Safran PILATUS PC12 M19 Manual

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WITH ILLUSTRATED PARTS LIST

DIRECT DRIVE COMPRESSOR MODULE

CONDENSER MODULE w/RECEIVER DRYER

AXIAL CONDENSER FAN

LEFT HAND EVAPORATOR MODULE

RIGHT HAND EVAPORATOR MODULE

ATA SPECIFICATION

Page | 1

SYSTEM DESCRIPTION AND

OPERATION MANUAL

PILATUS PC12 M19

R-134a AIR CONDITIONING SYSTEM COMPONENTS:

Original Release

12037 N Highway 99

Seminole, OK 74868

Phone (405) 382-0731

www.enviro-ok.com

passenger

www.safran‐

1150950-3

(Supersedes 1150950-2)

1150970-1

1250435-30

1150900-2

1150910-2

21-00-60

ATA 21‐00‐60

‐solutions.com

Table of Contents

Summary of Contents for Safran PILATUS PC12 M19

Page 1 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com SYSTEM DESCRIPTION AND OPERATION MANUAL WITH ILLUSTRATED PARTS LIST PILATUS PC12 M19 R-134a AIR CONDITIONING SYSTEM COMPONENTS: DIRECT DRIVE COMPRESSOR MODULE 1150950-3 (Supersedes 1150950-2) CONDENSER MODULE w/RECEIVER DRYER 1150970-1 AXIAL CONDENSER FAN 1250435-30...
Page 3: Table 1 Record Of Revisions
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com Table 1 Record of Revisions DESCRIPTION OF CHANGE DATE APPROVAL ORIGINAL RELEASE 6/24//20 Copyright © 2020 Original Release ATA 21‐00‐60 Page | 3 ...
Page 4: Table Of Contents
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com TABLE OF CONTENTS 1. MANUAL INTRODUCTION .......................... 7 1.1. General introduction (How to Use): ...................... 7 1.2. Acronyms, Abbreviations, and Symbols: .................... 8 1.3. Standard Torque Values: .......................... 9 1.4. Documents required: .......................... 9 2. SYSTEM DESCRIPTION AND OPERATION ...................... 1 0 2.1. General: .............................. 1 0 ...
Page 5 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 8.1. General: .............................. 3 0 8.2. Condenser Module Repair Procedures: .................... 3 0 8.3. Evaporator Module Assembly Repair Procedures: ................ 3 2 9. ASSEMBLY .............................. 3 4 9.1. General: .............................. 3 4 9.2. ...
Page 6 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com LIST OF ILLUSTRATIONS Figure 1 VCS Refrigerant Schematic ....................20 Figure 2 1150900-2 (Left) & 1150910-2 (Right) (1150910-2 Shown) ........... 39 Figure 3 1150970-1 Condenser Module ....................41 LIST OF TABLES Table 1 Record of Revisions ........................
Page 7: Manual Introduction
1.1. General introduction (How to Use): 1.1.1. This system description and operation manual (SDOM) covers the requirements for field servicing the R-134A air conditioning system for the Pilatus PC12 M19 aircraft. This document includes component descriptions, servicing, maintenance, inspection requirements and an illustrated parts list.
Page 8: Acronyms, Abbreviations, And Symbols
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 1.2. Acronyms, Abbreviations, and Symbols: • Component Maintenance Manual • Air Transport Association • Illustrated Parts Listing • Vapor Cycle System • Safety Data Sheet •...
Page 9: Standard Torque Values
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 1.3. Standard Torque Values: Table 2 Standard Torque Values TYPE FASTENER DESCRIPTION/LOCATION TORQUE .25-28 SET SCREW EVAPORATOR BLOWER WHEEL 12-15 IN LBS 6-32 SCREW ALL LOCATIONS...
Page 10: System Description And Operation
2. SYSTEM DESCRIPTION AND OPERATION 2.1. General: 2.1.1. The air conditioning system installed on the Pilatus PC12 M19 Aircraft is not considered a primary flight system. However, an air conditioning system does perform the important function of providing passenger and flight crew comfort during aircraft movement on the ground and while in flight.
Page 11: System Description And Operation
SAE standard J2210 and SAE standard J2099 for refrigerant purity. 2.2. System Description and Operation: 2.2.1. The cabin cooling system installed in the Pilatus PC12 M19 Aircraft operates using a closed vapor cycle concept using refrigerant R-134A as the heat absorption media. The R- 134A air conditioning system cools the aircraft in a similar manner as systems found in an automobile or home.
