You are on page 1of 232

NAVAIR 17-1-573

01 March 2009

GROUND SUPPORT EQUIPMENT MANUAL

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN

ENVIRONMENTAL CONTROL UNIT A/E32C-45A


PART NUMBER 1559AS400-1 GEC6

DISTRIBUTION STATEMENT C. Distribution authorized to US Government agencies and their contractors to protect publications required for official use or for administrative or operational purposes only, determined on 01 March 2009. Other requests for this document shall be referred to Naval Air Systems Command, Code 6.7.6.2, 47123 Buse Rd, Patuxent River, MD 20670 DESTRUCTION NOTICE: For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published by Direction of the Commander, Naval Air Systems Command

0817LP1091347

NAVAIR 17-1-573
01 MARCH 2009 NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES List of Current Changes Original ..........................0 ............................. 01 MARCH 2009

PAGE A

Only those work packages/pages assigned to the manual are listed in this index. Insert Changes as issued. Dispose of superseded work packages and deleted work packages. If change pages are issued to a work package, insert the changed pages in the applicable work packages. The portion of the text affected in a change or revised work package is indicated by change bars or the change symbol R in the outer margin of each column of text. Changes to illustrations are circled and/or indicated by pointing hands or change bars as applicable. Total number of pages in this manual is 232 consisting of the following: WP Number Title Page Page A........................................Numerical Index of Effective Work Packages TPDR..........................................List of Technical Publication Deficiency Reports Incorporated HMWS ........................................Warnings Applicable to Hazardous Materials Work Package 001 00 ................Alphabetical Index Work Package 001 01 ................Numerical Index of Part Numbers Work Package 001 02 ................Index of Reference Designators Work Package 002 00 ................Introduction Work Package 003 00 ................Description and Leading Particulars Work Package 004 00 ................Principles of Operation Work Package 005 00 ................Preparation for Use, Storage, and Shipment Work Package 006 00 ................Operating Instructions Work Package 007 00 ................Testing and Troubleshooting Work Package 008 00 ................Leak Test Work Package 009 00 ................Discharge / Recovery Work Package 010 00 ................Evacuation Work Package 011 00 ................Charging Work Package 012 00 ................Pressure Testing Work Package 013 00 ................Indoor Thermostat, Panels, and Covers Work Package 014 00 ................Chassis Assembly Work Package 015 00 ................Refrigeration Assembly Work Package 016 00 ................Control Box Assembly Work Package 017 00 ................Indoor Blower Assembly Work Package 018 00 ................Frame Assembly Work Package 019 00 ................Unit Wiring Inspection, Test, Repair, and Installation Work Package 020 00 ................Illustrated Parts Breakdown Title

NAVAIR 17-1-573
01 MARCH 2009 WP/Page No. Change No. WP/Page No. Change No. WP/Page No.

PAGE B
Change No.

(Manual) Title ................0 A ....................................0 TPDR-1..........................0 HMWS-1 ........................0 001 00............................0 002 00............................0 003 00............................0 004 00............................0 005 00............................0

006 00........................... 0 007 00........................... 0 008 00........................... 0 009 00........................... 0 010 00........................... 0 011 00........................... 0 012 00........................... 0 013 00........................... 0 014 00........................... 0

015 00 ...........................0 016 00 ...........................0 017 00 ...........................0 018 00 ...........................0 019 00 ...........................0 020 00 ...........................0

NAVAIR 17-1-573
01 MARCH 2009

TPDR-1

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN TECHNICAL PUBLICATION DEFICIENCY REPORTS ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

The TPDRs listed below have been incorporated in this issue. IDENTIFICATION NUMBER None LOCATION

NAVAIR 17-1-573
01 MARCH 2009

TPDR-2

THIS PAGE HAS INTENTIONALLY BEEN LEFT BLANK.

NAVAIR 17-1-573
01 MARCH 2009

HMWS-1

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN WARNINGS APPLICABLE TO HAZARDOUS MATERIALS ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

1.1 1.2

INTRODUCTION. Warnings for hazardous materials listed in this manual are designed to warn personnel of hazards associated with such items when they come in contact with them by actual use. Additional information related to hazardous materials is provided in OPNAVINST 5100.23, Navy Occupational Safety and Health (NAVOSH) Program Manual, NAVSUPINST 5100.27, Navy Hazardous Material Control Program, and the DoD 6050.5, Hazardous Materials Information System (HMIS) series publications. For each hazardous material used within the Navy, a Material Safety Data Sheet (MSDS) must be provided and available for review by users. Consult your local safety and health staff concerning any questions regarding hazardous materials, MSDSs, personal protective equipment requirements, and appropriate handling and emergency procedures and disposal guidance. Under the heading HAZARDOUS MATERIALS WARNINGS, complete warnings, including related icon(s) and a numeric identifier, are provided for hazardous materials used in this manual. Each hazardous material is assigned only one numeric identifier. Since only those hazardous materials addressed in this manual will be listed, the numeric identifiers may not appear in sequential order. In the text of the manual, the caption WARNING is not used for hazardous material warnings. Hazards are cited with appropriate icon(s), the nomenclature of the hazardous material, and the numeric identifier that relates to the complete warning. Users of hazardous materials shall refer to the complete warnings. EXPLANATION OF HAZARDOUS MATERIALS ICONS Biohazard The abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health. Cryogenic The symbol of a hand in a block or ice shows that the material is extremely cold and can injure human skin or tissue. Eye Hazard The symbol of a person wearing face shield shows that the material will injure eyes. Chemical / Corrosive The symbol of a liquid dripping onto a hand shows that the material will cause burns or irritation to human skin or tissue. Explosive Hazard This rapidly expanding symbol shows that the material may explode if subjected to hightemperature, sources of ignition, or high pressure. Fire Hazard The symbol of a fire shows that the material may ignite and cause burns.

1.3

1.4

NAVAIR 17-1-573
01 MARCH 2009
Poison The symbol of a skull and crossbones shows that the material is poisonous or is a danger to life. Breathing Hazard The symbol of a human figure in a cloud shows that the material vapors present a danger to life or health.

HMWS-2
Radiation The symbol of three circular wedges shows that a material emits radioactive energy and can injure human tissue or organs.

NAVAI 17-1-573
01 MARCH 2009

HMWS-3

REFRIGERANT - R134A

HAZARDOUS MATERIALS WARNINGS INDEX HAZARDOUS MATERIAL WARNING REFRIGERANT, R-134A, CAN CAUSE BURNS AND/OR FREEZING OF SKIN IF REFRIGERANT LIQUID AND/OR VAPOR CONTACTS SKIN. WEAR 1 APPROVED GLOVES. REFRIGERANT IS UNDER PRESSURE, WEAR APPROVED GOGGLES OR FACE MASK TO PROTECT EYES WHEN HANDLING. INHALATION OF REFRIGERANT MAY CAUSE IRRITATION OR BURNING OF RESPIRATORY SYSTEM AND/OR DIZZINESS, HEADACHE, AND NAUSEA. USE IN WELL VENTILATED AREA. IF INHALATION OCCURS GO TO AREA WITH FRESH AIR. IF SYMPTOMS PERSIST SEEK MEDICAL ATTENTION. COMPRESSED AIR IS USED FOR ANY CLEANING AND DRYING OPERATION. DO NOT EXCEED 15 PSIG AT THE NOZZLE. CONTACT WITH AIR STREAM CAN CUT SKIN. EYES CAN BE PERMANENTLY DAMAGED BY CONTACT WITH LIQUIDS OR LARGE PARTICLES PROPELLED BY COMPRESSED AIR. INHALATION OF AIR BLOWN PARTICLES OR SOLVENT VAPOR CAN IRRITATE AND DAMAGE RESPIRATORY SYSTEM. WHEN USING COMPRESSED AIR FOR CLEANING OR DRYING WEAR APPROVED GLOVES AND GOGGLES OR FACE SHIELD. GENERAL PURPOSE DETERGENTS CAN CAUSE GENERAL SKIN IRRITATION AND MORE SEVERE IRRITATION TO EYES AND UPPER RESPIRATORY SYSTEM. AVOID ORAL INGESTION OF DETERGENT. IT CAN IRRITATE CONTACTED AREAS AND CAUSE NAUSEA, VOMITING AND DIARRHEA. WEAR APPROVED PROTECTIVE GLOVES AND GOGGLES OR FACE SHIELD. CLEANING SOLVENT, MIL-PRF-680, TYPE III IS COMBUSTIBLE NEAR SPARKS, OPEN FLAMES, WELDING AREAS, HOT SURFACES, OTHER SOURCES OF IGNITION, OR WHILE SMOKING. INHALATION MAY CAUSE IRRITATION OR BURNING OF RESPIRATORY SYSTEM AND DIZZINESS. CONTAC WITH EYES/FACE/SKIN/ MAY CAUSE IRRITATION OR BURNING. INGESTION MAY CAUSE IRRITATION OR BURNING OF DIGESTIVE SYSTEM. USE GLOVES AND GOGGLES TO SHIELD FACE WHEN HANDLING.

COMPRESSED AIR

GENERAL PURPOSE DETERGENTS, MIL-D-16791

CLEANING SOLVENT, MIL-PRF-680 TYPE III

NAVAIR 17-1-573
01 MARCH 2009
INDEX

HMWS-4
HAZARDOUS MATERIAL WARNING ROBINAIR VACUUM PUMP OIL IS A HYDROTREATED HEAVY PARAFFINIC DISTILLATE. EXPOSURE MAY CAUSE TEMPORARY IRRITATION TO THE EYES. WEAR APPROVED GOGGLES OR FACE SHIELD. PROLONGED OR REPEATED EXPOSURE MAY CAUSE SLIGHT SKIN IRRITATION. USE CHEMICAL RESISTANT GLOVES AND LONG SLEEVE SHIRT. WASH HANDS/EXPOSED SKIN WITH SOAP AND WATER AFTER HANDLING.

ROBINAIR VACUUM PUMP OIL, 13203

NAVAI 17-1-573
01 MARCH 2009

HMWS-5

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

001 00
Page 1 of 2

ALPHABETICAL INDEX ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

Title WP Number Abbreviations........................................................................................ WP 002 00 Accumulator Assembly......................................................................... WP 015 00 Air Circulation Only Mode .................................................................... WP 006 00 Alphabetical Index ................................................................................ WP 00100 Arrangement and Use of Manual ......................................................... WP 002 00 Charging of ECU Refrigeration Assembly ........................................... WP 011 00 Compressor.......................................................................................... WP 015 00 Compressor / Control Box Section ...................................................... WP 003 00 Compressor Short Cycle Protection .................................................... WP 004 00 Condensate Drain ............................................................................... WP 003 00 Control Box Assembly ......................................................................... WP 003 00 Control Box Assembly .......................................................................... WP 014 00 Control Box Assembly .......................................................................... WP 016 00 Controls and Indicators ....................................................................... WP 006 00 Cool Cycle Power Distribution ............................................................. WP 003 00 Cooling Cycle ....................................................................................... WP 004 00 Cooling Mode ...................................................................................... WP 006 00 Corrosion Prevention and Control ....................................................... WP 002 00 Covers and Panels ............................................................................... WP 013 00 Defrost Cycle ....................................................................................... WP 003 00 Defrost Cycle........................................................................................ WP 004 00 Defrost Cycle Power Distribution ......................................................... WP 003 00 Discharge / Recovery of Refrigerant ................................................... WP 009 00 Evacuation of Refrigeration Assembly Accumulator ............................ WP 010 00 Expendable Materials and Durable Items Required ........................... WP 002 00 Filter-Dryer .......................................................................................... WP 015 00 Frame Assembly .................................................................................. WP 018 00 General Description.............................................................................. WP 003 00 General Theory of ECU........................................................................ WP 004 00 Group Assembly Parts List (GAPL)...................................................... WP 002 00 Hazardous Materials Warnings ............................................................ HMWS-1 Heat Cycle Power Distribution ............................................................. WP 003 00 Heater Cutout Switch .......................................................................... WP 014 00 Heating Cycle ....................................................................................... WP 004 00 Heating Element................................................................................... WP 014 00 Heating Mode ...................................................................................... WP 006 00 High Pressure Cutout Switch ............................................................... WP 015 00 Illustrated Parts Breakdown ................................................................. WP 020 00 Indoor Air Flow Section ....................................................................... WP 003 00 Indoor Blower Assembly....................................................................... WP 014 00 Indoor Blower Assembly....................................................................... WP 017 00 Indoor Coil Assembly ........................................................................... WP 015 00

NAVAIR 17-1-573
01 MARCH 2009 Title WP Number Indoor Thermostat ............................................................................... WP 003 00 Indoor Thermostat ................................................................................ WP 004 00 Introduction........................................................................................... WP 003 00 Introduction to the Illustrated Parts Breakdown ................................... WP 002 00 Key Features and Characteristics ........................................................ WP 003 00 Leading Particulars............................................................................... WP 003 00 Leak Testing......................................................................................... WP 008 00 List of Technical Publications............................................................... TPDR-1 Low-Pressure Cutout Switch ............................................................... WP 015 00 Motor and Fan Assembly ..................................................................... WP 014 00 Numerical Index of Effective Work Packages/Pages........................... Page A Numerical Index of Part Numbers ........................................................ WP 001 01 Numerical Index of Reference Designations........................................ WP 001 02 Operating Instructions ......................................................................... WP 004 00 Operation, Three Cycles ..................................................................... WP 004 00 Outdoor Coil Assembly......................................................................... WP 015 00 Ozone Delpleting Substances.............................................................. WP 002 00 Panels and Covers .............................................................................. WP 003 00 Power Distribution ................................................................................ WP 003 00 Preoperational Checkout ..................................................................... WP 006 00 Preparation for Shipment ..................................................................... WP 005 00 Preparation for Storage ........................................................................ WP 005 00 Preparation for Use .............................................................................. WP 005 00 Pressure Testing ................................................................................. WP 012 00 Primary Power...................................................................................... WP 003 00 Purpose and Scope of Manual............................................................. WP 002 00 Quality Assurance Requirements......................................................... WP 002 00 Record of Applicable Technical Directives........................................... WP 002 00 Reference Material ............................................................................... WP 002 00 Reversing Valve .................................................................................. WP 004 00 Reversing Valve Assembly................................................................... WP 015 00 Rotolock and Coupling Nuts Fittings .................................................... WP 015 00 Safety ................................................................................................... WP 002 00 Secondary Power ................................................................................. WP 003 00 Setup of Robinair Unit ......................................................................... WP 009 00 Shutdown ............................................................................................ WP 006 00 Support Equipment, TMDE, and Special Tools Required.................... WP 002 00 System Airflow ..................................................................................... WP 003 00 System Description ............................................................................. WP 003 00 Temperature Setting ............................................................................ WP 006 00 Troubleshooting.................................................................................... WP 007 00 Tube Assemblies.................................................................................. WP 015 00 Unit Wiring............................................................................................ WP 019 00 Warnings and Cautions Applicable to Hazardous Materials ................ WP 002 00

001 00
Page 2 of 2

NAVAIR 17-1-573
01 MARCH 2009

001 01
Page 1 of 4

NUMERICAL INDEX OF PART NUMBERS ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

PART NO. 154-211111-22000AA 1559AS127-2

WORK PACKAGE / FIGURE NO. / INDEX NO. 020 00 / 9 / 6 020 00 / 4 / 13 020 00 / 4 / 17 020 00 / 4 / 19 020 00 / 4 / 27 020 00 / 4 / 29 020 00 / 4 / 33 020 00 / 4 / 36

PART NO. 1559AS173-1 1559AS173-2 1559AS173-3 1559AS177-1 1559AS182-1 1559AS242-1 1559AS260-1 1559AS262-1 1559AS265-1 1559AS266-2 1559AS267-1 1559AS281-1 1559AS282-1 1559AS283-3 1559AS294-1 1559AS299-1 1559AS400-1 1559AS401-1 1559AS402-1 1559AS403-1 1559AS404-1 1559AS405-1 1559AS412-1 1559AS413-1 1559AS414-1 1559AS415-1 1559AS416-1

