Training DOCTR 039 AW 139 Air Conditioning/Heating and Forced Ventilation system: This configuration includes the previously described Heating and Forced Ventilation system control functions. There are two separated air conditioning loops respectively dedicated to the cockpit and to the cabin zone and each controlled by one ACCB. Training DOCTR 039 AW 139 The Air Conditioning Control Box – ACCB (1+2) functions for each loop:
Receiving A/C "ON/OFF" selection signal from the Cockpit Panel
Receiving Cockpit Fan or/and Cabin Fan “Low/High speed" signal from the Cockpit Panel
Monitoring of the re-circulation air Temperature Sensor
Monitoring of the evaporator air outlet Thermal switch 1+2
Monitoring of the refrigerant LP+HP switch
ON/OFF Control of the refrigerant scroll Compressor
ON/OFF Control of the Condenser Fan
Memorizing the HP.TS and Temperature Sensor fault message
Triggering A/C failure LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 231 .LP. Training DOCTR 039 AW 139 Detailed Operation: Operation: Air Conditioning System LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 232 . non flammable. and non aggressive for ozone layer (ODP=0). LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 233 . It is provided by many companies in the world. Training DOCTR 039 AW 139 A/C system + Refrigerant R134a explanations: In order to satisfy the cooling performance the air conditioning is made of two vapour cycle systems. dedicated respectively to the cockpit and the cabin zones. This fluid is non toxic. It is commonly used in domestic fridges and in automotive applications. The major components of each vapour cycle are identical and operate with HFC R134a refrigerant. The HFC 134a is gaining in customer acceptance worldwide as a substitute for CFC fluids. refrigerant change it state to gas at low temperature and low pressure. The different steps are as follows: •The compressor sucks refrigerant from evaporators and rise its temperature and pressure (BC line). •The liquid refrigerant is then pressure released by the expansion valve into a liquid-vapour mixture.Vapour Cycle Principale: A refrigerant pressure enthalpy diagram (see next figure) shows the cycle carried out by the Vapour Cycle System. The expansion occurs from high pressure to low pressure (DA line). the gas is cooled and change to liquid inside the heat exchanger called condenser. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 234 . Training DOCTR 039 AW 139 A/C . inside the two cockpit heat exchangers called evaporators and two cabin evaporators laid out in parallel . •Along AB line. •Then. Liquid refrigerant still under pressure. is recovered inside the receiver (CD line). Training DOCTR 039 AW 139 REFRIGERANT PRESSURE liquid vapor line line LIQUID CD = Condenser heat exchange per kg of refrigerant Condensing D pressure C D C ambient coolant air recirculated cabin air A VAPOR recirculated constant A cockpit air B temperature curve Evaporating pressure A B AB = Evaporator heat exchange per kg of refrigerant B’C’ = Energie of compression per kg of refrigerant Enthalpy at B’ C’ REFRIGERANT Enthalpy at Pf = Q x ∆H evaporator Enthalpy at ENTHALPY inlet evaporator compressor outlet outlet LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 235 . Temperature regulation is effected by ON/OFF cycles of the relevant compressor. The total combined heat load has been assumed to be generated in equal proportion by the cockpit and cabin zones. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 236 . The air conditioning system has been sized for re-circulation air in both cockpit and cabin zones. Training DOCTR 039 AW 139 System control for both cockpit and cabin zones is achieved separately within the dedicated air conditioning control box by comparison of the cockpit or cabin temperature with the desired temperature chosen by the pilot on the control panel. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 237 . This order controls the magnetic closing of the clutch which drives the compressor 1 or/and 2. Training DOCTR 039 AW 139 System Operation for each loop: An A/C selection input signal. the compressor clutch control order. It is compressed and then returned through the discharge pipe to the condenser where it is liquefied by giving up heat to the outside cooling air discharged overboard by the condenser fan. a ventilation control signal and temperature control signal are received by the ACCB 1 and 2 which generates (No system failure has been detected). The discharge flexible hose is equipped with a high pressure safety switch. The clutch rotation movement is generated by the accessories gear box drive shaft and is transmitted by a belt to each compressor pulley. Gaseous refrigerant is admitted into the compressor through the suction pipe. thermal load) while tolerating a certain leakage rate and conserving the cooling performances. Training DOCTR 039 AW 139 Air Conditioning System Operation for each loop: When the pressure exceeds the preset pressure threshold of 27 bar rel. The receiver capacity permits the system to operate at optimum efficiency despite different external conditions (temperature. the liquefied refrigerant passes through receiver filter drier which removes impurities. possible metallic particles. water particles and therefore avoids the formation of acids. (391. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 238 .7bar approximately. At the receiver output. a service valve enables unit refrigerant filling and recovery. it breaks the refrigeration cycle electrically if the fault is present more than 30 seconds. The system.5 psig) +/- 0. then has to be reset on the cockpit control panel (turn “Off” the A/C selection switch) At condenser output. The TEV control is ensured by a bulb attached to the evaporator outlet and connected to the TCV by a capillary tube which transmits the temperature information (the transmission fluid is of the same type as the refrigerant fluid .R134a). Once the pressure relieved. The TCV regulates the mass flow rate of refrigerant so as to guarantee overheating of the vapour (called superheating) at each evaporator output and avoid that refrigerant in a liquid state is sucked in the compressor and causes irreversible damage. feat with refrigerant via a T – HP port. Training DOCTR 039 AW 139 Air Conditioning System Operation for each loop: Located downstream of the receiver. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 239 . one Thermostatic Expansion Valve – TEV per evaporator ensures the refrigerant pressure relief. cold refrigerant passes into the evaporator where it is vaporised by taking heat from the cockpit or cabin recycling air carried by the evaporator fan. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 240 . A composite housing ensures recovery of the condensed water on the inner and outer walls of the evaporator. then has to be reset in the cockpit control panel (turn “Off” the A/C selection switch). a Low Pressure safety switch is installed. The sudden cooling of the recycled cockpit or cabin air.8 psig) +/. The system.4 bar rel. Training DOCTR 039 AW 139 Air Conditioning System Operation for each loop: At the TEV outlet.0. causes condensation of the ambient water vapour particles at the evaporator outlet. (5. The collected water is then drained overboard by a dedicated system. When the pressure falls below the preset threshold pressure of 0. the LP-switch opens and break the refrigeration cycle electrically if the fault is present for more than 30 seconds .2 bar approximately. That will stop the compressor for at least 3 minutes. Training DOCTR 039 AW 139 Air Conditioning System Operation for each loop: A Thermal switch on the evaporator outlet opens the electrical loop connected to the ACCB. Thus to protect evaporator matrix from frosting which would reduce its cooling capacity and the airflow in the cabin/cockpit. Note: The HP and LP – T port are also equipped with servicing valves permitting pressure monitoring for trouble shooting purpose. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 241 . when the evaporator air outlet temperature reaches 1°C +/-2°C. Training DOCTR 039 AW 139 Vapour Cycle general schematic (valid for each loop): Expansion LP-Switch valve Evaporator BP pressure switch Filling BP Evaporator (LP) port Liquid fan air flow flexible hose Insulated BP flexible hose Anti freeze Filling LP LP-Switch Thermal port switch Filling HP port HP pressure Scroll switch compressor Filling HP Condenser port fan air flow HP flexible Receiver hose filter drier Condenser LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 242 . Training DOCTR 039 AW 139 Air Conditioning System Component Location LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 243 . flapper valves and the fans. A/C general view without refrigerant hoses (left side) and Ventilation (right side): Gaspers + Demisters Thermal Switch Evaporator S/A TEV A/C . Training DOCTR 039 AW 139 Cockpit zone: The two evaporator S/As are located near to the pilot and co-pilot pedestals along with the ventilation ducts.Fan Dual .FV Ram Air Inlets LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 244 . Fan Dual . Training DOCTR 039 AW 139 Cockpit zone: Thermal Switch Gaspers + Demisters LP-Switch Evaporator S/A TEV A/C .FV LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 245 . Air intake Flapper valve Pack Fan Recirc.Training DOCTR 039 AW 139 Front face outlets Lower Side Cockpit Air Conditioning Window Demister Upper Side configuration schematic: Window Demister Main winshield Demister Air Cond. Heating Evaporator Heating Recirc. Fan Air intake Flapper valve Air Cond. Pack Main winshield Demister Upper Side Window Demister Lower Side Window Demister LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL Front face outlets SERVICES 246 . Training DOCTR 039 AW 139 A/C location on upperdeck general view: Cockpit Condenser Cabin Condenser Fan Cabin Cockpit comp. compressor Cabin Condenser Cockpit Receiver/Filter Cabin loop Condenser Fan A/C Cabin Fans Receiver/Filter Ram Air Cockpit loop Inlet Refrigerant Cabin FV hoses Cabin Recirc. Air LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 247 . Fan Pack Flapper Fan valve Plenum Air intake Singular gaspers manifold Side vents manifold LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 248 . Training DOCTR 039 AW 139 Cabin Ventilation for Air Conditioning configuration: Side vents manifold Evaporator Singular gaspers manifold Recirc. Training DOCTR 039 AW 139 Air Conditioning System Architecture LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 249 . - FAN-relay FAN-relay M M FWD-COND.. relay 0Vdc +12Vdc CLUTCH AFT- AFT-CLUTCH COMPRESSOR- relay CLUTCH ACCB1 ACCB2 FWD Maintenance connector AFT Maintenance FWD-TS1 connector FWD-TS2 AFT-TS1 FWD-LP AFT-TS2 FWD-HP AFT-LP AFT-HP FWD-TEMP. AFT-COND. Training DOCTR 039 AW 139 Helicopter System Architecture: +28Vdc 0Vdc +28Vdc 0Vdc FWD-COND.