Page 12: System Component Description And Operation
Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 2.3. System Component Description and Operation: The R-134A air conditioning system installed on the Pilatus PC12 M19 Aircraft uses the following major system components:  Direct Drive Compressor Module 1150950-3 (Supersedes 1150950-2) ...
Page 13 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 2.3.2. CONDENSER COIL ASSEMBLY: The condenser coil assembly is an aluminum micro- channel type. The coil heat rejection is 24,650 BTUH based on a 104°F inlet temperature. This assembly requires airflow of 900 CFM for proper operation. Coil face areas must be unrestricted at all times or system performance degradation will occur.
Page 14 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 2.3.3.2. BLOW ER MOTOR: The blower motor operates on 28 VDC with a rated current draw of 18 AMPS Max. and has a design RPM of 2170 - 4800. The blower motor is a brushless design with an integrated controller and was selected for its efficiency, excellent controllability, long life and low vibration at high speeds.
Page 15: Testing And Fault Isolation
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com TESTING AND FAULT ISOLATION 3. TESTING AND FAULT ISOLATION 3.1. General: 3.1.1 Testing and Fault Isolation of the R-134A Air Conditioning System may be necessary if the system does not operate and/or perform in accordance with information contained herein.
Page 16 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com • Thread sealant primer, PN 7471 (Loctite) • Thread sealant, PN 569 (Loctite) • Hose adapter (1/2 in. male acme to ¼ in. female flare) 3.2.3.1.
Page 17: Fault Isolation (Trouble-Shooting)
Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 3.2.3.11. Apply soapy leak check fluid to each fitting connection. If leaks are detected, attempt to tighten fitting without over tightening. If leak cannot be corrected with tightening, system must be evacuated (refer to Servicing, Section 13) and then fitting must be disconnected and new thread sealant applied.
Page 18: Table 4 Trouble-Shooting
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com Table 4 Trouble-shooting INDICATION PROBABLE CAUSE POSSIBLE SOLUTION A. No System Power 1. Ground power not connected 1. Plug in ground power cart 2. Aircraft power switch off 2.
Page 19 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com INDICATION PROBABLE CAUSE POSSIBLE SOLUTION F. Compressor Assembly Will 1. Circuit Breaker failed or off 1. Energize or replace Not Operate 2. System Over Charged/Over 2.
Page 20: System Plumbing Diagram
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com PLUMBING DIAGRAM 4. SYSTEM PLUMBING DIAGRAM 4.1. R-134A Refrigerant Flow Schematic: 4.1.1. The following schematic shows an air conditioning system and its associated components as well as the flow of the R-134A refrigerant.
Page 21: Disassembly
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com DISASSEMBLY 5. DISASSEMBLY 5.1. General: WARNING: SERVICE TECHNICIANS ARE ADVISED TO OBSERVE STANDARD SAFETY PRECAUTIONS, SUCH AS WEARING PERSONAL SAFETY GEAR, TO PREVENT INJURY WHILE PERFORMING SERVICE TO THE UNIT.
Page 22: Condenser Module Disassembly Procedures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com NOTE: Do not disassemble the parts unnecessarily. 5.1.7. Refer to Illustrated Parts Listing (IPL) for figure/item numbers (Section 11). 5.1.8. Tools, fixtures, equipment, or consumable items required: •...
Page 23: Evaporator Module Assembly Disassembly Procedures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 5.3. Evaporator Module Assembly Disassembly Procedures 5.3.1. Removal of Blower Motor/Blower Wheel 5.3.1.1. Remove 4 screws and washers securing the motor mounting plate to the scroll.
Page 24: Cleaning Procedures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com CLEANING 6. CLEANING PROCEDURES 6.1. General: 6.1.1. This section details the procedures required to perform certain cleaning functions. The components listed have certain cleaning procedures associated with them, however these procedures are in no way an all-encompassing list of what may be required.
Page 25: Condenser Module Cleaning Procedures
Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 6.2. Condenser Module Cleaning Procedures: 6.2.1. The following components of the Condenser Module will require periodic cleaning (refer to the Inspection Schedule in section 7 for time intervals). This is in no way an all- encompassing list.
Page 26: Evaporator Module Assembly Cleaning Procedures
Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 6.3. Evaporator Module Assembly Cleaning Procedures: 6.3.1. The following components of the Evaporator Module Assembly will require periodic cleaning (refer to the Inspection Schedule in section 7 for time intervals) •...
Page 27: Inspection Schedule
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com CHECK (INSPECTION SCHEDULE) 7. INSPECTION SCHEDULE 7.1. Condenser Module Assembly Inspection Schedule: NOTE: This is the recommended visual inspection schedule for the Condenser Module Assembly.
Page 28: Evaporator Module Assembly Inspection Schedule
Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 7.2. Evaporator Module Assembly Inspection Schedule: NOTE: This is the recommended visual inspection schedule for the Evaporator Module Assembly. Adherence to this schedule will ensure that all components of the assembly are in accordance with the manufacturer’s specifications and is necessary to detect structural failure, deterioration or damage, and to...
Page 29 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com returned for repair or overhaul. Table 7 Compressor Inspection Component Type Inspection Required Times Electrical connections Inspect insulation for cracks or deterioration. 12 Months Inspect for leaks and/or abrasion.
Page 30: Repair Procedures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com REPAIRS 8. REPAIR PROCEDURES 8.1. General: 8.1.1. Refer to Illustrated Parts Listing (IPL) for figure/item numbers. 8.1.2. The condenser fan and compressor assembly do not contain any field replaceable components, therefore repair procedures are not provided for these assemblies.
Page 31 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 8.2.1.1. Receiver Dryer Assembly The receiver dryer assembly can, over time, become damaged. The component can also become contaminated due to damaged, opened, cracked, or ruptured lines or hoses.
Page 32: Evaporator Module Assembly Repair Procedures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 8.3. Evaporator Module Assembly Repair Procedures: 8.3.1. The following components may require periodic repair and/or replacement: • Evaporator Coil • Evaporator Housing Assembly • Blower Assembly •...
Page 33 12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 8.3.1.3.1. If blower motor wheel is damaged, such as having bent or cracked blades, removal and replacement is required. 8.3.1.3.2. If blower motor scroll is damaged in any way, the entire Evaporator Module Assembly must be removed and sent to Enviro Systems for repair.
Page 34: Assembly
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com ASSEMBLY 9. ASSEMBLY 9.1. General: 9.1.1. Refer to Illustrated Parts Listing (IPL) during assembly procedures for figure/item numbers. 9.1.2. The condenser fan and compressor assembly do not contain any field replaceable components, therefore assembly procedures are not provided for these assemblies.
Page 35: Condenser Module Assembly Procedures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 9.1.6. Tools, fixtures, equipment, or consumable items required • Small hand tools and socket set • Gates Sonic Tension Meter 508C or equivalent • Shop air, 40 PSIG max •...
Page 36: Evaporator Module Assembly Procedures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 9.3. Evaporator Module Assembly Procedures 9.3.1. Assembly of Expansion Valve 9.3.1.1. Using a wire brush and cleaning solvent, completely remove old thread sealant. Apply a thin layer of thread sealant primer to fitting threads.
Page 37: Special Tools/Equipment
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 10. SPECIAL TOOLS/EQUIPMENT 10.1. General: 10.1.1. This section describes the necessary tools and test equipment required to perform maintenance, functional testing, troubleshooting, and repair procedures. Equivalent test equipment may be substituted only if it meets the listed equipment specifications.