WORK PACKAGE / FIGURE NO. / INDEX NO. 020 00 / 5 / 2 020 00 / 9 / 45 020 00 / 9 / 44 020 00 / 5 / 3 020 00 / 9 / 49 020 00 / 9 / 23 020 00 / 9 / 25 020 00 / 3 / 9 020 00 / 3 / 4 020 00 / 3 / 1 020 00 / 3 / 2 020 00 / 3 / 15 020 00 / 1 / 3 020 00 / 1 / 1 020 00 / 1 / 2 020 00 / 3 / 3 020 00 / 9 / 43 020 00 / 1 / REF 020 00 / 11 / REF 020 00 / 5 / 1 020 00 / 11 / 1 020 00 / 11 / 2 020 00 / 11 / 3 020 00 / 11 / 4 020 00 / 11 / 5 020 00 / 11 / 6 020 00 / 11 / 7 020 00 / 11 / 8 020 00 / 11 / 9

1559AS136-1 1559AS142-1

020 00 / 9 / 3 020 00 / 7 / 7 020 00 / 12 / 2 020 00 / 13 / 2 020 00 / 7 / 2

1559AS148 1559AS148-1 1559AS159-3 1559AS159-4 1559AS159-5 1559AS159-6 1559AS159-7 1559AS160-1 1559AS160-2 1559AS169-2 1559AS171-1 1559AS171-2

020 00 / 8 / 5 020 00 / 13 / 4 020 00 / 6 / 4 020 00 / 8 / 6 020 00 / 6 / 5 020 00 / 6 / 7 020 00 / 8 / 9 020 00 / 6 / 15 020 00 / 6 / 14 020 00 / 13 / 5 020 00 / 8 / 4 020 00 / 6 / 3 020 00 / 7 / 3 020 00 / 7 / 6 020 00 / 5 / 10 020 00 / 5 / 32

NAVAIR 17-1-573
01 MARCH 2009
WORK PACKAGE / FIGURE NO. / INDEX NO. 020 00 / 11 / 10 020 00 / 11 / 11 020 00 / 9 / 12 020 00 / 9 / 22 020 00 / 9 / 29 020 00 / 9 / 32 020 00 / 9 / 36 1559AS427-2 020 00 / 10 / 2 020 00 / 11 / 12 020 00 / 2 / 14 020 00 / 2 / 18 020 00 / 2 / 22 020 00 / 2 / 4 020 00 / 2 / 7 020 00 / 5 / 8 020 00 / 9 / 19 020 00 / 9 / 26 020 00 / 9 / 8 1559AS427-3 020 00 / 2 / 10 020 00 / 2 / 12 020 00 / 2 / 29 020 00 / 2 / 5 020 00 / 2 / 8 1559AS427-4 1559AS428-1 020 00 / 9 / 17 020 00 / 9 / 4 020 00 / 1 / 3 020 00 / 4 / 11 020 00 / 5 / REF 1559AS430 1559AS434 1559AS438 1559AS439 1559AS441-1 1559AS441-2 1559AS444 1559AS444 1559AS445 1559AS446 020 00 / 5 / 11 020 00 / 8 / 1 020 00 / 5 / 7 020 00 / 5 / 28 020 00 / 5 / 24 020 00 / 5 / 15 020 00 / 5 / 16 020 00 / 6 / REF 020 00 / 6 / 1 020 00 / 5 / 18 1559AS518 1559AS484-1 1559AS496 1559AS500 1559AS515-1 1559AS483-1 1559AS482 1559AS481 1559AS469 1559AS470 1559AS474 1559AS474-1 1559AS457-1 1559AS457-2 1559AS458 1559AS462-14 1559AS462-18 1559AS462-22 1559AS462-24 1559AS462-37 1559AS462-42 1559AS462-46 1559AS462-8 1559AS467 1559AS467-1 1559AS452-1 1559AS453 1559AS456

001 01
Page 2 of 4
WORK PACKAGE / FIGURE NO. / INDEX NO.

PART NO. 1559AS420-1 1559AS424-1 1559AS427-1

PART NO. 1559AS449 1559AS450-1

020 00 / 6 / 13 020 00 / 12 / 4 020 00 / 7 / 4 020 00 / 4 / 16 020 00 / 5 / 30 020 00 / 13 / 3 020 00 / 5 / 9 020 00 / 8 / 7 020 00 / 8 / 8 020 00 / 12 / 3 020 00 / 6 / 8 020 00 / 6 / 10 020 00 / 6 / 12 020 00 / 8 / 11 020 00 / 6 / 9 020 00 / 8 / 10 020 00 / 6 / 11 020 00 / 6 / 6 020 00 / 5 / 31 020 00 / 2 / 17 020 00 / 2 / 19 020 00 / 5 / 4 020 00 / 7 / 5 020 00 / 2 / 32 020 00 / 1 / 2 020 00 / 4 / REF 020 00 / 4 / 38 020 00 / 1 / REF 020 00 / 4 / 37 020 00 / 1 / REF 020 00 / 4 / 28 020 00 / 9 / REF 020 00 / 9 / 40 020 00 / 5 / 20 020 00 / 9 / 20 020 00 / 10 / REF 020 00 / 4 / 26 020 00 / 4 / 34

NAVAIR 17-1-573
01 MARCH 2009
WORK PACKAGE / FIGURE NO. / INDEX NO. 020 00 / 10 / 10 020 00 / 10 / 3 020 00 / 10 / 11 020 00 / 10 / 12 020 00 / 10 / 5 020 00 / 10 / 4 020 00 / 10 / 6 020 00 / 10 / 1 020 00 / 4 / 32 020 00 / 4 / 1 020 00 / 2 / 21 020 00 / 9 / 41 1559AS556-1 1559AS557-1 1559AS574-1 1559AS575-1 1559AS579-1 1559AS580-1 1559AS593-1 1559AS595-1 1559AS598-1 1559AS601 1559AS604 1559AS605-1 1559AS607 1559AS610 1559AS620-2 1559AS630-02 1559AS630-2 1559AS640 1559AS650 1559AS655-2 1559AS662 020 00 / 2 / 16 020 00 / 3 / REF 020 00 / 3 / 16 020 00 / 2 / 11 020 00 / 2 / 9 020 00 / 2 / 3 020 00 / 2 / 6 020 00 / 2 / 28 020 00 / 2 / 13 020 00 / 2 / 26 020 00 / 2 / 31 020 00 / 2 / 23 020 00 / 9 / 42 020 00 / 5 / 22 020 00 / 12 / REF 020 00 / 5 / 27 020 00 / 2 / 33 020 00 / 2 / 1 020 00 / 5 / 25 020 00 / 8 / 3 020 00 / 13 / 1 020 00 / 8 / 2 020 00 / 6 / 2 020 00 / 5 / 21 020 00 / 12 / 1 020 00 / 5 / 23 6X752 75-240301-2506AB 315-002 321P031A 350A035H16 35301 603-3F 2040QL2-43 2119 2166 224-010 3126-216 1559AS669 1559AS670 1559AS670-1 1559AS671-13 1559AS671-14 1559AS671-15 1559AS671-16 1559AS671-16 1559AS671-17 1559AS680-2 1559AS682 1599AS400-1

001 01
Page 3 of 4
WORK PACKAGE / FIGURE NO. / INDEX NO. 020 00 / 7 / REF 020 00 / 7 / 1 020 00 / 5 / 17 020 00 / 5 / 6 020 00 / 9 / 48 020 00 / 9 / 47 020 00 / 13 / REF 020 00 / 5 / 38 020 00 / 5 / 14 020 00 / 5 / 26 020 00 / 8 / REF 020 00 / 1 / 4 020 00 / 1 / 5 020 00 / 1 / 6 020 00 / 1 / 7 020 00 / 1 / 8 020 00 / 1 / 9 020 00 / 8 / 12 020 00 / 1 / 4 020 00 / 1 / 1 020 00 / 2 / REF 020 00 / 4 / 12 020 00 / 9 / 39 020 00 / 4 / 14 020 00 / 3 / 5 020 00 / 9 / 27 020 00 / 9 / 28 020 00 / 4 / 18 020 00 / 4 / 5 020 00 / 9 / 7 020 00 / 9 / 5 020 00 / 9 / 1 020 00 / 9 / 13 020 00 / 4 / 25 020 00 / 9 / 10 020 00 / 9 / 11 020 00 / 9 / 34 020 00 / 9 / 35

PART NO. 1559AS518-1 1559AS521 1559AS522 1559AS523 1559AS525-1 1559AS525-2 1559AS529-1 1559AS531 1559AS538-1 1559AS543-1 1559AS555-1

PART NO. 1559AS662-1 1559AS663 1559AS664 1559AS665 1559AS666-1 1559AS667-1 1559AS668

NAVAIR 17-1-573
01 MARCH 2009
WORK PACKAGE / FIGURE NO. / INDEX NO. 020 00 / 9 / 15 020 00 / 9 / 24 020 00 / 9 / 31 020 00 / 5 / 37 020 00 / 5 / 33 020 00 / 3 / 13 020 00 / 4 / 20 020 00 / 4 / 23 020 00 / 2 / 15 020 00 / 3 / 14 MIL-R-15624 CL1 MS**** MS20604-AS4T2 MS21316-36 MS21919WDG48 MS27183-10 020 00 / 2 / 30 020 00 / 5 / 29 020 00 / 2 / 27 020 00 / 3 / 10 020 00 / 5 / 19 020 00 / 10 / 9 020 00 / 3 / 12 020 00 / 4 / 3 020 00 / 4 / 7 020 00 / 5 / 36 MS27183-12 MS27183-42 MS35207-265 MS35338-44 020 00 / 5 / 13 020 00 / 3 / 7 020 00 / 3 / 6 020 00 / 10 / 8 020 00 / 3 / 11 020 00 / 4 / 4 MS35338-44 MS35338-44 MS35489-17 MS35489-17 MS35489-23 MS35489-6 MS35649-2252 MS35649-2312 020 00 / 4 / 8 020 00 / 5 / 35 020 00 / 9 / 33 020 00 / 9 / 37 020 00 / 9 / 38 020 00 / 4 / 35 020 00 / 4 / 9 020 00 / 5 / 12 MS90725-6 NO. 1357 SW4L-2030-010 MS4500-08-VF-10 MS51470-03 MS90725-3

001 01
Page 4 of 4
WORK PACKAGE / FIGURE NO. / INDEX NO. 020 00 / 5 / 5 020 00 / 9 / 14 020 00 / 9 / 2 020 00 / 9 / 16 020 00 / 3 / 8 020 00 / 10 / 7 020 00 / 4 / 2 020 00 / 5 / 34 020 00 / 4 / 6 020 00 / 2 / 24 020 00 / 4 / 10

PART NO. 812-8-KT79-KT81 97F5339 A22-391 AS21919WDG-3 AS21919WDG-8 C7988-1420 COMCO VINYL TUBING SIZE 31 ES500-1 LINACOUSTIC

PART NO. MS35649-2382 MS3600-03-VF-42

NAVAIR 17-1-573
01 MARCH 2009

001 02

NUMERICAL INDEX OF REFERENCE DESIGNATORS ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE DESIGNATOR

WP / TABLE Index No.

Part Number

B1 ............................................................019 00 / 1 ................................................TBD C1 ............................................................020 00 / 9 ................................................TBD DC ...........................................................020 00 / 9 ................................................TBD HR1-HR4 .................................................020 00 / 9 ................................................TBD K1 ............................................................020 00 / 9 ................................................TBD K2 ............................................................020 00 / 9 ................................................TBD K3 ............................................................020 00 / 9 ................................................TBD K4 ............................................................020 00 / 9 ................................................TBD K5 ............................................................020 00 / 9 ................................................TBD RV............................................................019 00 / 1 ................................................TBD S1 ............................................................020 00 / 9 ................................................TBD S2 ............................................................020 00 / 9 ................................................TBD S3 ............................................................020 00 / 4 ................................................TBD S4 ............................................................020 00 / 4 ................................................TBD S5 ............................................................020 00 / 9 ................................................TBD TB1 ..........................................................020 00 / 9 ................................................TBD TB2 ..........................................................020 00 / 9 ................................................TBD TB3 ..........................................................020 00 / 9 ................................................TBD

NAVAIR 17-1-573
01 MARCH 2009

001 02

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

002 00
Page 1 of 10

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN INTRODUCTION ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

Technical Manual, Pre-operational Checklist, Mobile Facility Program Environmental Control Unit A/E32C-45A .......................... NAVAIR 17-600-762-6-1 Technical Manual, Maintenance Requirements Manual Environmental Control Unit A/E32C-45A ......................................... NAVAIR 17-600-762-6-2 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................ NAVAIR 19-25-177 Department of Defense Standard Practice, Military Marking for Shipment and Storage...................................................................... MIL-STD-129 Operating Manual, Robinair Recovery, Recycling, and Recharging Unit................................................................................ Vendor Manual Navy Uniform Source, Maintenance, and Recoverability (SM&R) Codes ............................................................................................... NAVSUPINST 4423.29 Joint Regulation Governing the Use and Application of Uniform Source Maintenance and Recoverability Codes .............................. OPNAVINST 4410.2A Management of Ozone Depleting Substances ................................ OPNAVINST 5090.2 WP 002 00 - Introduction.................................................................. NAVAIR 17-1-573 WP 003 00 - Description and Leading Particulars ........................... NAVAIR 17-1-573 WP 005 00 - Preparation for Use, Storage, and Shipment .............. NAVAIR 17-1-573 WP 006 00 - Operation..................................................................... NAVAIR 17-1-573 WP 007 00 - Preventive Maintenance Checks and Services........... NAVAIR 17-1-573 WP 008 00 - Testing and Trouble Shooting ..................................... NAVAIR 17-1-573 WP 009 00 - Leak Test..................................................................... NAVAIR 17-1-573 WP 010 00 - Discharge / Recovery.................................................. NAVAIR 17-1-573 WP 011 00 - Evacuation................................................................... NAVAIR 17-1-573 WP 012 00 - Charging...................................................................... NAVAIR 17-1-573

NAVAIR 17-1-573
01 MARCH 2009
WP 013 00 - Pressure Test .............................................................. NAVAIR 17-1-573 WP 014 00 Indoor Thermostat, Panels, and Covers .................... NAVAIR 17-1-573 WP 015 00 - Chassis Assembly....................................................... NAVAIR 17-1-573 WP 016 00 - Refrigeration Assembly ............................................... NAVAIR 17-1-573 WP 017 00 - Control Box Assembly................................................. NAVAIR 17-1-573 WP 018 00 - Indoor Blower Assembly ............................................. NAVAIR 17-1-573 WP 019 00 - Frame Assembly ......................................................... NAVAIR 17-1-573 NAVAIR 17-1-573 WP 020 00 - Unit Wiring Inspection, Test, Repair, and Installation ........................................................................................ WP 021 00 Illustrated Parts Breakdown (IPB) .............................. NAVAIR 17-1-573 WP 022 00 - Illustrated Parts Breakdown ALPHABETICAL INDEX TITLE NAVAIR 17-1-573

002 00
Page 2 of 10

WP / Page Number

Abbreviations...............................................................................................002 00 / 4 Arrangement and Use .................................................................................002 00 / 3 Corrosion Prevention and Control (CPC)....................................................002 00 / 5 Expendable Materials and Durable Items Required ...................................002 00 / 7 Group Assembly Parts List (GAPL).............................................................002 00 / 8 Illustrated Parts Breakdown ........................................................................002 00 / 8 Ozone Depleting Substances......................................................................002 00 / 6 Purpose and Scope.....................................................................................002 00 / 3 Quality Assurance Requirements................................................................002 00 / 4 Record of Applicable Technical Directives..................................................002 00 / 5 Reference Material ......................................................................................002 00 / 5 Safety ..........................................................................................................002 00 / 5 Support Equipment, TMDE, and Special Tools. .........................................002 00 / 6 Warnings and Cautions Applicable To Hazardous Materials......................002 00 / 4