-SENSOR COCKPIT Connector for heating CONTROL and ventilation PANEL systems LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 250 . FWD-CLUTCH COMPRESSOR.-FAN +28Vdc R1 AFT-COND.-FAN R2 0Vdc +12Vdc +28Vdc FWD.-SENSOR AFT-TEMP. Training DOCTR 039 AW 139 System Electrical Wiring Block Diagram: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 251 . Training DOCTR 039 AW 139 System Electrical Wiring Block Diagram: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 252 . Training DOCTR 039 AW 139 System Electrical Wiring Block Diagram: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 253 . Training DOCTR 039 AW 139 System Electrical Wiring Block Diagram: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 254 . SENSOR Temperature sensor FWD-CLUTCH Forward 1 1351A010000 28V – 5A Compressor [Clutch] FWD-COND. Forward 1 3972A010000 28V – 35A FAN Condenser Fan LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 255 .. Forward 1 92279A010000 Sensor gain = 10 mV / °K TEMP.2b FWD.4b ± 0.7b FWD-LP Forward Low 1 20205-010 No Fault = closed Pressure sensor Open if P < 0. Training DOCTR 039 AW 139 ACRONYM DESIGNATION Qty PART NUMBER COMMENTS Main ACCB1 Air Conditioning 1 92183A020000 Components: Control Box1 FWD-TS1 Forward Thermal 1 14713-021 No Fault = closed Switch1 Open if T°≤ +1°C ± 2°C FWD-TS2 Forward Thermal 1 14713-021 No Fault = closed Switch2 Open if T°≤ +1°C ± 2°C FWD-HP Forward High 1 20204-062 No Fault = closed Pressure sensor Open if P > 27b ± 0. After 1 92279A010000 Sensor gain = 10 mV / °K TEMP.. Training DOCTR 039 AW 139 Equipments: ACRONYM DESIGNATION Qty PART NUMBER COMMENTS ACCB2 Air Conditioning 1 92183A020000 Control Box2 COCKPIT Cockpit Control 1 92108A010000 CONTROL Panel PANEL AFT-TS2 After Thermal 1 14713-021 No Fault = closed Switch2 Open if T°≤ +1°C ± 2°C AFT-HP After High 1 20204-062 No Fault = closed Pressure sensor Open if P > 27b ± 0.7b AFT-LP After Low 1 20205-010 No Fault = closed Pressure sensor Open if P < 0.2b AFT.SENSOR Temperature sensor AFT-CLUTCH After 1 1351A010000 28V – 5A Compressor [Clutch] AFT-COND. After Condenser 1 3972A010000 28V – 35A FAN Fan LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 256 .4b ± 0. Training DOCTR 039 AW 139 Air Conditioning System Component description and Operation LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 257 . Function Each control box drives its dedicated Refrigerant Circuit. When " A/C selection " is selected on the cockpit/cabin control panel. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 258 . It monitors the sensors. Training DOCTR 039 AW 139 Air Conditioning Control Box . the air conditioning system is in automatic mode and the air conditioning control boxes (ACCB 1+2) are switched ON . which allows to regulate cockpit and cabin ambient temperature. switches and warns the crew when a fault occurs.ACCB 1+2 (ACCB of the cockpit loop is interchangeable with ACCB of the cabin loop) The Air Conditioning control box 92183A01000 is a sub-assembly of the AB139 Environmental Control System. To get easy access to the ACCB memorised failures connect failure read out box P/N 92600A010000 to the helicopter maintenance connector. It also memorizes failures for the maintenance actions. each controller acts directly on the dedicated compressor to adapt by On/Off cycles the cooling production to the real need. LP-Switch fault ♦ High Pressure.P/N92183A020000/3G2150V00252 The control principle is based on the comparison of the real temperature measured by a cockpit and cabin sensor to the desired one fixed by the crew on the control panel. The ACCB 1 (2) is able to memorise 4 four failure messages (see trouble shooting section): ♦ Thermal Switch –TS fault ♦ Temperature Sensor – fault ♦ Low Pressure. HP-Switch fault LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 259 . From this comparison. Training DOCTR 039 AW 139 Air Conditioning Control Box-ACCB1+2 . ‘‘COMPRESSOR-ON’’ signal is active if : ‘’A/C-SELECTION-INPUT’’ signal is active. and ‘’EVAP-FAN1-FAULT’’ and ‘’EVAP-FAN2-FAULT’’ signals are not active in the same time (at least one of the two fans must be in operation ). and ‘’TS1-SIG’’ and ‘’TS2-SIG’’ signals are no active (with 30 s inhibition when icing failure appears). Training DOCTR 039 AW 139 LOGIC FUNCTIONS ‘’COND-FAN-ON’’ signal is active if ‘’A/C-SELECTION-INPUT’’ signal is active. and ‘’HP-SIG’’ signal is no active. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 260 . and ‘’FAN-ON’’ signal is active. and ‘’LP-SIG’’ signal is no active. and ‘’A/C-FAILURE’’ signal is no active and The time between 2 ON/OFF compressor is higher than 30s. and Temperature sensor is in operation. and The measured temperature is higher than the order temperature plus 2°C. (with 30 s inhibition during compressor starting). and The measured temperature is higher than +10°C and lower than +65°C. Training DOCTR 039 AW 139 ACCB .Block Diagram LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 261 . ♦ Low Pressure. FWD or AFT A/C failure is indicated on MAU. if open circuit or out of range –compressor stops. FWD or AFT A/C failure is indicated on MAU. Training DOCTR 039 AW 139 A/C . LP-Switch fault Inhibition for 30 sec. Presence of the failure during 3 minutes OR three underpressure events – compressor stops. FWD or AFT A/C failure is indicated on MAU.Failure detection logic: ♦ Thermal Switch – TS fault Inhibition for 30 sec. ♦ High Pressure. when icing failure appears. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 262 . HP-Switch fault Presence of the failure during 3 minutes OR three overpressure events – compressor stops. during compressor start-up. ♦ Temperature Sensor – fault Presence of the failure during 10 seconds. FWD or AFT A/C failure is indicated on MAU. Presence of the failure during 3 minutes OR both evaporator fan malfunction (under speed) – compressor stops. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 263 .P/N92183A020000 /3G2150V00252 General Description It consists of a metallic box containing the electronic cart with its electric connector. Training DOCTR 039 AW 139 Air Conditioning Control Box-ACCB 1+2 . The overall dimensions: 210 x 120 x 50 mm The weight is less than 500 g. Training DOCTR 039 AW 139 Air Conditioning Control Box Pin location: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 264 . SENSOR. Training DOCTR 039 AW 139 Air Conditioning Control Box Pin location: PIN ITEM TYPE NOM. +5v/OC O 2 / 10 mA SINGLE CORE FAULT 26 FWD-TS-FAULT +5v/OC O 2 / 10 mA SINGLE CORE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 265 . / MAX WIRE FROM / TO CURRENT 13 ANA-OUT1A Analog output (+) O 5 / 10 mA TWO TW SH CORE To ACCB2 19 ANA-OUT1B Analog output (-) O 5 / 10 mA 50 FWD-FAULT-SET-MEM GND /OC I 2 / 2 mA SINGLE CORE From / To FWD Maintenance 37 FWD-FAULT-RESET-MEM GND /OC I 2 / 2 mA SINGLE CORE Connector 38 FWD-FAULT-READ-MEM GND /OC I 2 / 2 mA SINGLE CORE 39 FWD-FAULT-ENABLE-MEM GND /OC I 2 / 2 mA SINGLE CORE 10 FWD-HP-FAULT +5v/OC O 2 / 10 mA SINGLE CORE 17 FWD-LP-FAULT +5v/OC O 2 / 10 mA SINGLE CORE 18 FWD-TEMP. SENSOR-FAULT +5v/OC O 2 / 10 mA SINGLE CORE 26 AFT-TS-FAULT +5v/OC O 2 / 10 mA SINGLE CORE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 266 . Training DOCTR 039 AW 139 Air Conditioning Control Box Pin location: PIN ITEM TYPE NOM. / MAX WIRE FROM / TO CURRENT 2 ANA-IN1B Analog input (+) I 5 / 10 mA TWO TW From ACCB1 SH CORE 3 ANA-IN1C Analog input (-) I 5 / 10 mA 50 AFT-FAULT-SET-MEM GND /OC I 2 / 2 mA SINGLE CORE From / To AFT Maintenance 37 AFT-FAULT-RESET-MEM GND /OC I 2 / 2 mA SINGLE CORE Connector 38 AFT-FAULT-READ-MEM GND /OC I 2 / 2 mA SINGLE CORE 39 AFT-FAULT-ENABLE-MEM GND /OC I 2 / 2 mA SINGLE CORE 10 AFT-HP-FAULT +5v/OC O 2 / 10 mA SINGLE CORE 17 AFT-LP-FAULT +5v/OC O 2 / 10 mA SINGLE CORE 18 AFT-TEMP. Training DOCTR 039 AW 139 Air Conditioning System "Refrigerant Circuit" Component description and Operation LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 267 . The sub-assembly is mainly composed of:
a light alloy body. The scroll compressor location in the refrigerant circuit is in-between the evaporator and the condenser. one for each cockpit and cabin circuit. They are mechanically driven by the accessory drive shaft pulley and a belt at 4000 rpm.
a magnet clutch sub-assembly. Training DOCTR 039 AW 139 Refrigerant Scroll Compressor Pack P/N1768B020000/3G2150V01153 (AFT Compressor 1362A010001/FWD Compressor 1363A010001) Each compressor increases the refrigerant gas pressure and temperature and insures the refrigerant fluid circulation inside the circuit.
a shaft. Two scroll compressors are provided.
a thermal switch. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 268 .
a scrolls sub-assembly.