Page 38: Illustrated Parts Listing
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com ILLUSTRATED PARTS LIST 11. ILLUSTRATED PARTS LISTING 11.1. Introduction: This Illustrated Parts Listing (IPL) is intended for use during testing and isolation, disassembly, cleaning, check (inspection), repair, assembly, and issuing the replaceable equipment components as well as in identification of new and reclaimed parts.
Page 39: Figure 2 1150900-2 (Left) & 1150910-2 (Right) (1150910-2 Shown)
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com Figure 2 1150900-2 (Left) & 1150910-2 (Right) (1150910-2 Shown) Copyright © 2020 Original Release ATA 21‐00‐60 Page | 39 ...
Page 40: Table 7 Evaporator Parts Listing
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com Table 8 Evaporator Parts Listing ITEM PART NUMBER DESCRIPTION BLOWER/MOTOR ASSEMBLY USED ON LEFT EVAPORATOR 1150920-1 ASSEMBLY PART NUMBER 1150900-2 BLOWER/MOTOR ASSEMBLY USED ON RIGHT EVAPORATOR...
Page 41: Figure 3 1150970-1 Condenser Module
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com Figure 3 1150970-1 Condenser Module Copyright © 2020 Original Release ATA 21‐00‐60 Page | 41 ...
Page 42: Table 8 Condenser Module Parts Listing
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com Table 9 Condenser Module Parts Listing ITEM PART NUMBER DESCRIPTION 1134275-23 RECEIVER-DRYER ASSEMBLY QS100M36H CLAMP, 2.50 DIA. – WORM 1150973-3 HOSE ASSEMBLY, R-134A 1133842-725-225 SLEEVE, SILICONE...
Page 43: Special Prodecures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com SPECIAL PROCEDURES 12. SPECIAL PRODECURES 12.1. General 12.1.1. Reclaiming the system refrigerant charge is required on systems before system removal, after an accidental line break, component failure, or when the system has excessive leaks. Due to the chemical nature of the refrigerant, every precaution must be taken to protect the service personnel from accidental exposure to the refrigerant.
Page 44: Evacuating The System
Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 12.3. Evacuating the system Note: The system must be evacuated for a minimum of 45 minutes to remove air and moisture, which can cause the system to have less than optimal performance.
Page 45: Flushing The System (Use Flushing Kit Part Number K1134100-500)
Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 12.5. Flushing the system (Use flushing kit part number K1134100-500) 12.5.1. System flushing is required only when the system has experienced a catastrophic failure of the compressor or receiver dryer. In addition, examination of the system refrigerant lubricant should be performed during component replacement.
Page 46: Table 9 Typical Operating Pressures
Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 12.5.13. Remove the compressor flushing adapter and reconnect the lines to the compressor drive assembly. 12.5.14. Remove the receiver dryer flushing adapter and install a new receiver dryer. 12.5.15. Remove the expansion valve flushing adapters and reinstall the expansion valves.
Page 47: Storage Procedures
12037 N Highway 99 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com STORAGE 13. STORAGE PROCEDURES 13.1. General: 13.1.1. This section defines the procedures and requirements necessary if the Compressor assembly is to be stored and not installed onto aircraft immediately. In addition, this section defines the procedures and requirements for operation on the aircraft during the cold winter months when the system is not typically needed or used.
Page 48: System Off-Season/On-Aircraft Functional Tests
Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com 13.2.4.2. Drain old oil into measuring cup to verify amount of oil being replaced. CAUTION: ONLY AN ENVIRO APPROVED TYPE OF OIL MAY BE USED IN THIS TYPE OF COMPRESSOR.
Page 49 Seminole, OK 74868 Phone (405) 382-0731 www.enviro-ok.com passenger www.safran‐ ‐solutions.com aircraft immediately, it is desirable that it be repackaged using the original Enviro Systems packaging. 13.4.1.4. If the component is removed from the original packaging and is not installed on the aircraft immediately and the original packaging is not available for repackaging, ensure that the component is packaged in the following manner.