NAVAIR 17-1-573
01 MARCH 2009

002 00
Page 3 of 10

1.1 1.2

PURPOSE AND SCOPE. This technical manual provides information and procedures for operation and intermediate maintenance of the A/E32C-45A, part number 1559AS400-1, Environmental Control Unit (ECU) used on Navy/Marine Mobile Facilities (MF). Requisitioning and automatic distribution of NAVAIR technical publications. Procedures to be used by naval activities and other Department of Defense activities requiring NAVAIR technical manuals are defined in NAVAIR 00-25-100, Naval Air Systems Command Technical Manual Program. To automatically receive future changes and revisions to NAVAIR technical manuals, an activity must be established on the Automatic Distribution Requirements List (ADRL) maintained by the NAVAL Air Technical Data and Engineering Service Command (NATEC). To become established on the ADRL, notify your activity central publications librarian. If you activity does not have a library, you may establish your automatic distribution by contacting the Commanding Officer, NATEC, Attn: Distribution, NAS North Island, Bldg. 90, P.O. Box 357031, San Diego, CA 92135-7031. Annual reconfirmation of these requirements is necessary to remain on automatic distribution. Please use your NATEC assigned account number whenever referring to automatic distribution requirements. If additional or replacement copies of this manual are required with no attendant changes in the ADRL, they may be ordered by submitting a MILSTRIP requisition in accordance with (IN ACCORDANCE WITH) NAVSUP 485 to Routing Identifier Code (RIC) NFZ. MILSTRIP requisitions can be submitted through your supply office, Navy message, or SALTS to Defense Automated Address System (DAAS), or through the DAAS or NAVSUP web sites. For assistance with a MILSTRIP requisition, contact the Naval Inventory Control Pint (NAVICP) Publications and Forms Customer Service at DSN 442-2626 0r (215) 697-2626, Monday through Friday, 0700 to 1600 Eastern Time. Incorporation of manual changes. To incorporate a manual change, insert revised and added work packages (WP) into the basic publication. If change pages are issued to a work package, insert the changed pages in the applicable work packages. Destroy superseded WPs and pages ARRANGEMENT AND USE. Arrangement of manual. This manual consists of introductory material, WPs for performing maintenance on the ECU, and an Illustrated Parts Breakdown (IPB). Publication date. Publication date of this manual is the copy freeze date. The copy freeze date is the date after which further additions, deletions and changes are not included in the manual. Last minute corrections of obvious errors essential to safety or equipment performance will be incorporated after the freeze date. Additions, deletions, and changes accumulated after the copy freeze date shall be incorporated in the next change to the manual. Work package/manual revision and change dates. To check the status of any individual WP page, or a WP as a whole, consult the numerical index of effective WPs at the beginning of this manual

1.3

1.4

1.5

1.6

2.1 2.2

2.3

2.4

NAVAIR 17-1-573
01 MARCH 2009
3.1 3.2 QUALITY ASSURANCE REQUIREMENTS.

002 00
Page 4 of 10

Certain procedures or steps are followed by the letters QA in parenthesis (QA). Improper performance of these procedures or steps may cause equipment failure or personnel hazards. A quality assurance of each step so marked shall be made prior to proceeding to the next step, unless such inspection can be performed after completing the entire procedure. WARNINGS AND CAUTIONS APPLICABLE TO HAZARDOUS MATERIALS. Warning and cautions for hazardous materials used in this manual are designed to alert personnel to hazards associated with such items when they come in contact with them by actual use. Additional information related to hazardous materials is provided in OPNAVINST 5100.23 Navy Occupational Safety and Health (NAVOSH) Program Manual and the DoD 6050.5 Hazardous Materials Information System (HMIS) series publications. Consult your local safety and health staff concerning specific personnel protective requirements and appropriate handling and emergency procedures. ABBREVIATIONS. Refer to Table 1 for a list of the abbreviations and acronyms used in this manual.

4.1 4.2

5.1 5.2

Table 1. Abbreviations and Acronyms Used in This Manual. Abbreviation/Acronym AC BTU CB CBR CPC DC DISCH DoD ECU HPCO IAW IPB LH LPCO MF MHE ODS PMCS PN RH RPL Full Text Alternating Current British Thermal Unit Circuit Breaker Chemical, Biological, Radiological Corrosion Prevention and Control Direct Current Discharge Department of Defense Environmental Control Unit High Pressure Cut Out In Accordance With Illustrated Parts Breakdown Left Hand Low Pressure Cut Out Mobile Facility Material Handling Equipment Ozone Depleting Substance Preventive Maintenance Checks and Services Part Number Right Hand Repair Parts List

NAVAIR 17-1-573
01 MARCH 2009

002 00
Page 5 of 10

Table 1. Abbreviations and Acronyms Used in This Manual. Abbreviation/Acronym RV TMDE WP Full Text Reversing Valve Test, Measurement, and Diagnostic Equipment Work Package

6.1 6.2

REFERENCE MATERIAL. Reference material related to and used in conjunction with this manual is listed on the title page of this WP. In addition, these reference materials also are listed on the title page of the applicable work packages. RECORD OF APPLICABLE TECHNICAL DIRECTIVES. There are no applicable technical directives. In the future, if there are any applicable technical directives, they will be listed on the title page of this WP. In addition, the applicable technical directives also will be listed on the appropriate WP title page. SAFETY. This manual is intended to provide safe procedures and processes for accomplishing the maintenance herein described. It is important that personnel thoroughly understand and follow the Warnings and Cautions of possible personnel death, injury, and equipment damage. The operating procedures often involve using equipment and materials that are potentially hazardous. Injury to personnel and damage to equipment caused by fire and misuse of equipment can be avoided by alert and responsible operators and technicians. Strict observance to established safety, care, and handling practices and procedures will allow personnel to perform their duties in a safe and hazard-free environment. Warnings, Cautions, and Notes. Warnings, captions, and notes will be found throughout the manual in various procedures. It is important that the significance of each be thoroughly understood by personnel using the manual. Their definitions are as follows.

7.1 7.2

8.1 8.2

8.3

1. WARNING alerts the technician to a procedure or practice, etc., which, if not strictly observed, will result in loss of life or injury to personnel. 2. CAUTION alerts the technician to a procedure or practice, etc., which will result in damage or destruction of equipment if not correctly followed. 3. NOTE used to highlight a procedure or practice, or provide information, to ensure correct maintenance. 9.1 9.2 CORROSION PREVENTION AND CONTROL (CPC). Corrosion Prevention and Control (CPC) of Navy material is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.

NAVAIR 17-1-573
01 MARCH 2009
10.1 OZONE DEPLETING SUBSTANCES (ODS).

002 00
Page 6 of 10

10.2 A key characteristic of the A/E32C-45A ECU is its use of the R-134A refrigerant which is not an ozone depleting substance. 11.1 SUPPORT EQUIPMENT, TMDE, AND SPECIAL TOOLS. 11.2 Refer to Table 2 for the list of the support equipment, and Test, Measurement and Diagnostic Equipment (TMDE), and special tools required to perform and/or verify each of the maintenance procedures described in this manual. In addition, the applicable support equipment is listed on the appropriate WP title page.

Table 2. Support Equipment and Tools Required. TOOLS OR TEST EQUIPMENT REF CODE 1 2 3 5 5a NOMENCLATURE NATIONAL STOCK NUMBER TOOL NUMBER (CAGE)

Tool Kit, General Mechanics Tool Kit, Service, Refrigeration Unit Pump, Vacuum Recovery and Recycle Unit, Refrigerant (for R22) Recovery and Recycle Unit, Refrigerant / Robinair (for R134A) Heat Gun Rivet Gun Welding Shop, Trailer Mounted Solder Gun Kit Thermometer Set Straightener Fin Screwdriver, Cross Tip Key, Socket Head Screw Tool Kit, Special Torque

5180-00-699-5273 5180-00-596-1474 4310-00-289-5967 4130-01-338-2707 4250-01-411-7240

SC5180-90-CL-N05 (50980) SC5180-90-CL-N18 (50980) 1550-Z138K-634AX (24123) 17500B (07295) 17800B (45225)

6 7 8 9 10 11 12 13 14

4940-01-042-4855 5120-00-508-1588 3431-01-090-1231 3439-00-930-1638 6685-00-874-5834 5120-00-157-2180 5120-01-412-3430 5120-00-076-1787

HG201 (83284) G11 (11815 SC-3431-95-CL-A04 (19204) 450K4 (11103) 211-001 (38508) P12 (17529)

34L (08125) A/E32C-45A-TTIC

NAVAIR 17-1-573
01 MARCH 2009
12.1 EXPENDABLE MATERIALS AND DURABLE ITEMS REQUIRED.

002 00
Page 7 of 10

12.2 Table 3, Expendable Materials and Durable Items Required List, identifies the expendable materials and durable items required to perform the maintenance required to maintain the ECU. In addition, the applicable expendable materials and durable items required are listed on the appropriate WP title page. 12.3 Quality of material. Material used for replacement and /or repair of the ECU must meet the requirements of this manual. If quality of material requirements is not stated in this TM, the material must meet the requirements of the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment. 12.4 Explanation of Columns in Table 3. 1. Item Number. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item. 2. National Stock Number. This is the NSN assigned to the item that you can use to requisition it. 3. Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number. This column provides the other information you need to identify the item. 4. Unit of Issue (U/I). This code indicates the physical measurement or count of the item, such as per gallon, dozen, gross, etc.

Table 3. Expendable and Durable Items List. ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION, CAGEC, NUMBER NUMBER PART NUMBER 1 Silicone Adhesive Sealant, RTV, General, MIL-A-46106, Type I 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Solder, Lead-Tin, QQ-S-571, Type SN60WRP2 3040-00-664-0439 Adhesive, General Purpose, 1 pint container 6830-00-292-0732 Nitrogen Industrial Sealant 800 Acid Swab Brush 9150-00-985-7316 Grease, General Purpose 4240-01-152-3555 Mask, Air Filtering 7920-00-205-1711 Rags 6830-00-439-0614 R-134A, 1,1,1,2 Tetrafluoroethane Refrigerant Tape PPP-T-60, Type IV, Class I Trichloromonofluoromethane, Technical: w/cylinder 50 lbs. (Refrigerant-11), BB-F-1421, Type II (81348) 8030-00-889-3534 Tape, Antiseize, Polytetmfluoroethylene, MIL-T-27730, Size I Lubricating Oil, VV-L-825, Type IV 6850-01-331-3349 Dry Cleaning Solvent, P-D-680 Type III (81348) Coater, Air Filter, MIL-L-2104 (81348) Adhesive, MMM-A-121 qt roll Qt 5 gal. cy roll pkg pt cy U/I

NAVAIR 17-1-573
01 MARCH 2009

002 00
Page 8 of 10

Table 3. Expendable and Durable Items List. ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION, CAGEC, NUMBER NUMBER PART NUMBER 18 Cellular Rubber Strips, MIL-R-6130, Type I, Grade A 19 20 21 22 23 24 25 26 27 Flexible Elastomeric Thermal Insulation (ASTM C 534, Type 2, Sheet) Acetone Insulation, Sheet, Cellular, MIL-I-14511 Plastic Foam, Unicellular, Sheet Form, MIL-P-15280 Adhesive, MMM-A-132, Type I, Class I Roninair Roto Lock Gasket (Large) Roto Lock Gasket (Small) Heat Shrink Tubing U/I ft shts pt

13.1 ILLUSTRATED PARTS BREAKDOWN. 13.2 The information contained in the Illustrated Parts Breakdown (IPB) found in WP 021 00 is intended for use in identifying and requisitioning replacement parts and components. 13.3 GROUP ASSEMBLY PARTS LIST (GAPL). All illustrated parts on the IPB are listed in columns of tabular data in order of assembly. The columns appear from the left margin to the right as follows: 1. Figure & Index Number. This column reflects the number of the figure that applies to the parts list, and index numbers that are key listed parts to the figure. 2. Part Number Column. This column lists the prime contractor part number, government standard part number, or other vendor part number. 3. Description Column. The description obtained from engineering drawings is given in this column. Descriptions are arranged with the identifying noun first. Next is (assembly) or any other modifiers required for positive identification of the part. The part may not be included on the engineering drawing. 4. Units per Assembly. This column contains the number of units per assembly, subassembly, or attaching parts as applicable. If more than one assembly is required, the total of such assemblies shall be known. 5. Usable On Codes. This column is used when more than one configuration is covered in the IPB. Alpha characters in the usable on code column identify which assembly uses that particular part. Absence of an alpha character in this column indicates the part is used on all assemblies. 6. SM&R Codes. Definitions and explanations of SM&R Codes used in this manual are contained in NAVSUP P-719, Navy SM&R Code Guide. See Table 6 for applicable SM&R Codes.

NAVAIR 17-1-573
01 MARCH 2009
Table 6. Navy Application of Joint Services Uniform SM&R Codes.

002 00
Page 9 of 10

NAVAIR 17-1-573
01 MARCH 2009

002 00
Page 10 of 10

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 1 of 16

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN DESCRIPTION AND LEADING PARTICULARS ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

ALPHABETICAL INDEX TITLE WP / Page Number

General Description.....................................................................................003 00 / 2 Introduction..................................................................................................003 00 / 2 Key Features and Characteristics ...............................................................003 00 / 2 Leading Particulars......................................................................................003 00 / 2 Purpose .......................................................................................................003 00 / 2 System Description .....................................................................................003 00 / 5 Compressor / Control Box Section...........................................................003 00 / 7 Control Box Assembly ..............................................................................003 00 / 7 Defrost Cycle and Condensate Drain.......................................................003 00 / 12 Indoor Air Flow Section ............................................................................003 00 / 6 Indoor Thermostat ....................................................................................003 00 / 8 Outdoor Airflow Section............................................................................003 00 / 9 Outdoor Thermostat .................................................................................003 00 / 8 Panels and Covers ...................................................................................003 00 / 10 System Airflow..........................................................................................003 00 / 11 System Power Distribution ..........................................................................003 00 / 13 Cool Cycle Power Distribution..................................................................003 00 / 13 Defrost Cycle Power Distribution .............................................................003 00 / 13 Heat Cycle Power Distribution .................................................................003 00 / 13 Primary Power..........................................................................................003 00 / 13 Secondary Power .....................................................................................003 00 / 13

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 2 of 16

1.1 1.2

INTRODUCTION. This WP provides a description of the A/E32C-45A, part number 1559AS400-1, Environmental Control Unit (ECU) and it leading particulars. GENERAL DESCRIPTION. A/E32C-45A, Environmental Control Unit (ECU). The ECU is a lightweight, vertical, compact, self-contained unit in a weatherproof aluminum case. It contains a built-in heat pump designed to provide a high capacity heat-cool environmental control system. It provides nominal cooling capacity of 36,000 British Thermal Units per hour (BTU/hr). It has a nominal heating capacity of 77,000 BTU/hr with supplementary heaters, and 36,000 BTU/hr without supplementary heaters when supplied with 208-VAC, 3-phase, 50/60 Hz, 3-wire power. PURPOSE. The ECU is used to provide conditioned air (heating or cooling) to a Navy / Marine Mobile Facility (MF). The ECU will control the temperature of an adequately enclosed MF within the variable range of 7 C to 32 C (45 F to 90 F) in ambient temperatures of -32 C to 52 C (25 F to 125 F). The temperature is controlled by a cool-heat control thermostat. LEADING PARTICULARS. Leading particulars are in Table 1. KEY FEATURES AND CHARACTERISTICS. Key features and characteristics of the A/E32C-45A ECU distinguish it from legacy ECUs.