bearings. Training DOCTR 039 AW 139 Refrigerant Scroll Compressor Pack P/N3G2150V01153/1768B010000 Compressor Discharge hole Compressor Suction hole Cockpit compressor Compressor Suction hole Futur modification: Cabin compressor Improved wiring and connector LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 269 . 5 Hz for a new belt 270 +/.20 Hz for an existing belt after 300Hrs ·Refrigerant operation values: Suction pressure range: 2 to 6 bars Suction temperature range: 20 °C Discharge pressure range: 29 bars Discharge temperature range: 125 °C LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 270 . Training DOCTR 039 AW 139 Refrigerant Scroll Compressor Pack P/N3G2150V01153/1768B010000 Characteristics: Clutch voltage: 28VDC Operation temperature: +10°C to 85°C Weight: < 20 kg Drive belt tension: 270 +/. oil is partially separated from refrigerant when going through the bearings to lubricates them. To improve bearings lubrication and cooling. Moreover. The scroll does not require oil separator. oil enables to reduce leakage between compression pockets and tends to migrate toward pockets set at lower pressure. One spiral member is fixed whereas the second is driven by an eccentric shaft. Training DOCTR 039 AW 139 Scroll compressor Operation principle The two spiral elements are fitted together rotating in an orbital motion building up several fluid pockets. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 271 . As a result the fluids pockets are moved toward the centre of the spiral where the discharge port is located reducing their volume : compression is implemented. the special design of the eccentric shaft is used to recover oil from carter and send it to the bearing housings. As a matter of fact. After one and an half turn the gas pockets A and B comes together to one pocket (A+B). 5.Sucked in at the beginning of the first revolution. 4.The end of the compression is achieved when after 2.25 turns it appears simultaneously two or three pairs of gas at different pressure levels. Pressure and temperature raises at the same time gradually. 2.25 turns the volume of the pocket (A+B) suddenly increase causing a pressure diminution and the closing of the overload valve. What explains the lower vibration level of a scroll compressor compared to a piston one. The gas pocket volume decrease until the pressure reach un level high enough to open the overload valve. Due to the fact that the whole compression cycle last 2.The overload valve discharge almost at a constant temperature the refrigerant to the condenser.A new pair of gas pockets is sucked in at each turn of the S/A. 3. after one full turn the gas pockets A and B moves on toward the center. Training DOCTR 039 AW 139 Scroll compressor detailed operation: 1. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 272 . Training DOCTR 039 AW 139 A A 1st revolution B B A+B 2nd revolution 3rd revolution New cycle LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 273 . 5A SINGLE CORE 0 Vdc2 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 274 . Training DOCTR 039 AW 139 Characteristics Refrigerant : R134a Oil qty. : 150cc +/-5cc of PAG244 (in each) Volume : 105cm3 Max. cut “IN” 110°C +/. / MAX WIRE FROM / TO CURRENT A FWD–CLUTCH-SIG 12V / OC 5A / 7. Rotation Speed : 3900 rpm Clutch requirements : 28 VDC Thermal protection at: cut “OFF” 125°C +/-3°C.5A SINGLE CORE From FWD CLUTCH relay (+) B FWD–CLUTCH-REF GND 5A / 7.6°C Pin location for both compressors: PIN ITEM TYPE NOM. The air flow through each condenser is provided by a condenser fan. a frame and two fans. The fan is driven by a 28VDC motor commanded by the control panel relay as soon as Air conditioning is switched on. Training DOCTR 039 AW 139 Condenser S/A description P/N3520B010000/3520C010000 P/N3G2150V01052 /3G2150V02351 Two condenser S/As are installed per aircraft. The Condenser S/A is mainly composed of two condensers. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 275 . near the main rotor gear box. Each air conditioning loop (Cockpit + Cabin) has its own Condenser S/A. The refrigerant discharged by the compressor is de-superheated inside the condenser and change at the same time its state into liquid. for both ground and flight operation. The Condenser Heat Exchanger transfers the refrigerant heat load to the outside ambient air. version C ≤ 23 Kg LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 276 . power consumption: ≤ 32 A Fan 93036A010001 version characteristic: Speed between 4100 rpm and 4900 rpm Max. power consumption: ≤ 60 A Weight of the condenser S/A version B < 18.5 kg. Training DOCTR 039 AW 139 Fan 8028A010001 version characteristic: Speed between 3250 rpm and 3850 rpm Max. Aluminium unit treated against corrosion. Dimension : 384 X 480 X 22. Training DOCTR 039 AW 139 Condenser characteristics and general view: Parallel Flow Refrigerant to air heat exchanger with a light alloy core. Max Operating Pressure : 29 Bars Proof Pressure : 43.5 Bars LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 277 .5 Bars Burst Pressure : 72. to ensure liquid feeding of the expansion valves. Training DOCTR 039 AW 139 Receiver Filter Drier description P/N 20204-061 One receiver/filter per loop (cabin/cockpit) is installed downstream the condenser and allows by a SCHRADER valve fitted on the receiver inlet refrigerant servicing and operating pressure monitoring. allows the refrigerant to counteract volumetric variations of liquid refrigerant. a special chemical cartridge ensure filtering. retains foreign particles and consequently avoids the build up of acid. As part of the receiver. The volume. removes moisture of the refrigerant. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 278 . One HP– safety switch per refrigerant loop (Cockpit/Cabin) is installed on the receiver inlet and protect the system against overpressure (opening the electrical loop to the ACCB). delimited by the receiver housing. Training DOCTR 039 AW 139 Receiver Filter Drier description • Burst pressure : 180 Bar • Total internal volume : 0. This filter can not be cleaned and has to be discarded.7 l • Filtering capacity : 12 µm • Drier sieve : 3 and 4 Å • Dimensions : ∅ 70 mm. During this maintenance action it is strongly recommended to change the desiccant filter/receiver. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 279 . L = 220 Note: Liebherr recommended to change every 2 years the refrigerant in both the cabin and cockpit loop (for details refer to the refrigerant servicing procedure). 3. Important: For easier maintenance the HP-switch can be replaced without removing the refrigerant out of the system (use heater gun to brake the Loctite 586). +/- 1 bar (close again at ~21. Training DOCTR 039 AW 139 Equipped with an HP-switch : The high pressure switch (normally closed) prevents any damage of the compressor and the condenser caused by too high discharge pressure which can have several reason described in the trouble shooting section. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 280 .1bar). It switch off an electrical circuit when sensed pressure rises 29 bar/rel.6 bar/rel +. / MAX WIRE FROM / TO CURRENT 1 FWD-HP-SIG 28V / OC 5 / 10 mA SINGLE To ACCB1 CORE 2 FWD-HP-REF 28V / OC 5 / 10 mA SINGLE +28Vdc2 CORE New design: Improved wiring and connector LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 281 . Training DOCTR 039 AW 139 HP–Switch NEW 20204-071 + 20204-072 pin location: PIN ITEM TYPE NOM. feeding the evaporator through a flexible hose with refrigerant. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 282 . The cockpit Evaporator is equipped with one Thermostatic Expansion Valve – TEV. Training DOCTR 039 AW 139 Cockpit Evaporator L/H 3522B010000/3G2150V00753 R/H 3521B010000/3G2150V00853 The evaporator assy is set in the cockpit area behind the control panel. Air is re-circulated from air distribution loop and then blown on the Heat Exchanger evaporator by the evaporator fan installed upstream in the system. The S/A is linked to the cooling loop by two rubber flexible ducts. The refrigerant expanded by the TEV is entirely evaporated and then super-heated up to 5°C regarding saturated state (see TEV operating description). An anti-freezing Thermal switch (previous P/N 14713-021 now 20204-076/20204-077) prevents icing conditions on the evaporator outlet. it opens when the evaporator air outlet temperature reach 1°C +/-2°C. The LP – Switch installed on the LEFT Evaporator S/A is screwed on a flexible hose between TEV and Evaporator inlet (screwed on a Schräder valve 34878-00). Training DOCTR 039 AW 139 L/H Cockpit Evaporator S/A general view: Weight: < 4.1 kg Cooled Air Outlet Thermal Switch Flexible hose Gasous Refrigerant Low Pressure Outlet Switch TEV Liquid Refrigerant Inlet Cockpit/Ram Air Inlet LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 283 . LP: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 284 . Training DOCTR 039 AW 139 COCKPIT (FWD) Thermal Switch TS1 (TS2): CABIN (AFT) Thermal Switch TS1 (TS2): COCKPIT (CABIN) LOW PRESSURE Switch . Air is re-circulated from air distribution loop and then blown on the two Heat Exchanger evaporators by the evaporator fans. One thermal switch (previous P/N14713-021 now 20204-075) measures the air temperature downstream of the evaporators and sends the result to the Cabin Air Conditioning Control Box to avoids any risk of freezing. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 285 . in front of the main transmission box. The refrigerant expanded by the TEV is entirely evaporated an then super-heated up to 5°C regarding saturated state. Training DOCTR 039 AW 139 Cabin Evaporator S/A 3G2150V00953 description This assembly is installed in the upper deck area. it opens when the evaporator air outlet temperature reach 1°C +/-2°C (reset at 11°C +/-2°C). The S/A is equipped with two Thermostatic Expansion Valves feeding the two evaporators with refrigerant through two flexible hoses. One LP – Switch at the Evaporator S/A is installed on the flexible hose between TEV and Evaporator inlet (screwed on a Schräder valve 34878-00). Important: For easier maintenance the LP-switch can be replaced without removing the refrigerant out of the system (use heater gun to brake the Loctite 586). 