2.1 2.2

3.1 3.2

4.1 4.2 5.1 5.2

1. R134a refrigerant. R134A refrigerant is not an ODS. Earlier refrigerants, such as R22, are ODSs and their use is now restricted or disallowed. 2. Roto-lock fittings. The roto-lock fittings eliminate the requirement for debrazing and brazing in order to remove and replace refrigeration assembly components. There are five Roto Lock fittings used, four of which are of a single size and the fifth is a smaller size. The roto locks fitting components are variously referred to as Straight Adapters, Brass Adapters, and Tube Coupling Nuts. 3. Scroll compressor. Previous ECU models used a reciprocating compressor. The scroll compressor works best with the R134A refrigerant. The scroll compressor requires correct phase matching when connected to external power. 4. Liquid fill charging. The A/E32C-45A ECU has fittings that allow liquid fill charging of the refrigeration assembly in minutes. This replaces the time consuming gas charge method used to introduce refrigerant into legacy ECUs. Gas charging may still be accomplished and is the method for adding additional refrigerant to an already charged ECU. 5. Digital indoor thermostat with LCD. The solid-state indoor thermostat allows for manual switching to select heating or cooling. It does not feature automatic switching from heating to cooling. It does not contain mercury as do legacy thermostats. 6. Compressor Quick Restart Protection Delay. A built in delay prevents the ECU from being restarted until 5 minutes has elapsed since the previous shutdown. This delay prevents damage to the compressor.

NAVAIR 17-1-573
01 MARCH 2009
Table 1. Leading Particulars. ITEM SPECIFICATION 1. ECU Dimensions Height ............................................................ 72.5 inches Width ............................................................. 39.2 inches Depth............................................................. 14.8 inches Net Weight ........................................................... Max. 500 pounds Power Requirements ........................................... 208 VAC, 3-phase, 50/60 Hz Cooling Capacity.................................................. 36,000 BTU/HR @ 60 Hz Heating Capacity ................................................. 76,000 BTU/HR @ 60 Hz Standard rating (45F)................................... 36,000 BTU/HR @ 60 Hz Application rating (20F)................................ 25,000 BTU/HR @ 60 Hz Supplementary Heaters ................................ 41,000 BTU/HR (2-steps, 6 KW each) Maximum input (total unit- ................................... 17,400 watts varies with ambient)

003 00
Page 3 of 16

Outdoor Thermostat....................................................Adjustable range -10 to 40F (-23 to 4.4C) (Factory set to 40F (4.4C) Compressor Type .............................................................. Sealed hermetic Power requirements ...................................... 200-220 VAC, 3-phase, 50 Hz 200-230 VAC, 3-phase, 60 Hz RPM .............................................................. 3,500 at 60 Hz; 2,900 at 50 Hz High-pressure cutout..................................... 375 psig 5 psig Low-pressure cutout...................................... 7 psig 5 psig Lubricant charge ........................................... at factory Compressor Quick Restart Protection .......... 5 Minute Delay from Previous Shutdown Refrigerant ........................................................... R-134A 7 lbs, 5 oz Suction Pressure ................................................. 35 PSIG 10 PSIG @ 90F Discharge Pressure.................................................... 150 PSIG 10 PSIG @ 90F Indoor Blower HP ................................................................. 1.0 Power Requirements..................................... 208-220 VAC, 50/60 Hz, 6.6 amp Phase ............................................................ 1-phase RPM .............................................................. 1,625

NAVAIR 17-1-573
01 MARCH 2009
Table 1. Leading Particulars. ITEM SPECIFICATION CFM (nom.) cooling....................................... 1,400 CFM (nom.) heating ...................................... 1,410 Lubricant..................................................................... None

003 00
Page 4 of 16

Outdoor Fan ............................................................... 20-inch dia. Propeller, 4-blade 27 pitch, clockwise Compressor Full load amperes.......................................... 17.4 Locked rotor amperes ................................... 156 Indoor Fan Motor (1.0 HP) Full load amperes.......................................... 6.6 Locked rotor amperes ................................... 39 Outdoor Fan Motor (1.0 HP) Full load amperes.......................................... 6.6 Locked rotor amperes ................................... 39 Minimum wire size type 75C AWG ................. No. 8 Maximum wire length for 3% voltage drop feet 150 Conduit size inches........................................... Maximum fuse size time delay type amperes 40 Disconnect switch size horsepower.................. 10 Control Wiring AWG ......................................... No. 18 National Electrical Code (N.E.C.) Class 2 Supplementary Heaters Nominal size KW ....... 12 Rated Amperes ............................................. 32 Minimum wire size type 75C AWG.................. No. 8 Maximum wire length for 3% voltage drop feet 150 Conduit Size inches .......................................... Maximum fuse size amperes............................ 40 Disconnect switch size amperes ...................... 60 2. INDOOR THERMOSTAT .................................... Two-stage heating, one-stage cooling Power requirements ...................................... 24-30 VAC Ambient temperature control range .............. -32C to 52C (-25F to 125F) Temperature control range of........................ 7C to 32C (45F to 90F) insulated compartment

NAVAIR 17-1-573
01 MARCH 2009
Table 1. Leading Particulars. ITEM 3. ELECTRICAL CHARACTERISTICS ECU Power .......................................................... 208 VAC, 3-phase, 50/60 Hz Applied Voltage (min/max)................................... 197-253 Compressor Full load amperes.......................................... 17.4 Locked rotor amperes ................................... 156 Indoor Blower Motor (1.0 HP) Full load amperes.......................................... 6.6 Locked rotor amperes.......................................... 39 Outdoor Fan Motor (1.0 HP) Full load amperes.......................................... 6.6 Locked rotor amperes ................................... 39 Minimum Wire Size Type 75C AWG .................. No. 8.3 wire SPECIFICATION

003 00
Page 5 of 16

Main Power Maximum Wire Length (For 3% voltage drop) ................................ 150 ft. Control Wiring AWG................................... No. 18 National Electric Code Class 2 Supplementary Heaters Nominal Size KW .......................................... 12 Rated Amperes ............................................. 32 Minimum Wire Size Type 75C ..................... No. 8, 3-wire Maximum Wire Length (For 3% voltage drop) ................................ 150 ft. Maximum Fuse Size Amperes.......................... 40 Disconnect Switch Size Amperes..................... 60

6.1 6.2

SYSTEM DESCRIPTION. The A/E32C-45A ECUs are designed for mounting to an MF. The units are patterned for installation with ductwork but may be applied as free-blow. The ECU air filters are part of the MF Accessories Assembly. The ECU is physically and functionally divided into three sections: the indoor airflow section; compressor / control box assembly section, and outdoor airflow section (Figure 1).

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 6 of 16

Figure 1. A/E32C-45A Environmental Control Unit (Indoor / Front View). 6.3 6.4 INDOOR AIRFLOW SECTION. The indoor airflow section recirculates interior airflow and heats or cools the air as selected. The main components consist of the indoor blower assembly, fresh air intake, indoor coil, and supplemental heaters with a high temperature cutout thermostat switch.

1. Indoor Blower Assembly. The indoor blower assembly consists of motor, which turns two fans (on either side of the motor) that introduces and recirculates conditioned air into the MF.

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 7 of 16

2. Fresh Air Intake. The fresh air intake is located on the upper rear (outdoor) service panel. When opened fresh exterior unconditioned air is drawn into the indoor airflow section. A sliding cover controls the quantity of outdoor air entering the indoor airflow section. 3. Indoor Coil. The indoor coil is the primary heat exchange element for providing conditioned air into the MF. 4. Supplemental Heating Elements. The supplemental heating elements are protected by two fail-safe, fuse links in each stage set to open at 306 F (152 C). The first stage supplemental heating is controlled through the indoor thermostat. The second stage of supplemental heating is controlled by the outdoor thermostat. 5. High Temperature Cutout Thermostat Switch. Overheating protection is provided by a 160 F (71 C) cutout (Thermoguard) located in the air return plenum over the indoor coil. 6.5 6.6 COMPRESSOR/CONTROL BOX SECTION. The compressor/control box section houses the compressor, reversing valve, accumulator, control box assembly, and outdoor thermostat.

1. Compressor. The ECU contains a 3500 RPM, 200-230 VAC, 3 phase, 50-60 Hz, scroll compressor. It is hermetically sealed and force feed lubricated with 60 oz. (initial), 56 oz. (wet). The compressor is designed for operation with Refrigerant R-134A. See Table 1 for other data. The scroll compressor requires correct phasing of external power supply to operate correctly. 2. Reversing Valve Assembly. The reversing valve assembly (Figure 2) enables the ECU to switch from cooling to heating or heating to cooling by reversing the refrigerants direction of flow. 3. Accumulator. The accumulator is where entrained (trapped and suspended in hydraulic fluid) liquid refrigerant is removed from the refrigerant vapor. Liquid-free vapor from the accumulator is drawn into the suction side of the compressor.

Reversing Valve Assembly

Figure 2. Reversing Valve Assembly (Shown Partially Connected). 6.7 6.8 CONTROL BOX ASSEMBLY. The control box assembly houses the electrical components (relays, transformers, cut-out switches, defrost control, thermostats, etc.) used to control and power the operation of the ECU. Access to the components in the control box is through the rear (outdoor) side of the ECU. Refer to Figure 3 for location of control box assembly components.

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 8 of 16

Figure 3. Control Box Assembly and Components. 6.9 Outdoor Thermostat. The outdoor thermostat, S5, activates the second stage of the supplemental heating unit when the outdoor temperature is less than 40F (4.4C).

6.10 Indoor Thermostat. The indoor thermostat (Figure 4 is a solid-state, low voltage (24-30 VAC) thermostat. It is wired to control operation of the ECU through the Control Box. It has sufficient wire to enable remote mounting inside the MF. It has a large back lit LCD digital display. The display shows the ambient (room) temperature and will display the set point. The thermostat has a system switch to control system operation. The system switch has positions EMER, HEAT, OFF, and COOL which enable manual switching from heating to cooling or to switch the system off. The EMER (emergency heat) position is not wired / not used. A fan switch has ON and AUTO positions which provide for continuous or intermittent operation of the indoor blower. The indoor thermostat controls incorporate a sensor that activates solidstate circuits. The sensor is hermetically sealed and calibrated for temperature range. Up and down arrows to the right of the LCD display. A push button switch located below the LCD display turns on / off an internal back light for the display.

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 9 of 16

Fan Switch System Switch

LCD Display

Wires to ECU Control Box

Temperature Setting Controls Light Switch for LCD Backlight

Figure 4. Indoor Thermostat. 6.11 OUTDOOR AIRFLOW SECTION. 6.12 The outdoor airflow section contains the outdoor fan, outdoor coil, expansion valve, sight glass, liquid charge valve, and filter drier. Unless otherwise noted see Figure 1 for location of components. 1. Outdoor Fan. The outdoor fan is located forward (on the MF side) of and facing towards the outdoor coil. It is surrounded on the indoor side by a protective shroud. It blows air across the outdoor coil to increase the exchange rate of heat from or to the refrigerant in the coil depending on the mode of operation (heating or cooling). 2. Outdoor Coil. The outdoor coil located on the bottom rear (outdoor) side of the ECU is where heat exchange occurs. 3. Expansion Valve Assembly. Liquid refrigerant under high pressure is circulated from the filterdrier to the thermostatic expansion valve assembly (Figure 5). The valve removes pressure from the liquid refrigerant so that it can expand and become refrigerant vapor. 4. Sight Glass. The sight glass (Figure 5) allows observation of the refrigerant. An indicator visible through the sight glass provides assessment of moisture level in the refrigerant charge. 5. Liquid Charge Valve. The liquid charge valve (Figure 5) allows rapid charging of an evacuated refrigeration assembly with liquid instead of gaseous refrigerant. 6. Filter Dryer. The bi-directional flow filter dryer (Figure 5) removes moisture and contaminants from the refrigerant. The filter dryer must be replaced each time the refrigeration system is opened to the environment.

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 10 of 16

Filter-Dryer

Expansion Valve

Sight Glass (rear view)

Liquid Charge Valve

Figure 5. Refrigeration Assembly Components Located in Outdoor Airflow Section. 6.13 PANELS AND COVERS. 6.14 The sides, rear, and top of the ECU are enclosed with aluminum panels (Figure 6). The panels are attached to the ECU chassis with hex head machine screws. A fiberglass duct liner (not shown) is applied to the interior of the panels enclosing the indoor air section.

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 11 of 16

3 6 4 7 5 6 8

7 8
LEGEND. 1 Top Cover 2 Fresh Air Intake Cover 3 Upper Rear Panel 4 Lower Rear Panel 5 Upper Side Panel Figure 6. ECU Panels and Covers. 6.15 SYSTEM AIRFLOW.

6 Lower Side Panel 7 Side (Slide) Panel 8 Side (Extension) Panel 9 Control Box Cover

6.16 OUTDOOR AIR INTAKE AND OUTDOOR AIR DISCHARGE. 6.17 Outdoor air is continuously drawn into the ECU through each side of the outdoor air intake (vent grid on lower side panels (6, Figure 6). Within the outdoor airflow section, the outdoor fan blows exterior air over the outdoor coil and, dependent upon mode of operation, heat is dissipated from the outdoor coil or absorbed into the system through the outdoor coil.

NAVAIR 17-1-573
01 MARCH 2009
6.18 INDOOR AIR SUPPLY AND INDOOR AIR RETURN.

003 00
Page 12 of 16

6.19 Conditioned air is supplied to the MF from the indoor air supply located at the top of the unit around the indoor coil and supplemental heaters. Indoor air is returned to the ECU in a continuous cycle through the indoor air return located in the area around the indoor blower assembly. 6.20 FRESH AIR INTAKE. 6.21 The fresh air intake permits fresh exterior air to be drawn into the indoor airflow section. A sliding cover (2, Figure 6) controls the quantity of outdoor air entering the indoor airflow section.

Figure 7. Air Flow Diagram. 6.22 DEFROST CYCLE AND CONDENSATE DRAIN. 6.23 The defrost cycle is automatic. Condensate is automatically drained at the bottom of the outdoor coil frame.

NAVAIR 17-1-573
01 MARCH 2009
7.1 7.2 7.3 SYSTEM POWER DISTRIBUTION. PRIMARY POWER.

003 00
Page 13 of 16

Refer to Figure 8 and Figure 9. The ECU requires 208-240 VAC, 50/60 Hz, 3-phase power for normal operation. Primary power (L1, L2, L3) applied via control circuits activates the compressor, indoor blower motor, and condenser fan motor, and the two booster heater stages. An additional single-phase primary power is applied directly to the compressor crankcase heater (208V). SECONDARY POWER. All ECU control circuitry requires 24 VAC for normal operation. A 208-24 VAC step-down transformer converts primary power to the required 24 VAC operating voltage. HEAT CYCLE POWER DISTRIBUTION. Heat control circuits are activated whenever the remote thermostat senses a temperature below the set point, the system switch is set to HEAT and the fan switch is set to ON or AUTO. Under these conditions, 24 VAC supplied by the step-down transformer activates a timed delay element when then activates the heat relay. Once activated, the heat relay contacts close providing 24 VAC to energize the reversing valve solenoid, placing the system in a heating configuration. Activation of the cool relay transfers 208 VAC, single-phase primary power to energize the contactor. When energized, the contactor supplies 3-phase primary power to the ECU compressor and 1 phase primary power to the outdoor fan relay. The outdoor fan relay is energized by the heat relay and transfers primary power to the outdoor fan motor. Similarly, the energized indoor fan relay transfers single-phase primary power to the indoor blower motor. If the temperature sensed by the remote thermostat falls below 68F, the booster heater No. 1 relay is energized by 24 VAC permitting primary power to activate booster heater No. 1. For outdoor temperatures less than 40F, 24 VAC is transferred by outdoor temperature sensor to activate booster heater No. 2 relay, permitting primary power to activate booster heater No. 2. COOL CYCLE POWER DISTRIBUTION.

7.4 7.5

7.6 7.7

7.8

7.9

7.10 Cool control circuits are activated whenever the remote thermostat senses a temperature above 76F, the system switch is set to COOL and the fan switch is set to either ON or AUTO. Under these conditions, 24 VAC supplied by the step-down transformer activates the cool relay and indoor and outdoor fan relays. Additionally, the reversing valve solenoid is deenergized, placing the system in a cooling configuration. Activation of the cool relay transfers 208 VAC, single-phase, primary power to energize the contactor. When energized, the contactor supplies 3-phase primary power to the ECU compressor and single-phase, primary power to the outdoor fan relay. Similarly, the energized indoor fan relay transfers single-phase, primary power to the indoor blower motor. 7.11 DEFROST CYCLE POWER DISTRIBUTION. 7.12 During the heat cycle, when the thermal defrost switch senses a coil temperature which could cause frost on the coil and the defrost control completes its 30 minutes cycle, the defrost control deactivates the reversing valve solenoid and the outdoor fan contactor. Also the booster heater(s) are activated. The defrost cycle is terminated by the thermal defrost switch on the outdoor coil when the coil reaches a temperature that assures that the frost has melted. An alternate termination of the defrost cycle is provided by the defrost control.

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 14 of 16

Figure 8. ECU Functional Block Diagram and Power Distribution.

NAVAIR 17-1-573
01 MARCH 2009

003 00
Page 15 of 16

Figure 9. ECU Schematic Diagram. (Refer to Table 2 for Definition of Component Labels).

NAVAIR 17-1-573
01 MARCH 2009
Table 2. Definition of Component Labels from ECU Schematic Diagram. LABEL B1 B2 B3 C1 CH DC HR1 -- HR4 K1 K2 K3 K4 COMPONENT Compressor Motor* Indoor Fan Motor* Outdoor Fan Motor* Capacitor Outdoor Fan Motor Crankcase Heater Defrost Control Electric Heater Elements Relay Compressor Motor Relay Indoor Fan Motor Relay Outdoor Fan Motor Relay Elec. Heaters 1st Stg. LABEL K5 RV S1 S2 S3 S4 S5 TB1 TB2 TB3 TR

003 00
Page 16 of 16

COMPONENT Relay Elec. Heaters 2d Stg. Reversing Valve High Pressure Cutout Switch Low Pressure Cutout Switch Defrost Termination Thermostat Switch Heater Cutout Switch 2d Stg Heater Thermostat Switch Terminal Board - Power In Electric Heat Terminal Board- Power In Heat Pump Terminal Board - Room Thermostat Transformer 24VAC Control Circuit

* Motors B1, B2 and B3 have thermal protection.

NAVAIR 17-1-573
01 MARCH 2009

004 00
Page 1 of 6

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN PRINCIPLES OF OPERATION ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

ALPHABETICAL INDEX TITLE WP / Page Number

Compressor Short Cycle Protection............................................................004 00 / 5 Cooling Cycle ..............................................................................................004 00 / 3 Defrost Cycle...............................................................................................004 00 / 5 General Theory of ECU...............................................................................004 00 / 2 Heating Cycle ..............................................................................................004 00 / 4 Indoor Thermostat .......................................................................................004 00 / 2 Principles of Operation ................................................................................004 00 / 2 Reversing Valve ..........................................................................................004 00 / 2 Three Cycles of Operation ..........................................................................004 00 / 2

NAVAIR 17-1-573
01 MARCH 2009

004 00
Page 2 of 6

1.1 1.2 1.3

PRINCIPLES OF OPERATION. GENERAL THEORY OF ECU. The A/E32C-45A ECU is a heat pump that can either remove heat from an indoor area and discharge this heat to the outside, or it can be used to pick up heat from the outside and discharge it into the indoor area for heating. The theory of the heat pump is based on the principle that heat will move from a high temperature to a lower temperature. This principle means that if a heat transfer coil can be maintained at a lower temperature than its environment, it will pick up heat from its environment. Therefore, if an evaporator coil of an ECU system can be kept at a temperature below its environment, it will pick up heat. If an evaporator coil is mounted outdoors and operated at a refrigerant temperature of 0F, it will remove heat from the air even though the outside temperature is only 10 or 15F. If this refrigerant, after it has evaporated, is compressed by a compressor to a temperature of 120 to 140F, it will release heat to the surrounding area, i.e., the inside of a MF. Then, if by using a system of valves, the evaporator coil is changed into a condenser, and the condenser is changed into an evaporator coil during hot weather, heat can be removed from indoors and discharged outdoors. THREE CYCLES OF OPERATION. The ECU works as a heat pump in one of three cycles; a cooling cycle, a heating cycle or defrosting cycle. INDOOR THERMOSTAT. As room temperature increases or decreases above or below a selected temperature, the indoor thermometers sensor changes resistance so that solid-state circuitry is activated. The solid-state switch turns the heating system off or the cooling system on, depending whether the thermostat system switch is manually set for heat or cool. REVERSING VALVE. A reversing valve (Figure 1) reverses the flow of refrigerant in the ECU system to provide heating or cooling. A four-way solenoid type sliding port reversing valve is used in this application. The solenoid coil is energized on the heating cycle causing the slide to move, reversing the refrigerant flow from the cooling cycle. In the cooling cycle, the solenoid is not energized.

1.4

1.5

1.6

NAVAIR 17-1-573
01 MARCH 2009

004 00
Page 3 of 6

Figure 1. Reversing Valve Schematic- Sliding Valve Type, Solenoid Activated. 1.7 COOLING CYCLE. The ECU operates as an air conditioner providing cooling air to the MF when the indoor thermostat system switch is set to cool. During the cooling cycle (Figure 2), low-pressure, low temperature refrigerant vapor from the indoor coil flows through the reversing valve into the accumulator where any entrained (trapped and suspended in hydraulic fluid) liquid refrigerant is removed from the refrigerant vapor. Liquid-free vapor from the accumulator is drawn into the suction side of the compressor, is compressed, and flows through the reversing valve in the form of high-pressure, high temperature refrigerant vapor to the outdoor coil. Compression of the refrigerant raises the pressure and temperature to a point where the outdoor coil temperature is above that of the ambient air. High-pressure, high temperature refrigerant vapor from the compressor enters the outdoor coil where heat is removed, changing the gaseous refrigerant into a high-pressure relatively lower temperature liquid. Heat is drawn from the refrigerant liquid by the outdoor coil and transferred to a cooling stream of ambient air induced by a motor-driven fan.

1.8

1.9

1.10 Liquid refrigerant flows from the outdoor coil through the bi-directional filter dryer removing entrained moisture, then through the capillary control assembly, which acts as a throttling valve, to the indoor coil where cooling of the indoor area is accomplished. 1.11 Temperature of the refrigerant at this point is lower than that of the indoor area air. As indoor air is circulated through the indoor coil by a motor-driven fan, heat is transferred from the air to the indoor coil. This heat is extracted from the indoor coil by the refrigerant as latent heat of vaporization. With this addition of heat, the refrigerant assumes a gaseous form. This lowpressure, low temperature vaporized refrigerant flows through the reversing valve into the accumulator and the cooling cycle is repeated from the air to the indoor coil. This heat is extracted from the indoor coil by the refrigerant as latent heat of vaporization. With this addition of heat, the refrigerant assumes a gaseous form. This low-pressure, low temperature vaporized refrigerant flows through the reversing valve into the accumulator and the cooling cycle is repeated.

NAVAIR 17-1-573
01 MARCH 2009

004 00
Page 4 of 6

Figure 2. ECU Operating in Cooling Cycle. 1.12 HEATING CYCLE. Primary heating is provided by operating the ECU in the heat mode when the indoor thermostat system switch is set to heat. A twostage supplemental heating assembly augments the primary heating. Each stage contains 6-KW heaters capable of dispersing a total of 41,000 BTU/hr. Overheating protection is provided by a 160 F (71 C) cutout (Thermoguard) located in the air return plenum over the indoor coil. Supplemental heating elements are protected by two fail-safe, fused links in each stage set to open at 306 F (152 C). The first supplemental heating stage is controlled through the second stage of the indoor thermostat. The second stage supplemental heating is controlled by an outdoor thermostat located on the control box. When the outdoor thermostat detects an outdoor temperature at or below 40 F (4.4 C) it will activate 1.13 During the heating cycle (Figure 3.), low-pressure, low temperature refrigerant vapor from the outdoor coil flows through the reversing valve (Figure 1) into the accumulator where any entrained liquid refrigerant is removed from the vaporous refrigerant. This liquid-free vapor from the accumulator is drawn into the suction side of the compressor, is compressed and flows through the reversing valve under high-pressure and temperature into the indoor coil. The indoor coil temperature is above that of the indoor area ambient air. 1.14 High-pressure, high temperature refrigerant vapor from the compressor enters the indoor coil where heat is removed, changing the gaseous refrigerant into a high-pressure relatively lower temperature liquid. Heat is drawn from the refrigerant liquid by the indoor coil and is transferred to the indoor area by a stream of ambient air induced by a motor-driven fan. 1.15 Liquid refrigerant flows from the indoor coil through the filter dryer and capillary control assembly to the outdoor coil where heat is transferred from the air to the outdoor coil. This heat is extracted from the outdoor coil by the refrigerant as latent heat of vaporization. With this addition of heat, the refrigerant assumes a gaseous form. This low-pressure, low temperature refrigerant vapor flows through the reversing valve into the accumulator and the heating cycle is repeated.

NAVAIR 17-1-573
01 MARCH 2009

004 00
Page 5 of 6

Figure 3. ECU Operating in Heating Cycle. 1.16 DEFROST CYCLE. A defrost cycle is automatically activated to remove frost that may be formed on the outdoor coil when the ECU is operating in the heating cycle. Condensate is drained through a tube at the bottom of the outdoor coil frame. 1.17 When the ECU is operating in the heating cycle, frost can form on the outdoor coil at outdoor temperatures below 50F. If not removed, the frost can build up sufficiently to block airflow over the coil. The ECU contains an automatic defrost cycle to preclude this frost buildup. 1.18 Defrost Switch. Frost removal is accomplished by action of the defrost electronic control sensor. This control has one outdoor coil temperature. At this time, a coil temperature of 30F (-1.1C) is sensed due to frost build up on the coil surface, which minimizes the airflow across the coil. The outdoor air feeler bulb temperature is used as a reference. As the outdoor coil begins to frost, the coil temperature drops and, at the predetermined temperature spread (15F) between the two sensing feeler bulbs, the defrost switch actuates, deenergizing the reversing valve and placing the ECU in the cooling cycle (see Figure 2). At the same time, the normally open contacts of the defrost switch energize the defrost relay. 1.19 The defrost relay normally open contacts energize booster heater relay No. 2 which energizes the second stage of the supplemental heater to temper the indoor air supply. The defrost relay normally closed contacts deenergize the outdoor fan relay, stopping it during the defrost cycle. At a predetermined coil temperature of 61F, the defrost switch is again actuated by the coil temperature sensing thermostat, returning the unit to the heating cycle. 1.20 COMPRESSOR SHORT CYCLE PROTECTION. When the system turns off in the cool mode the indoor thermostats built in short cycle protection delay prevents the system from turning on again until 5 minutes has elapsed. This protects the compressor from damage.

NAVAIR 17-1-573
01 MARCH 2009

004 00
Page 6 of 6

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

005 00
Page 1 of 6

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN PREPARATION FOR USE, STORAGE, AND SHIPMENT ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 014 00 - Indoor Thermostat, Panels, and Covers ............................. NAVAIR 17-1-573 Department of Defense Standard Practice, Military Marking for Shipment and Storage.............................................................................. MIL-STD-129 Pre-operational Checklist, Mobile Facility Program Environmental Control Unit A/E32C-45A ......................................................................... NAVAIR 17-600-762-6-1 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................................ NAVAIR 19-25-177 ALPHABETICAL INDEX TITLE WP / Page Number

Introduction..................................................................................................005 00 / 2 Preparation for Shipment ............................................................................005 00 / 4 Preparation for Storage ...............................................................................005 00 / 4 Preparation for Use .....................................................................................005 00 / 2 MATERIALS REQUIRED NOMENCLATURE NUMBER

Refrigerant........................................................................... R-134A Shipping Container.............................................................. ASTM-D-3951-95 Level AB, Domestic Type

NAVAIR 17-1-573
01 MARCH 2009

005 00
Page 2 of 6

1.1 1.2

INTRODUCTION. Because of the many various methods of installing the A/E32C-45A Environmental Control Unit (ECU) in a Mobile Facility (MF), it is not practical to provide detailed installation instructions for all individual situations. When the MF is being transported, the ECU is moved on roller slides into the MF interior, rigidly secured in transport position, and the ECU access door or panel is closed and latched. Refer to NAVAIR 19-25-177 for additional data on preparation for use and operation of MF ECU. PREPARATION FOR USE. The applicable preparation for use procedure depends if the ECU was transported within an MF or if the ECU is new or a replacement unit that now will be installed in an MF and placed into service. NOTE The A/E32C-45A, part number 1559AS400-1, ECU is prepared for use and installed into / removed from an MF in the same manner as its predecessor, A/E32C-45, part number 1559AS100-1, ECU. Use the procedure provided in NAVAIR 19-25-177 for the A/E32C-45 ECU, except as noted herein, when preparing for use, installing or removing an A/E32C-45A ECU.

2.1 2.2

2.3 2.4

ECU Transported in MF. To prepare for use an ECU that was transported within the MF do as follows.

1. Move ECU into the operating position IAW procedure in NAVAIR 19-25-177. 2. Inspect ECU to ensure no damage and all connections are secure. 3. Perform pre-operational inspection IAW NAVAIR 17-600-762-6-1. 2.5 2.6 New or Replacement ECU. To prepare for use a new or replacement ECU, the ECU must be removed from shipping protection, installed in an MF, connected to electrical power, and, as needed, a new indoor thermostat installed.

WARNING
Sharp edges sometimes produced in the forming process of the ECUs aluminum panels, especially at the top panel corners and at the air inlet openings can cause severe injury. CAUTION ECUs must always be kept in an upright position to avoid damage to compressor and refrigeration system. 2.7 Removal of Shipping Protection.

1. Select a location where the ECU may be uncrated without exposure to inclement weather, and which is convenient to installation site.

NAVAIR 17-1-573
01 MARCH 2009

005 00
Page 3 of 6

2. If unit was inadvertently placed in any position other than upright, then move the unit into the upright position and leave for 48 hours before energizing. 3. Remove exterior shipping protection. Remove side service panels as needed (WP 014 00) to unbolt ECU from wood pallet. 4. Remove any shipping protection material from the interior of the ECU. Access may be gained from the indoor (MF) side. Remove service panels (WP 014 00) as needed if additional access is required. 5. Remove accessories kit from area below indoor blower. 2.8 Initial Inspection (Prior to Installation in an MF).

1. Visually examine housing assembly for damage. 2. Handle ECU carefully to prevent damage to system components due to excessive shock or vibration. 3. Verify all refrigeration system components, pipes, capillaries, are properly connected and undamaged. 4. Observe sight glass. Sight glass should be clear; indicator should be green. 5. Ensure condensate drain for indoor coil is securely connected and properly routed. 6. Check for missing parts and hardware. 7. Confirm data plate is present and securely fastened to side service panel. 8. Ensure This Unit Contains R-134A Refrigerant decal is affixed near to the data plate on the side service panel. CAUTION Dropping or inverting ECU may result in loss of refrigerant charge due to separation of system piping connections. NOTE Installation of new or replacement ECU in a Mobile Facility (MF). The ECU is mounted on a drawer-type, roller-slide assembly that extends through the MF outside sidewall when in its operational position. 2.9 HANDLING ECU.

1. Handling of the ECU may be accomplished by using a forklift or similar Material Handling Equipment (MHE) using a wood pallet to support the underside of the ECU. 2.10 Install ECU in MF IAW NAVAIR 19-25-177.

WARNING
Extreme care must be observed when working on electrical portions of the ECU. Voltages present are very dangerous and may cause death or serious injury if contacted. 1. Perform electrical power hookup of ECU to MF IAW NAVAIR 19-25-177. 2. Perform preoperational inspection IAW NAVAIR 17-600-762-6-1. Run ECU through one heating and/or cooling cycle. Observe for proper operation.