5 kg Liquid Low Pressure Refrigerant Switch Inlet Cabin/ Ram Air Inlet Thermal Switch Cooled Air Cabin/ Ram Air Outlet Inlet Gasous TEV Refrigerant Outlet LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 286 . Training DOCTR 039 AW 139 Cabin Evaporator S/A general view: Weight: < 7. Training DOCTR 039 AW 139 Parts common to the Cockpit and Cabin Evaporator LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 287 . Four identical HFC R134a evaporators are installed on helicopter. Description Light alloy core dimensions : 235 x 230 x 65 Aluminium unit treated for biological growth and corrosion. Characteristic Max Operating Pressure : 12 Bars Proof Pressure : 18 Bars Burst Pressure : 30 Bars LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 288 . Training DOCTR 039 AW 139 Evaporator characteristics and general view: Function The 6 pass cross counter flow Heat Exchanger Evaporator use the cabin/cockpit air heat load to change the refrigerant from liquid to gas. and any risk of liquid suction by the compressor is avoided. The TEV achieve the expansion of the refrigerant at a regulated flow rate in order to ensure the refrigerant to be in a gaseous phase at the inlet of the compressor (refrigerant superheating of around 7°C (2°C to 15°C) at the outlet of the evaporator ). the evaporator area is optimised. Training DOCTR 039 AW 139 Thermostatic Expansion Valve .TEV S4300-05 description and general view: Each TEV is installed on the inlet of each evaporator and is fully interchangeable between the two cockpit and two cabin evaporator S/As. Hence. No further adjustment is needed. Note: The TEV is factory set up in order to provide the requested superheating. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 289 . TEV S4300-05 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 290 . Training DOCTR 039 AW 139 Thermostatic Expansion Valve . Training DOCTR 039 AW 139 Thermostatic Expansion Valve – TEV EIRT = Evaporator Inlet Refrigerant Temperature EORT = Evaporator Outlet Refrigerant Temperature Capillary Tube Recirculation air TO Cabin TEV BULB EVAPORATOR Example: EIRT = 8°C EORT = 13°C Delta t = 5°C superheating Recirculation air FROM Cabin LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 291 . Training DOCTR 039 AW 139 Thermostatic Expansion Valve – TEV : Refrigerant in a gasous state Capillary Tube Recirculation air TO Cabin TEV EVAPORATOR BULB 5°C EIRT = 8°C Normal EORT = 13°C Superheating Recirculation air FROM Cabin LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 292 . Training DOCTR 039 AW 139 Thermostatic Expansion Valve – TEV : Refrigerant in a gasous state Capillary Tube Recirculation air TO Cabin TEV EVAPORATOR BULB 20°C EIRT = 8°C Superheating to EORT = 28°C High Recirculation air FROM Cabin LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 293 . Training DOCTR 039 AW 139 Thermostatic Expansion Valve – TEV : Refrigerant in a gasous state Capillary Tube Recirculation air TO Cabin TEV EVAPORATOR BULB 0°C EIRT = 8°C No SuperheatingEORT = 8°C Recirculation air FROM Cabin LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 294 . 3 bar).5 bar/rel. The LP – Switch at the Evaporator S/A is installed on the flexible hose between TEV and Evaporator inlet. Important: For easier maintenance the LP-switch can be replaced without removing the refrigerant out of the system (use heater gun to brake the Loctite 586). Training DOCTR 039 AW 139 LP – Switch (previous 20205-010 now 20204-073 + 20204-074) function/installation and general view: The low pressure switch prevents any damage of the compressor caused by a lack of lubrication which can occur when the evaporating pressure drops to much (low heat load) and allows no longer sufficient oil back flow to the compressor suction port. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 295 .5 bar/rel. +/-0. It signals also a lack of refrigerant (leakage) by switching off an electrical circuit when sensed pressure drops down to 0. +/-0.3 bar (the LP-switch close again when the pressure goes up to 1. Training DOCTR 039 AW 139 LP – Switches pin location: PIN ITEM TYPE NOM. / MAX WIRE FROM / TO CURRENT 1 FWD-LP-SIG 28V / OC 5 / 10 mA SINGLE To ACCB1 CORE 2 FWD-LP-REF 28V / OC 5 / 10 mA SINGLE +28Vdc2 CORE New design: Improved wiring and connector LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 296 . -076. Training DOCTR 039 AW 139 Evaporator air outlet Thermal Switch (previous 14713-021 new 20204-075. it resets automatically at a temperature of 11°C +/. electrical contacts open below the preset value of 2°C and close by means of a push rod. When the diaphragm snaps. The temperature-switch consists of a housing and a micro switch in contact with a metallic bellow and is hermetically sealed.2 °C. Characteristic · Precision : ± 3% · Temperature range : -65 to +175°C · Setting temperature : 2°C LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 297 . -077) description: It survey the air outlet temperature of both cockpit and both cabin evaporators and opens the electrical circuit (loss of continuity) to the ACCB at a preset value. It avoids the risk of evaporator matrix icing. Training DOCTR 039 AW 139 Thermal Switch Pin identification : PIN ITEM TYPE NOM. / MAX WIRE FROM / TO CURRENT 1 FWD-TS1-SIG 28V / OC 5 / 10 mA SINGLE To ACCB1 CORE 2 FWD-TS1-REF 28V / OC 5 / 10 mA SINGLE +28Vdc2 CORE New design: Improved wiring and connector LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 298 . receiver and evaporator consists of rubber based hoses with a nylon barrier equipped on both ends with metallic connection fittings. Training DOCTR 039 AW 139 Refrigerant Hoses function/installation : The refrigerant hoses which connects the compressor. They close the refigerant loop using on the fittings either o-rings or flared connections and have three different diameters: Ø 10 for the High pressure hoses (compressor to condenser) Ø 8 for the High pressure hoses (filter to expansion valve) Ø 16 for the Low pressure hoses (evaporator to compressor) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 299 . condenser. Training DOCTR 039 AW 139 Air Conditioning System Other Components "Not" part of the Refrigerant Circuit LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 300 . is closed for cockpit recirculation air non admission and outside air admission and open for cockpit recirculation air admission and outside air non admission. The flap.8 kg Current at nominal torque of 0. The ECS Cockpit Flapper Valve is a rectangular composite valve with an aluminium flap.12 mdaN: <1A Maximum opening and closing time: 5s Operating temperature: -40 °C / +70°C LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 301 . Supply voltage: 17 Vdc to 32Vdv Weight: 0. equipped at the outlet with an Non Return Valve. driven by an electrical actuator. Training DOCTR 039 AW 139 Cockpit FLAPPER valve 6039B010000/3G2150V00652 (Air conditioning only) In the Air Conditioning configuration two cockpit flapper valves installed upstream of each of the two cockpit evaporator S/A providing fresh air either from the RAM air intakes or re- circulation air from the cabin sucked in by a fan. Training DOCTR 039 AW 139 Cockpit FLAPPER valve 6039B010000 (Air conditioning only) Valve in Closed position: Ram air open Recirculation closed Example: Valve in full closed position Valve in Open position: Ram air closed Recirculation open LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 302 . Training DOCTR 039 AW 139 Cockpit FLAPPER valve 6039B010000 general view: Heating duct connection New design: Additional flange for installation of a check valve LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 303 . Training DOCTR 039 AW 139 ECS - Cockpit Evaporator Fan 8011A030000/3G2150V00553 function: There are 2 two speed brush less cockpit fans per helicopter on 2 symmetrical ventilation systems. Both fans sucks air from the ram air intake and generates ventilation air flow towards the cockpit outlets and are used for ground and flight operation. They are controlled by the ECS Cockpit panel. Fan characteristics: Power supply: 28Vdc Normal working temperature range: - 40°C to + 70°C Low speed flow rate at 30°C and at see level: min. 4900 rpm / 2.5 A High speed flow rate at 30°C and at see level: min. 9300 rpm / 6.5 A Nominal current consumption: 7 A (start up 14 A) Weight: 1.55 kg LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 304 Training DOCTR 039 AW 139 ECS - Cockpit Evaporator Fan 8011A030000/3G2150V00553: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 305 Training DOCTR 039 AW 139 ECS - Cockpit Evaporator Fan general view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 306 Training DOCTR 039 AW 139 Cockpit A/C Fan (both interchangeable) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 307 Training DOCTR 039 AW 139 ECS - Cockpit Evaporator Fan (with flapper valve) general view: Cockpit fan Flapper valve LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 308 Training DOCTR 039 AW 139 Cabin Double Flapper Valve 4577B010000/3G2150V01352 general : The CABIN FLAPPER VALVE is a specific 90°C butterfly into a composite housing, driven by an electrical actuator. In the composite housing there are installed two check valves avoiding ram air back flow via the recirculation duct into the cabin. This valve is made of 2 main sub-assemblies: • one valve S/A consisting of one body S/A fitted with an equipped shaft assembly a dual butterfly at 90°, actuated by an electrical actuator, • one electrical actuator P/N 9300E040000. According to pilot selection on the control panel (Recirculation or Normal) the Valve is driven to the full open or full closed position allowing the evaporator fans to sucks air from outside or from inside the cabin. When the valve reach its full open or closed position two end travel switches cuts the power supply to prevent motor over consumption. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 309 Training DOCTR 039 AW 139 Cabin Double Flapper Valve electrical schematic : 2 Valve in Closed position: NOT CONNECTED FV-FC 5 FV-CMD-L OPEN 28 V on 4 Ram air open Re-circulation 3 0 V on 3 closed CLOSED 28 V on 3 0 V on 4 M CONTACT BETWEEN 6 AND 5 EQUAL TO FULL CLOSED POSITION Valve in Open position: 6 FV-FC/FO RETURN FV-FC 1 CONTACT BETWEEN 6 AND 1 Ram air closed Re- FV-CMD-H 4 EQUAL TO FULL OPEN POSITION circulation open VALVE CLOSED WHEN ACTUATOR CLOSED LTS 0565 The full opening command is ensured when the 28V is applied on Pin 4 and O V applied on Pin 3 . The full closing command is ensured when the 28V is applied on Pin 3 and O V applied on Pin 4 . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 310 Training DOCTR 039 AW 139 Cabin Double Flapper Valve general view (with ducting): Check Valve LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 311 . Reminder : There is ONE cabin FAN per aircraft for the heating configuration. There are TWO cabin FAN per aircraft for the Air Conditioning configuration. The cabin FAN sucks outside and/or re-circulation air and blows it through the evaporators inside the low pressure distribution system. Training DOCTR 039 AW 139 Cabin A/C Fan description P/N 8012A030000/8020A010000 P/N 3G2121V00553/3G2150V02251 In this configuration we will find two 2 speed brush less cabin fan per helicopter. The dual speed brush less fan is used for ground and flight operation. The two cabin FANs are installed upstream of the two evaporators. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 312 . The 28Vdc cabin FAN is controlled either by the Cockpit or the Cabin control panel. + 85°C Low speed flow rate: 7500 rpm / 5A High speed flow rate: 13200 rpm / 17A Nominal current consumption: 17 A (start up 23 A) Weight: 1.40°C to max. + 85°C Low speed flow rate: XXXX rpm / 5A High speed flow rate: XXXX rpm / 20A Nominal current consumption: ≤ 20 A (start up 25 A) Weight: ≤1.79 kg LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 313 .6 kg Cabin A/C Fan 8020A010000/ 3G2150V02251 characteristics: Characteristics at 30°C OAT and sea level (1013mbar ): Fan characteristics: Power supply: 28 Vdc Normal working temperature range: .40°C to max. Training DOCTR 039 AW 139 Cabin A/C Fan 8012A030000/ 3G2121V00553 characteristics: Characteristics at 30°C OAT and sea level (1013mbar ): Fan characteristics: Power supply: 28 Vdc Normal working temperature range: . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 314 . With power supplied and OFF selection the under-speed pin detection shall be open circuit. The under-speed detection level will be the half off low speed and half off high speed ±15% (in tr/mn). a fault is indicated (Ground) only if the speed is inferior to the under speed limit during 3 to 5s. Training DOCTR 039 AW 139 Cabin Fan under speed detection: In ON mode. During the start up phase when ON selection is activated the under-speed pin detection is open circuit during 5 seconds. In this case the fan will be stop and a OFF/ON selection is necessary for start again the fan. An under-speed fault is detected if the under-speed pin detection is ground after the start up phase. With no power supplied the under-speed pin detection shall be Open. Training DOCTR 039 AW 139 Cabin Fan electrical logic: o ON/OFF selection : o Under-speed detection : o Ground → ON o Ground → Fault o Open Circuit → OFF o Open Circuit → No fault o High speed / Low speed selection : o Ground → Low speed o Open Circuit → High speed LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 315 . Training DOCTR 039 AW 139 Cabin Fan Pin Location : LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 316 . Training DOCTR 039 AW 139 Cabin Fan (Forced ventilation/heating) general view: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 317 . Fan 8028A010001 version characteristic: Speed between 3250 rpm and 3850 rpm Max. Training DOCTR 039 AW 139 Condenser Fan characteristics and general view: The condenser fan motor is a single-speed 28 VDC motorized axial fan. power consumption: ≤ 60 A LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 318 . power consumption: ≤ 32 A Fan 93036A010001 version characteristic: Speed between 4100 rpm and 4900 rpm Max. 15 ’’ skewed ring blade fan driven by a brushless DC motor. Training DOCTR 039 AW 139 Condenser Fan pin location: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 319 . The sensor is composed of one integrated circuit temperature probe (PT1000) potted in a tubular housing. A stern allows the air to circulate around the electronic probe resulting in better thermal response while protecting it from accidental damage. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 320 . This information is used for the automatic control of the air conditioning system. The temperature sensor is ventilated by a small fan to obtain an accurate measurement. Training DOCTR 039 AW 139 Ventilated Temperature Sensor 92279A010000/3G2150V01251 description: Two ventilated sensors one dedicated to the cockpit and the other to the cabin zone measures the temperature and provide this information to the associated Air Conditioning control box. 1 A max Sensor gain : 10 mV /°K Measuring range : -40 °F to +160 °F (-40 °C to +70 °C) Output voltage : 0V at 0 °K Response time : ≤ 15 s Faulty when Sensor open circuit: ventilated temperature > 90°C Fan characteristics : Power supply 24 VDC. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 321 . 0. Training DOCTR 039 AW 139 Ventilated Temperature Sensor characteristics/general view: Characteristic Weight < 75 g Power Supply : 28 Vdc. 100 mA max. Training DOCTR 039 AW 139 Ventilated Temperature Sensor pin location (idem for ACCB2): LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 322 . Training DOCTR 039 AW 139 AIR CONDITIONING SYSTEM TROUBLE SHOOTING TIPS LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 323 . Training DOCTR 039 AW 139 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 324 . Training DOCTR 039 AW 139 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 325 . Training DOCTR 039 AW 139 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 326 . Training DOCTR 039 AW 139 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 327 . Training DOCTR 039 AW 139 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 328 . FROB’s and BOB’s: Break Out Box – BOB 92612A010000 (Ventilation/Heating/Air Conditioning) Break Out Box – BOB 92613A010000 (Ventilation/Air Conditioning) Failure read Out Box – FROB 92600A010000 (Air Conditioning) Caution: Before connecting the special tool’s to the electrical harness switch-off the 28Vdc helicopter power supply. Training DOCTR 039 AW 139 AB139 Air Conditioning trouble shooting guide Testing using LTS . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 329 . Training DOCTR 039 AW 139 Ventilation/Air Conditiong System test LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 330 . Training DOCTR 039 AW 139 Vapour Cycle general schematic (valid for each loop): Cockpit + Cabin compressor Cockpit condenser Fan Cabin evaporator Cockpit HP-switch Cabin evaporator fans L/H cockpit evaporator Cockpit Panel Cabin condenser Fan R/H cockpit Cabin FV evaporator Cabin HP-switch Cabin LP switch Cockpit TS2 Cabin TS2 Cockpit LP switch Cockpit evaporator fans Cockpit TS1 EATS Cockpit FV’s CockpitTemp. Sensor LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 331 . Training DOCTR 039 AW 139 System Architecture: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 332 . Training DOCTR 039 AW 139 Note: In order to check the Air Conditioning/Ventilation system the BOB 92612A010000. BOB 92913A010000 and FROB 92600A010000 should be used. CONDITIONING LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 333 . Training DOCTR 039 AW 139 FROB 92600A010000 (Air Conditioning) Note: Used for Air Conditioning trouble shooting only CONDITIONING LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 334 . located in the L/H side of the luggage compartment just behind the main access door (from production helicopter N°22 on. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 335 . Training DOCTR 039 AW 139 1) Connect the FROB P/N 92600A010000 to the helicopter upper ECS-FWD (ACCB1) or lower ECS-AFT (ACCB2) maintenance connector. before helicopter N°22 the maintenance connector was located n ear to the ACCB). Another function of the FROB is to SET / RESET the memory stage of the connected ACCB 1(2). The FROB allows to read out the failure(s) memorised in each ACCB and to get real time system information in « SCAN » mode. Reminder: The FROB should be used during trouble shooting to help to identify quickly the faulty component. do reset the message (cut off 28VDC) 3) No failure present and reset not possible – replace ACCB 1 or 2. Training DOCTR 039 AW 139 2) Heating and Ventilation System trouble shooting: Possible memorised failures: • HP fault • LP fault • TS fault • Temp. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 336 . Sensor fault Note (see next page): Press  "IP means: Press on the push button part of each program. an "In Progress" message will be indicated on the display. Reason for the message "Reset Memory Faulty": 1) Failure still present 2) MAU failure message still illuminated. K.K. Sensor fault or No Memorised Failure Press SELECT Read out Set/Reset Press SELECT Press  Set Reset "IP" Press Press SET MEMORY Memory Reset Start Abort Start Abort Press  Press "IP" Set Memory O. or Reset Memory Faulty* LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 337 . Training DOCTR 039 AW 139 2 a) Failure read out «flow chart»: FAILURE READ OUT Memory Scan Press  "IP" Press HP-Fault/LP-Fault/TS-Fault/Temp. Press  Press  "IP" "IP" Reset Memory O. Sensor fault Press SELECT Read out Set/Reset To continue refer to previous page LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 338 . Training DOCTR 039 AW 139 2 b) Failure read out «flow chart» in « SCAN MODE »: Scan: This function permit to detect immediately (in real time) a failure as soon as it occurs during ground run or testing. * If no failure is present the indication will be : SCAN Failure – « Press » push button to go back to initial menu. FAILURE READ OUT Memory Scan Press Scan Failure* or Failure message indicated : HP- Press Fault/LP-Fault/TS-Fault/Temp. which allows failure confirmation. Training DOCTR 039 AW 139 BOB 92612A01000: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 339 . The connector J02 on the Cockpit Panel back side must remain connected. Training DOCTR 039 AW 139 Important: In order to test the whole Air conditioning system. both BOB’s should be connected. 3) The BOB 92612A01000 must be connected between the Cockpit Panel J01 and the helicopter harness. Connector J03 (only used when cabin panel Connector J02 installed) Connector J01 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 340 . Training DOCTR 039 AW 139 BOB 92613A01000: LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 341 . ACCB and the helicopter harness. Training DOCTR 039 AW 139 4) Once the ventilation system components have been found correct. continue with the Air Conditioning system components check. 