NAVAIR 17-1-573
01 MARCH 2009
2.11 PREPARATION FOR STORAGE AND SHIPMENT.

005 00
Page 4 of 6

CAUTION ECUs must always be kept in an upright position to avoid damage to compressor and refrigerant system. Prior to shipping or storing an ECU separately, crate in suitable container in the upright position, and mark IAW MIL-STD-129. 3.1 3.2 PREPARATION FOR STORAGE. Short Term Storage.

1. Disconnect power supply and remove from shelter IAW NAVAIR 19-25-177. 2. Make sure unit is clean and dry. 3. Store in a clean dry area in upright position. 3.3 Long Term Storage.

1. Disconnect power supply and remove from shelter IAW NAVAIR 19-25-177. 2. Make sure unit is clean and dry. Blow out condensate drains. NOTE Wrap cable connectors in cushioning material before packaging. 3. Package all hardware, cable connectors, technical manuals, etc. in a cushioned protective sack. Staple shut and secure to unit. 4. Seal all openings with polyethylene film and -inch pressure sensitive tape. 5. Cover the entire unit with a polyethylene film shroud and secure with -inch pressure sensitive tape. 6. Store ECU in a dry, dust-free space and in upright position. 4.1 4.2 PREPARATION FOR SHIPMENT. The ECU may be shipped inside the MF or it may be removed from the MF and prepared for separate shipment. Shipment in an MF.

4.3

1. To ship an ECU in the MF the ECU must be moved into the MF interior / shipping position IAW NAVAIR 19-25-177. 2. There are no other shipment and storage procedures when the ECU is transported in the MF interior. 4.4 4.5 Separate Shipment. After an ECU has been removed from an MF IAW NAVAIR 19-25-177, prepare it for shipment as follows.

1. Prepare unit as prescribed for long-term storage.

NAVAIR 17-1-573
01 MARCH 2009

005 00
Page 5 of 6

2. Fabricate Shipping Container (Figure 1). Fabricate a corrugated paper-shipping container conforming to ASTM-D-3951-95 Level AB, Domestic Type. A minimum of 1-9 inch clearance will exist between the ECU and walls of the box. The box will be modified with a wood pallet located so that the bolts securing the ECU pass through the skids. 3. Pack ECU in shipping container and secure to the wood pallet skids with four bolts (3/8-24) and washers. Bolt heads will be countersunk into the bottom of the pallets. The bolts with washers should protrude at least 3/8 inch above the pallet and not more than inch. 4. Wood spacers will be padded with water resistant cushioning material to prevent abrasion. Corner pads constructed of corrugated paper will be used on all top and bottom edges of the ECU. 5. Close shipping container and secure with steel strapping material. CAUTION ECUs must always be kept in an upright position to avoid damage to compressor and refrigerant system. 6. The ECU must be shipped in the upright position. Stencil or otherwise mark the words THIS END UP and include arrows pointing upwards within the upper third of each side of the shipping container. Letters must be black and at least 3 inches high.

NAVAIR 17-1-573
01 MARCH 2009

005 00
Page 6 of 6

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

006 00
Page 1 of 4

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN OPERATING INSTRUCTIONS ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 008 00 - Testing and Trouble Shooting ............................................. NAVAIR 17-1-573 Pre-operational Checklist, Mobile Facility Program Environmental Control Unit A/E32C-45A ......................................................................... NAVAIR 17-600-762-6-1 ALPHABETICAL INDEX TITLE WP / Page Number

Controls and Indicators ...............................................................................006 00 / 2 Introduction..................................................................................................006 00 / 2 Operation.....................................................................................................006 00 / 3 Air Circulation Only Mode ........................................................................006 00 / 4 Cooling Mode ...........................................................................................006 00 / 3 Heating Mode ...........................................................................................006 00 / 3 Shutdown .................................................................................................006 00 / 4 Preoperational Checkout.............................................................................006 00 / 3 Temperature Setting....................................................................................006 00 / 3

NAVAIR 17-1-573
01 MARCH 2009

006 00
Page 2 of 4

1.1 1.2

INTRODUCTION. This WP identifies and describes controls and indicators used for operation of the A/E32C-45A, part number 1559AS400-1, ECU that is used to heat and cool MFs. CONTROLS AND INDICATORS. Controls and indicators required for system operation consist of the switches, button, and LCD display located on the ECUs Indoor Thermostat (Figure 1). These are identified and their respective functions explained as follows.

2.1 2.2

Figure 1. Indoor Thermometer Control and Indicators. 2.3 SYSTEM SWITCH. The system switch located at the top left of the indoor thermostat has four labeled settings: emer, heat, off, and cool, which can be manually selected to set the mode of operation of the ECU. Position the raised button on the sliding system switch above emer, heat, off or cool to select the mode of operation. emer position The emer switch position is not wired / not used for the A/E32C-45A ECU. heat position place the system switch to heat to cause the ECU to operate in the heat pump mode. off position place the system switch to off to turn off both heating and cooling modes. This does not remove primary power from the ECU. It only prevents the ECU from turning on in either the heating or cooling mode regardless of the thermostat temperature setting.

2.4 2.5

2.6

NAVAIR 17-1-573
01 MARCH 2009
2.7

006 00
Page 3 of 4

cool position place the system switch to cool to cause the ECU to operate in the heat pump cooling mode. FAN SWITCH. The fan switch is identified by the fan symbol between the two settings auto and on. It controls the operation of the indoor blower motor. Position the raised button on the sliding system switch above on or off to select the mode of operation of the indoor blower motor. auto Position the fan switch to auto to cause the indoor fan to operate only when the system switch is set to heat or cool and the ecu is running.

2.8

2.9

2.10 on -- Position the fan switch to on to cause the indoor fan to operate continuously when the system switch is in the heat, off, or cool setting. 3.1 3.2 TEMPERATURE SETTING. Manually adjust the up and down touch pads on the right-side of the indoor thermostat cover to set the target temperature for the ECU. The up touch pad () increases the set point temperature in either the heat or cool mode. The down touch pad () lowers the set point temperature in either the heat or cool mode. PREOPERATIONAL CHECKOUT. Perform the preoperational checklist in NAVAIR 17-600-762-6-1 prior to each use. OPERATION. NOTE The indoor thermostat has a built-in compressor short cycle protection delay that prevents the ECU from turning on until the 5 minute delay has elapsed since the previous shutdown. This protects the compressor from damage. In the AUTO mode, the indoor fan blower may not turn on immediately when the ECU turns on in either the heat or cool mode. There is a built in fan delay. 5.2 HEATING MODE.

4.1 4.2 5.1

1. Set fan switch to on for continuous operation or auto for intermittent (cycle dependent) operation. When indoor fan blower turns on the display will show a fan symbol. 2. Set temperature to desired value (F) by using the up touch pad () or down touch pad (). 3. Set system switch to heat. The ECU will turn on when the room temperature is less than the set temperature. CAUTION Do not use cooling mode / set system switch to cool if the temperature is below 50F, otherwise damage to ECU can occur. 5.3 COOLING MODE.

1. Set fan switch to on for continuous operation or auto for intermittent (cycle dependent) operation. When fan blower turns on the display will show a fan symbol. 2. Set temperature to desired value (F) by using the up touch pad () or down touch pad ().

NAVAIR 17-1-573
01 MARCH 2009

006 00
Page 4 of 4

3. Set system switch to cool. The ECU will turn on when the room temperature is greater than the set temperature. 4. After approximately 5 minutes in cool mode operation, observe sight glass to check for moisture and low refrigerant charge. Yellow indicates moisture; bubbles or milky appearance indicates low charge. If a discrepant condition is found perform troubleshooting (WP 008 00) as needed to identify cause of discrepancy and perform corrective action. 5.4 AIR CIRCULATION ONLY MODE.

1. Set system switch to off. ECU heating or cooling operation will cease. 2. Set fan switch to on. Indoor fan blower will turn on and run continuously. 5.5 SHUTDOWN.

1. Set system switch to off. 2. Set fan switch to auto.

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 1 of 16

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN TESTING AND TROUBLESHOOTING ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 008 00 - Leak Test................................................................................ NAVAIR 17-1-573 WP 009 00 - Discharge / Recovery............................................................. NAVAIR 17-1-573 WP 010 00 - Evacuation.............................................................................. NAVAIR 17-1-573 WP 011 00 - Charging................................................................................. NAVAIR 17-1-573 WP 012 00 - Pressure Test ......................................................................... NAVAIR 17-1-573 WP 014 00 - Chassis Assembly.................................................................. NAVAIR 17-1-573 WP 015 00 - Refrigeration Assembly .......................................................... NAVAIR 17-1-573 WP 016 00 - Control Box Assembly............................................................ NAVAIR 17-1-573 WP 018 00 - Frame Assembly .................................................................... NAVAIR 17-1-573 WP 019 00 - Unit Wiring Inspection, Test, Repair, and Installation ............ NAVAIR 17-1-573 Technical Manual, Maintenance Requirements Manual Environmental Control Unit A/E32C-45A ............................................................................ NAVAIR 17-600-762-6-2 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................................... NAVAIR 19-25-177 ALPHABETICAL INDEX TITLE WP / Page Number

Introduction..................................................................................................007 00 / 2 Troubleshooting...........................................................................................007 00 / 2

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 2 of 16

1.1 1.2

INTRODUCTION. This WP provides troubleshooting procedures used to identify the cause of unsatisfactory operation and other system discrepancies with the A/E32C-45A ECU. TROUBLESHOOTING. Table 1 provides information in troubleshooting and correcting of the ECU. Most operational difficulties have definite symptoms that serve as clues to the cause of system performance and/or condition discrepancies. Combinations of problems listed in Table 1, as well as other malfunctions are possible. Troubleshooting should be approached in a logical manner and the most obvious troubles checked first. Refer to WP 019 00 for schematic and wiring diagrams as an aid in troubleshooting.

2.1 2.2

2.3

Table 1. Troubleshooting. PROBLEM 1. ECU inoperative in all modes of operation. PROBABLE CAUSE a. Tripped circuit breaker in main power source. FAULT ISOLATION 1. Check MF power panel for 208 V, 60 Hz, 3 phase (NAVAIR 1925-177) for open circuit breaker (CB). 1. Check power cables connection. REMEDY 1. Refer to Mobile Facility Technical Manual NAVAIR 19-25177. Reset circuit breaker in power distribution panels. 1. Connect power cables. Refer to Mobile Facility Technical Manual NAVAIR 19-25177.

b. No input power.

2. Check power at ECU terminal board (TB2) in Control Box Assembly Panel. c. Defective transformer with respect to secondary winding (24 VAC). 1. In Control Box Assembly check for 24 VAC at transformer secondary winding with multimeter. Read 24 VAC 3 between TB3-C AND TB3-R. Replace defective transformer (WP 014 00).

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 3 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE FAULT ISOLATION REMEDY

NOTE Prior to troubleshooting, remove the indoor thermostat cover to expose the terminals on the PC board. d. Indoor thermostat defective. 1. FAN CIRCUIT. Place Fan switch to on. Refer to Figure 1. Place multimeter leads across R (24 VAC Transformer) on TB1 and G (Fan Relay) on TB3. The multimeter should read zero volts. Then place FAN switch to auto. Multimeter reading should be 24 3 volts when control is not calling for cooling. If thermostat calls for cooling, multimeter should read 3 volts or less. 2. COOLING CIRCUIT. Place multimeter across R and Y1. When control calls for cooling, the multimeter should read 3 volts or less. When control is not calling for cooling, the multimeter should read 24 3 volts. 1. Replace defective indoor thermostat (WP 014 00).

2. Replace defective thermostat (WP 014 00).

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 4 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE FAULT ISOLATION 3. HEATING CIRCUIT. 1st Stage Heating: Place multimeter across terminals R and B. When control calls for heating, the multimeter should read 2 to 3 volts. When control is not calling for heating, the multimeter should read 24 3 volts. 2nd Stage Heating: Place multimeter across terminals R and W2. Values for heating and not heating correspond to those found with 1st stage heating. REMEDY 3. Replace defective indoor thermostat (WP 014 00).

NOTE Turn off power to both unit and electrical heat prior to making continuity checks. e. Wiring open or shorted to ground. Check wiring for continuity with multimeter (Figures 1 thru 3, WP 019 00). Repair or replace defective wiring (WP 019 00).

NOTE Prior to troubleshooting, remove the thermostat from its wall mounting and carefully turn it over to expose test points on back of PC board. 2. ECU inoperative in cooling mode (with a room ambient temperature >76F/ 24C). Fan set AUTO. System set ON. a. Indoor thermostat defective. COOLING CIRCUIT. Place multimeter across R and Y1. When control calls for cooling, the multimeter should read continuity. When control is not calling for cooling, the multimeter should read open. Check indoor fan relay K2 coil terminals RD and BK for continuity with multimeter. Replace defective indoor thermostat (WP 014 00).

b. Indoor fan relay inoperative.

Replace defective indoor fan relay.

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 5 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE c. Contactor inoperative. FAULT ISOLATION Use multimeter to check contactor K1 coil terminals RD and BK for continuity. REMEDY Replace defective contactors.

NOTE Secure both unit and electrical heat power prior to making continuity checks. d. Indoor blower motor inoperative. Use multimeter to check indoor blower motor B2 for continuity of winding and shorts. Read continuity from motor lead RD to motor lead BK on K2 relay. Check motor lead RD to ground for short in motor. Test compressor motor B1 windings for continuity and shorts with multimeter. Remove cover from compressor junction box. Read the following: T1-T2 T2-T3 T1-T3 1 to 2 ohms 1 to 2 ohms 1 to 2 ohms Replace indoor blower motor (WP 018 00).

e. Compressor inoperative.

Replace defective compressor (WP 016 00).

Check T1 to gnd for short. Check T2 to gnd for short. Check T3 to gnd for short. f. HPCO switch tripped or defective 1. Check for tripped HPCO switch. 2. Using a multimeter, check between terminals for continuity. 1. Allow time for pressure equalization (2 min.). 2. Replace HPCO switch (WP 016 00).

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 6 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE g. LPCO switch tripped or defective. FAULT ISOLATION 1. Check system pressure for 40 PSI. REMEDY 1. Discharge system, repair leak, evacuate, and recharge system (WP 008 00 thru WP 012 00). 2. Replace LPCO switch (WP 016 00).

2. Using a multimeter check between LPCO switch S2 terminals for continuity. h. Outdoor fan relay inoperative. Check outdoor fan relay K3 terminals BE and BK for continuity with multimeter.

Replace defective outdoor fan relay.

NOTE Turn off power to ECU prior to making continuity checks.

WARNING
Discharge capacitor prior to fault isolation. i. Outdoor fan motor inoperative. Check outdoor fan motor B3 leads RD to BN and BK (on capacitor) to BN for continuity. Read outdoor fan motor lead RD to ground for short. Check wiring for continuity with multimeter. (Figures 1 thru 3, WP 019 00). Replace outdoor fan motor (WP 015 00).

j. Associated wiring open.

Repair or replace defective wiring (WP 019 00).

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 7 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE FAULT ISOLATION REMEDY

NOTE Prior to troubleshooting, remove the thermostat cover to expose test terminal points on PC board. 3. ECU inoperative in heat mode (with a room ambient <72F/22C). Fan set AUTO. System set ON. HEAT a. Faulty indoor thermostat. HEATING CIRCUIT: 1st Stage Heating: Place multimeter across terminals R and B. When controls calls for heating, the multimeter should read continuity. When control is not calling for heating, the multimeter should read open. 2nd Stage Heating: Place multimeter across terminals R and W2. Values for heating correspond to those found with 1st stage heating. b. High-pressure cutout switch tripped. 1. Check for tripped HPCO switch S1. 2. Using a multimeter check between terminals for continuity. 3. System overcharged. 1. HPCO switch. Allow time for pressure equalization (2 min.) 2. Replace HPCO switch (WP 016 00). 3. Discharge, evacuate and recharge the system (WP 008 00 thru 012 00). Replace defective indoor thermostat (WP 014 00).

WARNING
Turn off power to ECU prior to making continuity checks. c. Reversing valve coil inoperative. d. Outdoor fan relay inoperative. Check for continuity across coil terminals RV. Check outdoor fan relay K3 coil terminals BE and BK for continuity with multimeter. Replace reversing valve solenoid coil (WP 009 00). Replace defective outdoor fan relay.

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 8 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE FAULT ISOLATION REMEDY

WARNING
Turn off power to ECU prior to making continuity checks.

WARNING
Discharge capacitor prior to fault isolation. e. Outdoor fan motor inoperative. Check outdoor fan motor B3. Read continuity on outdoor fan motor between motor lead RD to BN and BK (on capacitor) to BN. Read outdoor fan motor lead RD to ground for short. Using multimeter, check contactor K1 coil terminals RD and BK for continuity. 1. Check system pressure for 40 PSI. Replace fan motor (WP 015 00).

f. Contactor inoperative.

Replace contactor.

g. LPCO switch tripped or defective.

1. Discharge system, repair leak, evacuate, and recharge system (WP 008 00 thru WP 012 00). Replace LPCO switch (WP 016 00).

2. Using a multimeter check between terminals for continuity.

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 9 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE FAULT ISOLATION REMEDY

WARNING
Turn off power to ECU prior to making continuity checks. h. Compressor inoperative. Test compressor motor B1 windings for continuity and shorts with multimeter. Remove cover from compressor junction box. Read the following: T1-T2 T2-T3 T1-T3 1 to 2 ohms 1 to 2 ohms 1 to 2 ohms Replace defective compressor (WP 016 00).

Check T1 to gnd for short Check T2 to gnd for short. Check T3 to gnd for short. i. Indoor fan relay inoperative. Check indoor fan relay K2 coil terminals RB and BK for continuity with multimeter. Replace defective indoor fan relay.

WARNING
Turn off power to ECU prior to making continuity checks. j. Indoor blower motor defective. Use multimeter to check indoor blower motor B2 for continuity of winding and shorts. Read continuity from motor lead RD to motor lead BK on relay K2. Check motor lead RD to ground for short in motor. Replace indoor blower motor (WP 018 00).

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 10 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE k. Reversing valve defective; stuck valve. FAULT ISOLATION Check reversing valve for switching action. Operate ECU in heating mode then in cooling mode. System should work in both modes. REMEDY Replace defective reversing valve (WP 016 00).

WARNING
Turn off power to ECU prior to making continuity checks. l. Associated wiring open. Check wiring for continuity with multimeter (Figures 1 thru 3, WP 019 00). Repair or replace defective wiring (WP 019 00).

NOTE Prior to troubleshooting, remove thermostat cover to expose test points on PC board. 4. Supplemental heat first stage inoperative (with room temperature <68F/20C). Fan switch set ON. System switch set to HEAT a. Indoor thermostat defective in 2nd stage heat. HEATING CIRCUIT. 2nd Stage Heat: Place multimeter across indoor thermostat terminals R and W2. When control calls for heating, the multimeter should read continuity. When control is not calling for heating, the multimeter should read open. Check heater relay K4 coil with multimeter between coil to terminal wire BE to terminal wire BK for continuity. Replace defective indoor thermostat (WP 014 00).

b. Electric heater relay defective.

Replace electric heater relay.

WARNING
Turn off power to ECU prior to making continuity checks. c. Heater cutout switch S4 defective. Check heater cutout switch S4 with multimeter. Check for continuity between terminals. Replace defective heater cutout switch S4 (WP 015 00).

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 11 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE d. Reversing valve defective; stuck valve. FAULT ISOLATION Check reversing valve for switching action. REMEDY Replace defective reversing valve (WP 016 00).

WARNING
Turn off power to ECU prior to making continuity checks. e. Associated wiring open. Check wiring for continuity with multimeter (Figures 1 thru 3, WP 019 00). Repair or replace defective wiring (WP 019 00).

WARNING
Secure power prior to making continuity checks.

NOTE Prior to troubleshooting, remove thermostat cover to expose test points on PC board. f. Heater cutout switch S4 defective. Check heater cutout switch S4 with multimeter. Check for continuity between terminals. Check wiring for continuity with multimeter (Figures 1 thru 3, WP 019 00). Visually check for open link or un-energized coil. Replace defective heater cutout switch S4 (WP 015 00).

g. Associated wiring open.

Repair or replace defective wiring (WP 019 00). Replace heating element (WP 015 00).

h. Fusible link or heating element defective.

WARNING
Secure power prior to making continuity checks. 5. Supplemental heat second strip inoperative (with an outdoor temperature <40F/4.4C) (first strip operative). Fan set ON. System set ON. Heat/Cool set a. Outdoor thermostat S5 defective. Check outdoor thermostat for continuity of thermostat terminals with multimeter. Replace defective outdoor thermostat.

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 12 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE b. Electric heater 2 relay defective. FAULT ISOLATION Check electric heater relay K5 coil with multimeter between coil terminal wire BE and terminal at wire BK for continuity Check wiring for continuity with multimeter. (Figures 1 thru 3, WP 019 00). Visually check for open link or unlit coil. REMEDY Replace defective electric heater relay.

c. Associated wiring open.

Repair or replace defective wiring (WP 019 00). Replace heating element (WP 015 00).

d. Fusible link or heating element defective.

WARNING
Turn off power to ECU prior to making continuity checks. 6. Unit will not defrost after outdoor coil ices up. a. Defective defrost control. Check defrost control output voltage to reversing coil for zero volts. Ensure thermal defrost switch is in contact with outdoor coil. b. Reversing valve solenoid defective. c. Associated wiring open. Check reversing valve for switching action. Check wiring for continuity with multimeter (Figures 1 thru 3, WP 019 00). Replace defective defrost control (WP 019 00, Figure 3). Reposition defrost switch sensor. Replace defective solenoid (WP 016 00). Repair or replace defective wiring (WP 019 00).

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 13 of 16

Table 1. Troubleshooting. PROBLEM PROBABLE CAUSE FAULT ISOLATION REMEDY

WARNING
Secure power prior to making continuity checks. NOTE Prior to troubleshooting, remove thermostat cover to expose test points on PC board. 7. Unit will not operate in ventilate mode. System switch set OFF. Fan switch set ON. a. Indoor thermostat defective. FAN CIRCUIT. Place FAN switch to ON. Place multimeter across R and G. The multimeter should read continuity. Then place FAN switch to AUTO. Multimeter reading should be open when control is not calling for cooling. If control calls for cooling, multimeter should read continuity. Check indoor fan relay K2 coil terminals for continuity with multimeter. Discharge capacitor and test with multimeter. Use multimeter to check indoor blower motor for continuity of winding and shorts. Read continuity from motor lead RD to motor lead BK on contactor. Check motor to ground for short in motor. Check wiring for continuity with multimeter (Figures 1 thru 3, WP 019 00). Check for proper electrical phasing. Check for leaks. Check mounting bolts. Replace defective indoor thermostat (WP 014 00).

b. Indoor fan relay defective.

Replace defective indoor fan relay.

c. Indoor blower motor capacitor defective. d. Indoor blower motor defective.

Replace capacitor

Replace defective indoor blower motor (WP 018 00).

e. Associated wiring open.

Repair or replace defective wiring (WP 019 00). Correct power wiring connections. Recharge with oil as necessary (WP 011 00). Tighten mounting bolts (WP 016 00).

8. Compressor noisy.

a. Compressor motor in reverse rotation. b. Compressor oil charge low. c. Compressor mounting assembly loose.

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 14 of 16

Table 1. Troubleshooting. PROBLEM 9. Indoor blower or outdoor fan noisy. PROBABLE CAUSE a. Fan mounting assembly loose. FAULT ISOLATION Check fan motor assembly mounting screws and bolts. Check motor for binding; or rubbing worn bearings. Visually check housing. Check for restricted airflow. REMEDY Tighten fan motor mounting screws and bolts (WP 015 00 and 018 00). Replace motor (WP 008 00 and 010 00). Remove foreign objects. Clean or replace indoor air filter and clean outdoor coil, louvers, and fan area. Straighten fins with fin comb. Remove any foreign material blocking airflow (NAVAIR 17-600-762-62). Discharge system; repair leak, evacuate and recharge system (WP 008 00 and WP 012 00). Discharge system; repair leak, evacuate and repair system (WP 008 00 and WP 012 00). Replace filter-dryer (WP 016 00). Replace defective fan (WP 015 00 or WP 018 00).

b. Defective bearings.

c. Foreign objects in fan housing. 10. ECU operates inefficiently. a. Indoor air filter or outdoor coil blocked causing poor air circulation. b. Bent cooling fins. c. Blocked or dirty coils.

Check for bent/damaged fins. Check for restricted airflow.

d. Leak in refrigerant system.

Check system for refrigerant leaks (WP 010 00).

e. Icing of indoor/outdoor coils (low refrigerant charge).

Check system for refrigerant leaks (WP 010 00).

f. Restricted filter-dryer will cause low suction pressure. g. Indoor or outdoor fan motor inoperative.

Check filter-dryer.

Check indoor or outdoor fan motor.

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 15 of 16

Terminals

Figure 1. Indoor Thermostat Circuit Board.

NAVAIR 17-1-573
01 MARCH 2009

007 00
Page 16 of 16

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

008 00
Page 1 of 10

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN LEAK TEST ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 007 00 - Testing and Troubleshooting Procedures .................... NAVAIR 17-1-573 WP 010 00 - Evacuation.................................................................... NAVAIR 17-1-573 WP 011 00 - Charging....................................................................... NAVAIR 17-1-573 WP 012 00 - Pressure Test ............................................................... NAVAIR 17-1-573 WP 015 00 - Refrigeration Assembly ................................................ NAVAIR 17-1-573 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ..................................... NAVAIR 19-25-177 ALPHABETICAL INDEX TITLE WP / Page Number

Leak Test.....................................................................................................008 00 / 3 Leak Test Methods...................................................................................008 00 / 3 Electronic Leak Detector. ......................................................................008 00 / 3 Soap Solution Leak Detection...............................................................008 00 / 3 Troubleshooting Leak Test..........................................................................008 00 / 3 Post Maintenance / Pre Charge Leak Test ..............................................008 00 / 6 When Leak is Detected after Post-Maintenance / Pre Charge Leak Test..................................................................................................008 00 / 8 When No Leak Is Found After Post-Maintenance / Pre Charge Leak Test..................................................................................................008 00 / 9 SUPPORT EQUIPMENT REQUIRED DESCRIPTION NUMBER

Detector Kit, Gas (Soap Solution Kit)......................................................... 4180-53 (07295)

NAVAIR 17-1-573
01 MARCH 2009
DESCRIPTION NUMBER

008 00
Page 2 of 10

Gloves ........................................................................................................ MIL-G-521 Goggles ...................................................................................................... GG-G-521 Leak Detector, Refrigerant (R-134A) ......................................................... - Manifold, AC, R134, 4 Valve with Hose Set............................................... 3XL15 Respirator................................................................................................... GGG-M-125 Robinair Recovery, Recycling, and Recharging Unit ................................. 17800B Walkaround Bottle ...................................................................................... 1428AS100 MATERIALS REQUIRED NOMENCLATURE NUMBER

3M Coating ................................................................................................. _._ Glycerin ...................................................................................................... - Refrigerant.................................................................................................. R134A Recovery Bottle .......................................................................................... - Dry Nitrogen Cylinder ................................................................................. - -

NAVAIR 17-1-573
01 MARCH 2009

008 00
Page 3 of 10

1.1 1.2

INTRODUCTION. This WP provides instructions for performing a leak test of the refrigeration system assembly of the A/E32C-45A ECU. LEAK TEST. There are two instances when a leak test of the refrigeration assembly is performed. One instance is the troubleshooting leak test which is performed when directed by the troubleshooting procedures (WP 007 00). The other instance is the post-maintenance / pre charge leak test, which is performed after repair or replacement of any part and/or component of the refrigerant system. The post maintenance / pre charge leak test is performed to confirm the refrigerant system has no leaks before charging the ECU with R134A refrigerant. Areas to test for refrigerant leaks listed in relative order of susceptibility for leaks include: rotolock fittings, flare nuts, indoor and outdoor coils, brazed joints under insulation, and capillary tubes. LEAK TEST METHODS. There are two methods to leak test the refrigeration system. Electronic Leak Detector. Use of an electronic refrigerant gas leak detector is the preferred method for detecting refrigerant leaks when troubleshooting an ECU containing some refrigerant charge. The electronic refrigerant gas leak detector is highly sensitive to the presence of a minute quantity of refrigerant gas in the air making it very effective in the detection of even very small leaks. However, it may be necessary to use the soap solution method to pin point the source of a leak detected by the electronic leak detector. Soap Solution Leak Detection. In this method, a strong solution of a liquid detergent and water is brushed onto exposed tubing and fittings of the refrigeration assembly where leak is suspected. A few drops of glycerin added to the solution will cause lather to remain wet longer. The soap solution is then closely visually observed for the formation of bubbles. TROUBLESHOOTING LEAK TEST. Troubleshooting Suspected Refrigerant Leak Test Using Electronic Leak Detector.

2.1 2.2

2.3

2.4 2.5 2.6

2.7

3.1 3.2

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177.

NAVAIR 17-1-573
01 MARCH 2009

008 00
Page 4 of 10

NOTE It is necessary for the refrigeration assembly to contain sufficient charge (pressure) with at least some R134A refrigerant gas for the electronic leak detector to detect and locate a leak. If additional charge is needed to perform leak test then charge system with nitrogen and a minute quantity of R134A. 2. Ensure refrigeration system has a minimum charge of R134A refrigerant IAW WP 012 00, Pressure Test. If there is sufficient charge then go to step 3.2.3. Otherwise, charge refrigeration system for leak test with nitrogen and a minute quantity of R-134A refrigerant, refer to, Post-Maintenance / Pre Charge Leak Test, this WP. Then proceed as follows. Leave charging manifold in place until leak test is completed. 3. Refer to Figure 1, Refrigeration Assembly. Using electronic leak detector IAW manufacturer instructions systematically check refrigeration system for leaks. Check entire system tagging, marking, or recording areas where leaks are detected. If a leak is detected but cannot be pinpointed then use the soap solution procedure, this WP, to pinpoint source of leak. 4. If a leak is detected, refer to, When Leak is Detected, this WP. 5. If no leak is detected return to troubleshooting procedures (WP 007 00). 3.3 Troubleshooting Suspected Refrigerant Leak Test Using Soap Solution.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. NOTE Leak test using the Soap Solution procedure does not require the presence of R134A in the refrigeration assembly. If a charge is needed to perform the test, the system may be pressurized with dry nitrogen alone. 2. Ensure refrigeration system has sufficient charge (pressure) IAW WP 012 00, to accomplish leak test. Leave charging manifold in place until leak test is completed. If there is sufficient charge then go to step 3.3.3. Otherwise, discharge / recover any refrigerant in system IAW WP 010 00, then charge refrigeration assembly with nitrogen using walkaround bottle / nitrogen cylinder as follows. a. Ensure power to ECU is secured by turning off circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177.

WARNING
High pressures used in this test may cause serious injury to personnel if unit should fail suddenly. Stand in a safe location while building up pressure. b. Prior to connecting manifold, close valves. Ensure walkaround bottle / nitrogen cylinder regulator shutoff valve is closed. c. Connect walkaround bottle / nitrogen cylinder hose (yellow hose) to manifold center connection.