5) The BOB 92613A01000 must be connected between the Air Conditioning Control Box . ACCB 1 Cockpit ACCB 1 ACCB 2 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 342 . AFT cabin air cond. ACCB 1 Cockpi ACCB t ACCB 1 2 LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 343 . Note 2: Connect the BOB to the system to be tested: . Note 3: To check the correct functionning of the ACCB’s. loop . loop . Training DOCTR 039 AW 139 Note 1: The cabin overhead liner must be removed to get access to the ACCB’s. we suggest to use the A/C break out box 92613A010000 (liner removed) to allow cross connection of the ACCB1 (fwd) to the aft system (or the other way around) rather than swap the controllers.ACCB 2 -R/H side.FWD cockpit air cond. .ACCB 1-L/H side. CONTR in « CREW » position and TEMP CONTR in « Min » 7) Connect 28Vdc power to the helicopter and put GEN switch to ON. 8) The BOB initial configuration should be: TS 1 = «GREEN» LED is «ON» TS 2 = «GREEN» LED is «ON» LP = «GREEN» LED is «ON» HP = «GREEN» LED is «ON» A/C FAILURE = «RED» LED is sligtly lit. Training DOCTR 039 AW 139 6) Put all selection buttons on the cockpit panel in « OFF » position. Note: All other LED’s are « OFF » Reminder: The cockpit evaporator’s are equipped with two thermal switches and the cabin evaporator with only one TS (indicated as TS 2). Warning : The Condenser fan might start for a couple of secondes. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 344 . ⇒Check the wiring and connection and if O. if not check helicopter 28Vdc power supply on jumper 8. For further analisis refer to the ACCB failure detection logic.K change TS1 (installed on L/H cockpit evaporator) Note 1: TS1 . Training DOCTR 039 AW 139 8a) If the TS1 «RED» LED (cockpit loop only) is « ON » (A/C not running): ⇒Double check the indication with the information shown on the FROB 92600A010000. (TS fault should be indicated in SCAN mode).No failure (switch closed). LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 345 . ⇒Check the wiring and connection and if O.2°C in ord er to avoid icing conditions. 28Vdc between jumper 8 and 44. 28Vdc between jumper 9 and 44. 8b) If the TS2 «RED» LED (cockpit or cabin loop) is « ON » (A/C not running): ⇒Double check the indication with the information shown on the FROB 92600A010000. Reminder: With air conditioning running the thermal switch(es) opens (corresponding LED goes OFF) at an evaporator AIR outlet temperature of 1°C +/. Note 2: TS1 Cabin loop green LED shall always be LIT. (at an outlet temperature >4°C the TS-switch should be closed). (TS fault should be indicated in SCAN mode).No failure (switch closed).K change TS2 (installed on R/H cockpit or on the cabin evaporator) Note: TS2 . Note: The LP-switch must be closed at a suction pressure higher than >0.No failure (switch closed).K. 28Vdc between jumper 14 and 44. ⇒Double check the indication with the information shown on the FROB 92600A010000. (LP fault should be indicated in SCAN mode). ⇒Check the wiring. Note: LP switch . ⇒Check refrigerant pressure – no pressure means that the system is empty (without refrigerant) – search for a leak. gaspers should be open). connection and the switch if O. 8d) If the LP «RED» LED (cockpit or cabin loop) goes « ON » during A/C operation at an OAT lower than <30°C (A/C running): ⇒Check the correct airflow through the evaporator (no collapsed ducts.5bar rel. Training DOCTR 039 AW 139 8c) If the LP «RED» LED (cockpit or cabin loop) is « ON » (A/C not running): Note: LP-switch is installed on L/H cockpit and on the cabin evaporator. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 346 . if the LP «RED» LED (cockpit or cabin loop) goes « ON » during A/C operation at an OAT lower than <30°C (A/C running): ⇒Desiccant filter partially clogged.. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 347 . O. if the LP «RED» LED (cockpit or cabin loop) goes « ON » during A/C operation (A/C running): ⇒Check Thermostatic expansion valve filter (clean if required) and valve conditions (capillary tube). Training DOCTR 039 AW 139 8e) Airflow O. partially clogged difference ∆t > 3°C between inlet and outlet .K. if the LP «RED» LED (cockpit or cabin loop) goes « ON » during A/C operation at an OAT lower than <30°C (A/C running): ⇒Insufficient refrigerant charge. of refrigerant 8f) No leakage.replace the receiver desiccant filter 8g) New desiccant filter..K. refrigerant qty. perform the leak check and re-charge the system with the correct qty. ⇒Check the wiring. ⇒Double check the indication with the information shown on the FROB 92600A010000. Training DOCTR 039 AW 139 8h) If the HP «RED» LED (cockpit or cabin loop) is « ON » (A/C not running): Note: The HP-switch is installed on the upper deck receiver L/H for the AFT cabin and R/H for the FWD cockpit loop. (HP fault should be indicated in SCAN mode). connection and the switch replace/repair faulty element LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 348 . too much refrigerant in the system or refrigerant mixed with air. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 349 . ⇒ If OK. if clogged replace filter. Note2: The HP-switch must be closed at a discharge pressure lower than <26 bar rel.No failure (switch closed). ⇒ Drain. a) If OAT higher than >55°C : ⇒No maintenance action. b) If OAT higher than >30°C : ⇒Check the correct airflow through the condenser (heat exchanger clogged. ⇒ If OK. 28Vdc between jumper 15 and 44. check desiccant filter condition: Partially clogged difference ∆t > 3°C between inlet and outlet. of refrigerant. select ventilation mode. vacuum and re-charge the system with the correct qty. (HP fault should be indicated in SCAN mode). Training DOCTR 039 AW 139 8i) If the HP «RED» LED (cockpit or cabin loop) goes «ON» during A/C operation (A/C running): ⇒Double check the indication with the information shown on the FROB 92600A010000. Note1: HP switch . condenser fan faulty). Training DOCTR 039 AW 139 9) Put the VENT CREW and/or PAX switch to the «FAN LOW» position: ⇒ Ventilation Selection «GREEN» LED comes «ON» LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 350 . . ⇒Check the wiring between the cockpit panel and the ACCB. Training DOCTR 039 AW 139 9a) If the Ventilation Selection «GREEN» LED remaines «OFF»: ⇒Check continuity between jumper 36 and 44. if missing.K.replace cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 351 . if O. these outputs are not connected inside the Cockpit Panel (no indication). LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 352 . the CLUTCH «GREEN» LED comes «ON» if cockpit or/and cabin temperature is higher than 15°C Note: EVAP-FAN 1 FAILURE and EVAP-FAN 2 FAILURE. Training DOCTR 039 AW 139 10) Put the COND switch to « NORM » position : ⇒A/C Selection = «GREEN» LED comes «ON» ⇒COND FAN-ON = «GREEN» LED comes «ON» Attention: Condenser fan starts-up ⇒After a time delay of ~30 sec. - replace cockpit panel LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 353 . Training DOCTR 039 AW 139 10a) If the A/C Selection «GREEN» LED remaines «OFF» (Cond FAN – ON and Clutch are also «OFF»): ⇒Check continuity between jumper 29 and 44. if missing. ⇒Check the wiring between the cockpit panel and the ACCB if O.K. replace condenser fan LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 354 . if missing 10c) COND FAN-ON LED is «ON» (contiuity between jumper 43 and 44) but condenser fan does not start.K . Training DOCTR 039 AW 139 10b) If the COND FAN-ON «GREEN» LED remaines «OFF» (Clutch is also «OFF»): ⇒ Check continuity between jumper 43 and 44. ⇒ Check the condenser fan relay. wiring and connection and if O. Fan-ON) no failure – replace ACCB.TS.) if cockpit or cabin temperature higher than 20°C: ⇒ Check the correct functioning of the cockpit panel potentiometer using voltmeter between jumper 11 and 12: -TEMP CONTR switch in « MIN » position ~ 0. ⇒ Check absence of any fault (Temp. Sensor. -TEMP CONTR switch in « MAX » position ~ 3.5 Vdc. Cond. HP. Ventilation Selection.2 Vdc (or ~4 Ohm jumper removed) -TEMP CONTR switch in « Middle » position ~1. Training DOCTR 039 AW 139 10d) If the CLUTCH «GREEN» LED remaines «OFF» (after the time delay of 30sec.0 Vdc (or ~7 KOhm jumper removed) ⇒ Check continuity between jumper 49 and 44. if missing. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 355 . LP. connection and clutch engagment (shunt between jumper 49 and 44) and if O. ⇒ Check the compressor relay. wiring. Training DOCTR 039 AW 139 10e) CLUTCH LED is «ON» (continuity between jumper 49 and 44) but compressor does not start.replace compressor LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 356 .K . CLUTCH = «GREEN» LED goes «OFF» LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 357 . Training DOCTR 039 AW 139 11) To check red A/C FAILURE «LET» brightly lit. simulate a LP failure by removing jumper 14 (time delay of 3 minutes): TS 1 = «GREEN» LED is «ON» (cockpit loop ACCB1) TS 2 = «GREEN» LED is «ON» LP = «RED» LED comes «ON» HP = «GREEN» LED is «ON» Ventilation Selection = «GREEN» LED comes «ON» A/C Selection = «GREEN» LED is «ON» COND FAN-ON = «GREEN» remains «ON» A/C FAILURE = «RED» LED becomes brightly lit. Training DOCTR 039 AW 139 11a) If red A/C FAILURE «LET» does not brightly lit: ⇒ replace ACCB LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 358 . Training DOCTR 039 AW 139 12) To check the correct functionning of the «Temp Sensor» measure a voltage between jumper 5 and 6: V = 2.73VDC + (0.93VDC LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 359 .2VDC 20°C = 2.01VDC x °C) Example for: 20°C = 2.73VDC + 0. K. Training DOCTR 039 AW 139 12a) If «Temp Sensor» voltage out of range: ⇒ Check wiring and connection and if O. – replace temperature sensor LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 360 . Training DOCTR 039 AW 139 General Maintenance Recommendations LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 361 . After assembly. leading to a unit failure.During unit repair. cap all fittings as soon as opened and leave them capped until just before they are re-connected. the refrigerant generates a corrosive acid (chloridric type) which can cause major damages or failure to the components. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 362 . to ensure the removal of moisture which may have been absorbed by the oil in the compressor and in the circuit. In order to avoid this. When in contact with ambient moisture. inspection intervals. vacuum pump the system for at least 45 minutes before recharging. Any damage to this valve would cause a continuous leakage. a particular care must be taken to the receiver servicing valve when using the command device P/N SBE 1261. During refrigerant servicing operation and/or leakage test. CAUTION: Do not operate air conditioning system with condenser air outlet blocked. Training DOCTR 039 AW 139 General Recommendations Procedures are provided for general maintenance tips. we recommend to observe the following points: . . rather try to adjust the temperature demand on the Cockpit/Cabin control panel. Leak check. The inspections are simple visual inspections requiring a minimal amount of time. receiver/filter Recharge system with refrigerant R134a : 1200g for the cockpit loop and 1000g for the cabin loop. we recommend the air conditioning system "on ground" and during "take off" to be operated in recirculation mode and to switch to ram air mode during cruise. LTS considers that the location of the recirculation air inputs in the cockpit and cabin presents no particular heat exchanger pollution risk. then Tension or replace as necessary every 300 hours or 2 years Evaporator and condenser air Every 100 hours or 6 months Clean as necessary matrix dirty Replace refrigerant and Every 2 years Drain. Damage necessary Compressor Belt Tension. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 363 . Avoid to close the cockpit and cabin gaspers. Therefore. Wear Within 5 hours of installing new belt. Training DOCTR 039 AW 139 INSPECTION INTERVALS Periodic inspections of the air conditioning system will keep the system operating at peek efficiency. Recover. Vacuum. Indeed the main risk of pollution exists in ram air mode. Air Conditioning System Every 100 hours or 6 months Clean or replace component as Components Dirt . Training DOCTR 039 AW 139 System Refrigerant Servicing LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 364 . VACCUM 3 min DO THE LEAK TEST FILL WITH 15 BARS OF NITROGEN LEAKAGE TEST OK: NO LEAKAGE DO THE VACCUM LEAK SEARCH 45MIN CHARGE WITH R134a QTY DO THE REPAIR DO A GROUND RUN TO CHECK THE COOLING PERFORMANCE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 365 .Training DOCTR 039 AW 139 MAINTENANCE FLOW CHART MAINTENANCE * *Only system draining and charging without opening of the refrigerant circuit. Training DOCTR 039 AW 139 REPAIR FLOW CHART REPAIR * *Refrigerant circuit will be opened for repair ADD OIL INTO THE COMPRESSOR SUCTION HOLE DO THE LEAKAGE TEST FILL WITH NITROGENE LEAKAGE TEST OK: NO LEAKAGE LEAK SEARCH DO THE VACUUM 45MIN CHARGE WITH R134a QTY DO THE REPAIR DO A GROUND RUN TO CHECK THE COOLING PERFORMANCE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 366 . the same quantity of new oil should be injected into the system prior charging with refrigerant (refer to the charging bench manual). Otherwise. Once the compressor S/A is installed on the upper deck with the belt. 2) In service maintenance : No scheduled oil check must be performed ! No oil gauge is provided on the compressor! 3) During the refrigerant draining and filling of the air-conditioning system without opening of the circuit (without disconnecting of the refrigerant pipes and replacement of the compressor): If the servicing bench allows to measure the recovered oil quantity. No additional oil should be added to the unit during refrigerant charging. Training DOCTR 039 AW 139 A) Oil Filling and Top-up: 1) During the first installation of a new air conditioning system : Each compressor is already filled with the correct quantity 150 cc of oil PAG 244. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 367 . add 30 cc of the oil PAG 244 to the system. remove the plugs and connect the discharge and suction pipe to the compressor. do not forget to take into account the length of the refrigerant hose between charging bench and receiver valve (approximately 20g to 30g of refrigerant per meter) 4) During refrigerant draining/filling along with the replacement of a part of the refrigerant circuit. Add the quantity of 30cc of the oil PAG 244 and charge the loop with refrigerant without opening of the system. Nota : During charging pay attention to the refrigerant quantity. please refer to the previous recommendation in 3) and add for each following part the specified quantity : Evaporator 30cc (+ recovered oil quantity or 30 cc) Condenser 30cc (+ recovered oil quantity or 30 cc) Receiver desiccant filter 20cc (+ recovered oil quantity or 30 cc) Suction pipe 30cc (+ recovered oil quantity or 30 cc) Discharge pipe 10cc (+ recovered oil quantity or 30 cc) LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 368 . Training DOCTR 039 AW 139 This quantity of oil should be injected through the discharge hose servicing valve once the nitrogen leak check and the vacuum pump phase (pump down) completed. HP+LP switch : 10 cc (+ recovered oil quantity or 30 cc). Training DOCTR 039 AW 139 Important : The additional oil must always be filled into the compressor by the suction hole. Other parts like : Rigid pipes. Compressor mechanical failure: Flushing of the refrigerant circuit and replacement of the receiver/filter is strongly recommended. Reminder : Always perform the filling through the suction hole. Thermostatic expansion valve. Further to an opening of the refrigerant circuit the replacement of the receiver / filter is strongly recommended. Subsequently to a compressor clutch failure : Replace the compressor and make sure to have 100 cc of oil PAG244 inside the new compressor. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 369 . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 370 . Prior charging of the system. the quantity of lost oil is different. than evacuate/pump down for at least 45 minutes. fill 50 cc of oil PAG 244 into the suction hole of the corresponding compressor. Training DOCTR 039 AW 139 5) Oil top-up subsequently to a refrigerant leakage (system empty): Estimate approximately the quantity of oil at the vicinity/surrounding area of the leakage. Once the leakage repaired and if it is not possible to estimate the amount of lost oil. perform the nitrogen leak check under 10 bar. Depending on the type of leakage small or big. has practically no odor. No other refrigerant or compressor oil should be used. Although R134a is classified as a safe refrigerant. Refrigerant R134a is non explosive. non-flammable. Training DOCTR 039 AW 139 B) Refrigerant Recovery/Charging GENERAL The air conditioning system uses refrigerant R134a and the compressor lubricating oil used is ELFRIMA PAG 244. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 371 . certain precautions must be observed to personnel and property when working with R134a refrigerant. non -corrosive. and is heavier than air. full or empty. the immediate area of the air conditioning system. Always wear safety goggles when servicing any part of the refrigerant system to prevent refrigerant from coming into contact with the eyes. if handled incorrectly. or in. or use excessive amounts of heat on. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 372 . or refrigerant supply tank. d. while they are closed to atmosphere. solder. The refrigerant service cart/container has a safe strength. Liquid R134a. 52°C) or drop it. never weld. However. b. use a blow torch. CAUTION: Do not operate air conditioning system with condenser air outlet blocked. evaporates so quickly that it tends to freeze anything that it contacts. at normal atmospheric pressure and temperature. Therefore. always follow the instruction on the label. never store it in a hot location (above 126°F. In particular. Care must be taken to prevent any liquid refrigerant from coming into contact with skin. Training DOCTR 039 AW 139 WARNING: a. c. it will explode. steam clean. To avoid explosion. 2) Discharge the air conditioning system in accordance with the recovery unit's instructions. Discharging Procedure 1) Connect R134a compatible recycling/recovery unit to the R134a servicing valves on the compressor discharge (HP) and suction (LP) hose. After component replacement refer to the oil top-up chapter. normally indicated on the recovery unit once the process completed. Use only an R134a compatible recycling/recovery unit when discharging the air conditioning system. This amount of oil will have to be added back to the system during charging. 3) Note the amount of oil removed from the system during discharging. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 373 . Federal law prohibits discharging refrigerant into the atmosphere. Training DOCTR 039 AW 139 SYSTEM DISCHARGING General The air conditioning system refrigerant must be discharged prior to disconnecting or removing any components in the refrigerant loop. to define the correct oil quantity which should be filled directly into the compressor suction hole. a – Connect the nitrogen bottle equipped with an pressure regulator to a manifold. b – Screw the blue hose on one side to the High Pressure outlet of the manifold and on the other side to the servicing valve of the suction hose.This test allows detection of important leakages of the refrigerant circuit pipe connections by applying a MAXIMUM pressure of 15 bar of dry nitrogen. c – Open the nitrogen bottle and adjust a MAXIMUM pressure of 15 bar. check the value on the gauge of the manifold. check the correct installation and torque tighten of all pipe connections. pressure manifold etc…). Training DOCTR 039 AW 139 PRESSURE LEAKAGE TEST Before charging the A/C with refrigerant. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 374 . PRESSURE LEAK TEST OF THE REFRIGERANT CIRCUIT(strongly recommended) Note : The pressure leak test has to be implemented by using standard equipment procurable on the local market (refrigerant connection hoses and taps. f . with a standard aerosol using soapy water to localise leakages by bubbles 3. The leak detection can be performed in the following order : 1. Training DOCTR 039 AW 139 d – Open the tap on the suction hose side and the tap on the pressure manifold. whistling noise 2. using an R134a electronic leak seeker (mix nitrogen with R134a) g – If the pressure remains stable for at least 30 minutes the system can be considered as correct.Close all taps and the nitrogen bottle and start looking for a leak. h – Disconnect the blue hose from the quick connection and slowly decrease the nitrogen pressure inside the refrigerant circuit. e – Apply a MAXIMUM pressure of 15 bar to the refrigerant circuit of the A/C. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 375 . Training DOCTR 039 AW 139 15 Bar Suction hose valve LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 376 . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 377 . Evacuating the system removes any moisture that may be in the system. in-between the discharge or suction hose and the recovery/recharging unit. Evacuating Procedure 1) Connect R134a compatible recycling/recharging unit to the R134a servicing valves on the discharge (HP) and suction (LP) hose. Training DOCTR 039 AW 139 EVACUATING SYSTEM General The air conditioning system must be evacuated prior to charging the system with refrigerant. interconnect an absolute pressure gauge protected by a tap. If recovery unit does not have absolute pressure gauges. 2) Evacuate the air conditioning system in accordance with the recovery unit instructions for a minimum of 45 minutes (up to 2 hours). Use only an R134a compatible recycling/recovery unit when evacuating the air conditioning system. search for a leak. Note: To eliminate all refrigerant gas pockets vacuum up to 2 hours. stop vacuuming and search for a leak. 3) After 45 minutes of vacuum pumping note the remaining pressure and isolate the pump. If the pressure increases quickly. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 378 . 4) Once the air conditioning system has been evacuated. Training DOCTR 039 AW 139 SYSTEM EVACUATING Note:Open the tap on the absolute pressure gauge and closely survey it. it is then ready for charging with new/recycled R134a refrigerant. If the pressure after 10 minutes of vacuum pumping does not reach the value of at least 50 mbar absolute. The pressure should remain almost stable and very slowly increase (due to possible remaining refrigerant gas pockets). For each meter you have to add around 30 g of refrigerant. 2) Charge the air conditioning system in accordance with the recovery/recharging unit instructions. Federal law prohibits discharging refrigerant into the atmosphere. IMPORTANT : Never forget to take into account the length of the flexible hose (normally 3 meters) between the recovery/recharging unit and the receiver valve on the condenser S/A. Use only an R134a compatible recycling/recharging unit when charging the air conditioning system. Therefore the best is to proceed in 2 steps: 1st – To fill the flexible hose with liquid refrigerant. 1000g ± 50 g of refrigerant R134a for the cabin loop and 1200g ± 50 g for the cockpit loop. Charging Procedure 1) Connect R134a compatible recycling/recharging unit to the servicing valve on the discharge (HP) hose. 2nd – To charge the system 3) Disconnect the R134a compatible recycling/recharging unit from the HP servicing valve. Training DOCTR 039 AW 139 SYSTEM CHARGING General Use only R134a refrigerant when charging air conditioning system. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 379 . two different procedures for the transfer into the air-conditioning system can be used. 2) Once filled with the correct qty of refrigerant. a) To push the refrigerant out of the charging cylinder using nitrogen: .connect a hose in-between the lower tap of the charging cylinder and the air conditioning system (this hose should be equipped on each side with an insulation tap and a special push valve tool on the A/C receiver side) .bleed the air out of the refrigerant hose by unscrewing slightly the hose at the second insulation tap (3) near to the air conditioning receiver LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 380 . it is mandatory to vacuum it in order to remove the ambient moisture. Training DOCTR 039 AW 139 System charging with a charging cylinder: 1) Connect the R134A bottle to the lower side of the charging cylinder and fill it with 1500 g of refrigerant R134a.align the scale of the charging cylinder to the pressure indicated on the absolute pressure gauge .open first the lower tap on the charging cylinder .open the insulation tap (2) on the charging cylinder side . Note: If the charging cylinder is used for the first time or was let open for a long time. Training DOCTR 039 AW 139 Hose connection for the nitrogen bottle to push the refrigerant R134a Hose connection going to the air conditioning unit LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 381 . Training DOCTR 039 AW 139 R134a Absolute pressure gauge indicating R134a pressure Scale aligned to the read pressure gauge value LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 382 . Training DOCTR 039 AW 139 N i Pressure t 1 regulator r o g e n b o Discharge t hose or t receiver/dryer l e 4 Insulation tap on 2 Insulation tap on 3 receiver side cylinder side LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 383 . 1350g – 1000g (1200g) = 350g (150g) .connect a hose in-between the nitrogen bottle and the upper tap of the charging cylinder .retain the exact qty of refrigerant inside the cylinder and substrate 1000g (1200g) Example: Remaining qty inside the cylinder 1350g.open slowly the pressure regulator (1) on the nitrogen bottle and adjust the pressure inside the charging cylinder to 15 bar (do not align the scale to the new pressure value) .open the push valve on the air conditioning receiver by means of the special tool (4) .once the refrigerant level went down to 350g (150g) close the insulation tap (3) on the receiver side. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 384 .open first the insulation tap (3) on the air conditioning side and than carefully the tap (2) on the charging cylinder side and watch closely the refrigerant level indicator on the charging cylinder side glass . Training DOCTR 039 AW 139 System charging using a charging cylinder continue: 2) a) once the refrigerant hose is filled with liquid refrigerant tighten again the fitting and close the insulation tap (2) on the charging cylinder side . close all taps and disconnect the hoses and the special tool from the air conditioning system. Training DOCTR 039 AW 139 System charging using a charging cylinder continue: 2) a) . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 385 . Reminder: Never forget to put the cup on the receiver valve once charging accomplished. connect a hose in-between the lower tap of the charging cylinder and the air conditioning system (this hose should be equipped on each side with an insulation tap and a special push valve tool on the A/C receiver side) .open the insulation tap (2) on the charging cylinder side . .once the refrigerant hose is filled with liquid refrigerant tighten again the fitting and close the insulation tap (2) on the charging cylinder side .align the scale of the charging cylinder to the pressure indicated on the absolute pressure gauge 12 bar abs LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 386 .open first the lower tap on the charging cylinder .switch on the integrated electrical heater (1) and heat up the refrigerant in order to obtain a pressure of 12 bar abs inside the charging cylinder . Training DOCTR 039 AW 139 System charging using a charging cylinder continue: 2) b) To use the integrated electrical resistance to heat up the refrigerant and consequently raise the pressure inside the charging cylinder.bleed the air out of the refrigerant hose by unscrewing slightly the hose at the second insulation tap (3) near to the air conditioning receiver. retain the exact qty of refrigerant inside the cylinder and substrate 1000g (1200g) Example: Remaining qty inside the cylinder 1350g. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 387 . . 1350g – 1000g (1200g)= 350g (150g) . close all taps and disconnect the hoses and the special tool from the air conditioning system. Reminder: Never forget to put the cup on the receiver valve once charging accomplished.open the push valve on the air conditioning receiver by means of the special tool (4) .switch off the heater. Training DOCTR 039 AW 139 System charging using a charging cylinder continue: 2) b) .open first the insulation tap (3) on the air conditioning side and than carefully the tap (2) on the charging cylinder side and watch closely the refrigerant level indicator on the charging cylinder side glass .once the refrigerant level went down to 350g (100g) close the insulation tap (3) on the receiver side. Training DOCTR 039 AW 139 Discharge hose or 1 Integrated receiver/dryer electrical heater 4 Insulation tap on 2 Insulation tap on 3 receiver side cylinder side LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 388 . It is imperative to discard and replace all O-rings before assembly. the following points must be strictly observed: . of the unit. Training DOCTR 039 AW 139 C) Component replacement : Hose replacement: During maintenance.All coupling nuts must be torque tightened. . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 389 .Do not twist or bend the flexible hoses during installation and tightening. . Clean the hoses by flushing (R11. Replace the receiver desiccant filter . LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 390 .Excess or lack of oil in the compressor and/or in the system.Pollution of the circuit by particles coming from previous unit failure (compressor damage). the following points must be strictly observed: . Protene S1 etc.) Note: Some of the failures (mechanical) could have been caused by the following reasons: . Flush the condenser . . Training DOCTR 039 AW 139 Compressor Failure: During maintenance of the system subsequently to a compressor failure. These tools are specific for the refrigerant technology. Training DOCTR 039 AW 139 Special Tooling and Ingredients Beside the Break out box and the Failure Read out Box. These extra tools can be obtained at your authorized local suppliers in accordance with the laws in force in your country. SEE TABLE NEXT PAGE LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 391 . moreover standard mechanic tools are also required. the following listed tools are necessary for the maintenance of the Refrigeration System. Belt Tensiometer Y Y Local market Refrigerant skin Temp. closing taps LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 392 .Training DOCTR 039 AW 139 P/N Description Required Required for field for repair maintenance Local market Servicing valve command device Y (LP-HP port connection taps) Local market R134a Refrigeration Y Y Management unit for recovering/charging 35494-00 or Special tool for servicing valve Y Local market removal Local market LP 0-10bar+HP 10-30bar Service Y Pressure Gauge / Manifold Local market Multi-meter Y Y Local market Electronic R134a refrigerant leak Y Y detector Local market Comp. Sensors Y Y (thermo-couples) Local market Various refrigerant connection Y Y hoses. or any information storage and retrieval system. der Herstellung von Aufnahmen und sämtlicher anderer Formen der Speicherung und Wiedergabe. Tous droits réservés. électronique ou mécanique y compris photocopies. LIEBHERR-AEROSPACE TOULOUSE January 2009 Issue 1 TECHNICAL SERVICES 393 . ohne zuvor die schriftliche Genehmigung der Liebherr-Aerospace Toulouse erhalten zu haben.Training DOCTR 039 AW 139  Liebherr-Aerospace Toulouse 2006. Kein Teil dieses Dokumentes darf in irgendwelcher Form wiedergegeben oder unter Verwendung irgendwelcher Übermittlungsmittel übermittelt werden. einschliesslich der Herstellung von Photokopien. recording. Alle Rechte vorbehalten.  Liebherr-Aerospace Toulouse 2006. without prior written permission from Liebherr-Aerospace Toulouse. All rights reserved. electronic or mechanical. Aucune partie de ce document ne peut être reproduite ou transmise sous quelque forme que ce soit ou par n’importe quel moyen de reproduction ou transmission. 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