NAVAIR 17-1-573
01 MARCH 2009

008 00
Page 5 of 10

d. Remove hose connection protective caps from the refrigeration assembly high and low pressure service valves. Refer to Figure 1, Refrigeration Assembly (Leak Test Set-Up). e. Connect manifold red and blue hoses to high and low pressure service valves of refrigeration assembly. f. Set pressure regulator on walkaround bottle / nitrogen cylinder for minimum pressure.

g. Slowly open high side manifold valve. h. Slowly open walkaround bottle / nitrogen cylinder shutoff valve. i. j. k. Slowly increase system pressure to 300 PSIG (21.2kg/cm) by adjusting pressure regulator on walkaround bottle / nitrogen cylinder. Hold system pressure at 300 PSIG (21.2kg/cm) with pressure regulator. Coat all refrigeration assembly fittings, seals and exposed tubing with soap solution. Observe soap solution coated areas for formation of soap bubbles. Bubbles will form in area of leak. Tag, mark or record locations of any leaks.

l.

WARNING
Do not attempt to repair a leak, except as noted on paragraph 5.1.2, with the refrigeration assembly under pressure. Serious injury or death to personnel may result. m. Adjust nitrogen pressure regulator for minimum pressure. n. Close walkaround bottle / nitrogen cylinder shutoff valve. o. Shut manifold high side valve (red). p. Release nitrogen pressure trapped in hose using walkaround bottle / nitrogen cylinder bleed valve, if equipped. q. Disconnect walkaround bottle / nitrogen cylinder hose from manifold. r. s. t. Slowly open manifold high side valve (red) to release nitrogen pressure from refrigeration assembly. Disconnect manifold hoses from high and low pressure service valves of refrigeration assembly. Install the protective caps on the high and low-pressure service valves.

3. Refer to Figure 1, Refrigeration Assembly. Mix soap and water to obtain a solution that will lather freely. A few drops of glycerin added to the solution will cause lather to remain wet longer. Apply soap solution systematically to the suspected joint(s). Visually observe solution for bubbles forming which indicates a leak. Check entire system noting areas where leaks are detected. 4. If nitrogen was added, discharge nitrogen into the atmosphere. 5. If no nitrogen was added and a leak is detected, discharge / recover any refrigerant in system IAW WP 009 00, make repairs to refrigeration assembly IAW WP 015 00, and then perform post maintenance / pre charge leak test. 6. If no leak is detected return to troubleshooting procedures (WP 007 00).

NAVAIR 17-1-573
01 MARCH 2009
4.1 POST-MAINTENANCE / PRE CHARGE LEAK TEST.

008 00
Page 6 of 10

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. NOTE A post-maintenance / pre charge leak test is performed whenever the refrigeration assembly is opened to the environment for repair and/or replacement of a component. The postmaintenance / pre charge leak test is performed after repairs are complete and the filter dryer is replaced. 2. Charging manifold or Robinair Recovery / Recycling / Recharging unit should remain in place until leak test is completed. 3. Perform post maintenance / pre charge leak test using electronic leak detector or soap solution. 4. If using electronic leak detector do as follows. NOTE It is necessary for the refrigeration assembly to be charged with nitrogen and a minute quantity of R134A refrigerant gas for the electronic leak detector to detect and locate a leak.

REFRIGERANT - R134A

a. Charge system with nitrogen and a minute quantity of R134A as follows: b. Remove the hose connection protective caps from the high and low pressure service valves. c. Connect the hoses from a charging manifold to the service valves.

d. Connect a cylinder of R134A to the center hose connection of the charging manifold. CAUTION Connect the R134A cylinder in the upright position so that only gas will be used for pressurization. e. Open both charging manifold valves. f. Open the refrigerant cylinder valve slightly and allow a small amount of refrigerant gas to enter the system.

g. Close the charging manifold valves and the refrigerant cylinder valve. h. Remove the R134A cylinder from the center hose connection and connect to the nitrogen regulator.

NAVAIR 17-1-573
01 MARCH 2009
i. j.

008 00
Page 7 of 10

Open the charging manifold valves and the nitrogen cylinder and regulator valve. Allow system pressure to build up until gauges read 300 PSIG (21.2kg/cm). Use electronic leak detector IAW manufacturers instructions to systematically check refrigeration system for leaks. Check entire system noting areas where leaks are detected. If a leak is detected but cannot be pinpointed then use the soap solution procedure. If a leak is detected, refer to, When Leak is Detected, this WP. If no leak is detected, refer to, When No Leak Is Found After Post-Maintenance / Pre Charge Leak Test, this WP.

k. l.

5. If using soap solution do as follows. NOTE Leak test using the soap solution procedure does not require the presence of R134A in the refrigeration assembly. 6. Charge refrigeration assembly with dry nitrogen using walkaround bottle or nitrogen cylinder as follows.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. a. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177.

WARNING
High pressures used in this test may cause serious injury to personnel if unit should fail suddenly. Stand in a safe location while building up pressure. b. Prior to connecting manifold, close valves. Ensure walkaround bottle / nitrogen cylinder regulator valve shutoff valve is closed. c. Connect walkaround bottle/ nitrogen cylinder hose (yellow hose) to manifold center connection.

d. Remove hose connection protective caps from the refrigeration assembly high and low pressure service valves. Refer to Figure 1, Leak Test Set-up. e. Connect manifold hoses to high and low pressure service valves of refrigeration assembly. f. Set pressure regulator on walkaround bottle / nitrogen cylinder for minimum pressure.

g. Slowly open high side manifold valve. h. Slowly open walkaround bottle / nitrogen cylinder shutoff valve. i. j. Slowly increase system pressure to 300 PSIG (21.2kg/cm) by adjusting nitrogen with pressure regulator on walkaround bottle / nitrogen cylinder. Hold system pressure at 300 PSIG (21.2kg/cm) with pressure regulator.

NAVAIR 17-1-573
01 MARCH 2009
k.

008 00
Page 8 of 10

Coat all refrigeration assembly fittings, seals and exposed tubing with soap solution. Observe soap solution coated areas for formation of soap bubbles. Bubbles will form in area of leak. Tag, mark or record locations of any leaks.

l.

m. Adjust nitrogen pressure regulator for minimum pressure. n. Close walkaround bottle shutoff valve. o. Shut manifold high side valve (red). p. Release nitrogen pressure trapped in hose using walkaround bottle bleed valve. q. Disconnect walkaround bottle / nitrogen cylinder hose from manifold. r. s. t. Slowly open manifold high side valve (red) to release nitrogen pressure from refrigeration assembly. Disconnect manifold hoses to high and low pressure service valves of refrigeration assembly Install the protective caps on the high and low-pressure service valves.

7. Mix soap and water to obtain a solution that will lather freely. A few drops of glycerin added to the solution will cause lather to remain wet longer. Apply soap solution systematically to small sections of the refrigeration system visually observing solution for bubbles forming which indicates a leak. Check entire system noting areas where leaks are detected. 8. If a leak is detected, refer to, When Leak Is Detected, this WP. 9. If no leak is found, refer to, When No Leak Is Found After Post-Maintenance / Pre Charge Leak Test, this WP. 5.1 WHEN LEAK IS DETECTED.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat.. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177.

WARNING
Do not attempt to repair a leak, except as noted on paragraph 5.1.2, with the refrigeration assembly under pressure. Serious injury or death to personnel may result. 2. If leak is found to be at rotolock and/or flare nut fitting/connection tighten rotolock and/or flare nut IAW WP 015 00 beyond initial minimum torque value and check to see if leak is eliminated. If leak cannot be eliminated by tightening leaking rotolock or flare fitting/connection, do as follows. 3. Release pressure from refrigeration assembly. 4. Replace rotolock gasket or Teflon tape on flare fitting (WP 015 00). 5. Repeat leak test.

NAVAIR 17-1-573
01 MARCH 2009

008 00
Page 9 of 10

6. If no leak is found, refer to, When No Leak Is Found After Post-Maintenance / Pre Charge Leak Test, this WP. 7. If leak persists and cannot be found replace ECU IAW this manual and NAVAIR 19-25-177. 6.1 WHEN NO LEAK IS FOUND AFTER POST-MAINTENANCE / PRE CHARGE LEAK TEST.

1. Replace any insulation that was removed from refrigeration assembly tubing to facilitate leak test (WP 015 00). 2. Apply 3M coating to all exposed fittings and connections NAVAIR 19-25-177. 3. Evacuate refrigeration assembly IAW WP 011 00, then charge system IAW WP 012 00 and prepare ECU for use IAW WP 005 00.

NAVAIR 17-1-573
01 MARCH 2009

008 00
Page 10 of 10

HIGH PRESSURE HOSE (RED)

(BLUE) NITROGEN REGULATOR AND DRY NITOGEN TANK OR WALK AROUND BOTTLE

(YELLOW)

Figure 1. Leak Test Setup.

NAVAIR 17-1-573
01 MARCH 2009

009 00
Page 1 of 12

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN DISCHARGE / RECOVERY ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 013 00 - Indoor Thermostat, Panels, and Covers ...................... NAVAIR 17-1-573 WP 015 00 - Refrigeration Assembly ................................................ NAVAIR 17-1-573 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility NAVAIR 19-25-177

Management of Ozone Depleting Substances ................................. OPNAVINST 5090.2 ALPHABETICAL INDEX TITLE WP / Page Number

Alternate Method for Discharge / Recovery of Refrigerant .........................009 00 / 11 Discharge / Recovery of Refrigerant with Robinair Unit..............................009 00 / 8 Introduction..................................................................................................009 00 / 3 Setup of Robinair Unit .................................................................................009 00 / 3 SUPPORT EQUIPMENT REQUIRED DESCRIPTION NUMBER

Gloves ........................................................................................................ MIL-G-521 Goggles ...................................................................................................... GG-G-521 Manifold, AC, R134, 4 Valve with Hose Set............................................... 3XL15 Respirator................................................................................................... GGG-M-125 Robinair Recovery, Recycling, and Recharging Unit ................................. 17800B MATERIALS REQUIRED NOMENCLATURE NUMBER

Dry Nitrogen Cylinder ................................................................................. - -

NAVAIR 17-1-573
01 MARCH 2009
NOMENCLATURE NUMBER

009 00
Page 2 of 12

Recovery Bottle .......................................................................................... - Refrigerant R134A...................................................................................... R134A Robinair 50 lb (23 kg) Unit (Storage) Tank, 1/4 Inch Flare Fittings ........... 17506 Robinair Filter Dryer .................................................................................. 19776 Robinair Vacuum Pump Oil (1 Quart) ........................................................ 13203

NAVAIR 17-1-573
01 MARCH 2009
1.1 INTRODUCTION.

009 00
Page 3 of 12

This WP provides instructions for using the Robinair Recovery, Recycling, and Recharging Unit, part number 17800B to discharge / recover the refrigerant from the A/E32C-45A ECU. For an alternate procedure (not using the Robinair unit) for discharge / recovery refer to, Alternate Method For Discharge / Recovery Of Refrigerant, this WP. 2.1 SETUP OF ROBINAIR UNIT. NOTE Operation of the Robinair recovery/recycling unit must be by authorized personnel only. 2.2 Perform setup when Robinair unit is being used for the first time or as needed after unit tank replacement, maintenance, etc. Pressure / Temperature Chart

Door Screw

System Oil Drain Valve

Vacuum Pump

Door Screw

Figure 1. System Oil Drain Valve / Access to Vacuum Pump. 1. Open the system oil drain valve and allow the Robinair unit to depressurize. (Figure 1.) NOTE If an extension cord must be used, use a No. 14 AWG minimum and keep cord length 25 feet or less in length. 2. Plug the Robinair unit into a 110/120 VAC grounded electrical outlet.

NAVAIR 17-1-573
01 MARCH 2009
3. Close the system oil drain valve.

009 00
Page 4 of 12

4. On Robinair control panel use main power switch to turn on the Robinair unit. The control panel display may flash door, 134a or R12. (Figure 2). NOTE The A/E32C-45A, ECU, uses R-134A refrigerant and 1/4 inch flare fitting service valves. However, the Robinair unit, designed for use with automotive air conditioning systems, has hardware and software that equate use of R-134A refrigerant with 1/2 inch Acme fittings. This creates the potential for confusion because the Robinairs R-12 (1/4 inch) fittings must be used in order to purge/recover, evacuate, and charge the A/E32C-45A, ECU. In addition, because of the position of the lockout door, the Robinair display will show R12 when actually R-134A is being used. 5. Slide the lockout door (in upper left corner of the back of unit) to the right to expose the 1/4 inch fittings (the R-12 position). The door will lockout (cover) the 1/2 inch fittings. (Figure 3).

Liquid Vapor Indicator Tank Pressure Gage System Oil Indicator Low Side Gage High Side Gage

Tank Temperature Gage High Side Valve Air Purge Valve Display Main Power Switch Low Side Valve Unit Circuit Breaker (17000B Only Oil-less Compressor Protector

Keypad

Keypad Expanded View

Figure 2. Robinair Control Panel With Expanded View of Keypad.

NAVAIR 17-1-573
01 MARCH 2009

009 00
Page 5 of 12

Lockout Door

1/4 inch Fittings

Figure 3. Lockout Door with R-12 (1/4 inch) Fittings Exposed. 6. On the control panel, press SHIFT/RESET. 7. Connect the 36 inch red hose to the RED 1/4 inch fitting. (Figure 3). 8. Connect the 36 inch blue hose to the BLUE 1/4 inch fitting. (Figure 3). 9. Connect the 36 inch yellow hose to the YELLOW 1/4 inch fitting. (Figure 3). NOTE A new unit (storage) tank comes with a dry nitrogen charge of 5 to 10 psi to keep it clean and dry during shipment. 10. Purge the nitrogen charge in a new unit tank by opening the gas (vapor) valve on the tank. Vent the pressure to the atmosphere ; then close the valve. 11. Place the unit tank inside the ring on the scale platform at the back of the Robinair unit. Loop the tank strap through the tank collar, and secure the latch end of the strap to the metal loop at the other end of the strap. Tighten the thumb screw on the scale ring to secure the tank to the scale platform. 12. Connect the 36 inch red hose to the RED valve on the unit tank. Open the valve. 13. Connect the 36 inch blue hose to the BLUE valve on the unit tank. Open the valve. 14. Connect the 36 inch yellow hose to the air purge fitting. 15. On the Robinair control panel, open both the low- and high-side valves. (Figure 2).

NAVAIR 17-1-573
01 MARCH 2009

009 00
Page 6 of 12

NOTE The Robinairs vacuum pump is shipped without oil in the reservoir. Before starting the vacuum pump the first time it is necessary to fill it with oil.

ROBINAIR VACUUM PUMP OIL, 13203

16. Attach flexible spout and cap to a bottle of vacuum pump oil. 17. Remove the door access screws from the right side of the Robinair unit. Open the door to access the vacuum pump (Figure 1). 18. Remove the black plastic plug from the vacuum pumps oil fill port. Do not discard plug. (Figure 4). 19. Pour no more than eight (8) ounces of vacuum pump oil into the vacuum pump. This is the only time oil is added to the reservoir when the pump is not running. Oil Filler Tube For Vacuum Pump Oil Bottle

Pump Exhaust Inlet Oil Fill Port

Sight Glass

Oil Drain Fitting

Figure 4. Robinair Vacuum Pump.

NAVAIR 17-1-573
01 MARCH 2009

009 00
Page 7 of 12

NOTE To fully charge the vacuum pump oil reservoir the vacuum pump must be running. The capacity of the vacuum pump oil reservoir is approximately 13 ounces. 20. On the Robinair control panel press SHIFT/RESET and ENTER at the same time; then press 1. The vacuum pump will start and run continuously. 21. Slowly pour oil into the vacuum pump oil fill port until the level of oil is even with the line on the pump reservoir sight glass. 22. Insert the black plastic plug into the oil fill port. 23. Operate the vacuum pump for 5 minutes after adding oil to the reservoir. This removes any air from the system. 24. On the Robinair control panel press HOLD/CONT to turn off vacuum pump. 25. On the Robinair control panel press SHIFT/RESET to exit the diagnostics mode. 26. Connect the 96 inch blue hose to the low side port. (Figure 3). 27. Connect the 96 inch red hose to the high side port. (Figure 3). NOTE The unit (storage) tank must be purged of its shipping nitrogen charge and pulled into a vacuum before it can be charged with refrigerant. 28. If not previously accomplished, purge the 5 to 10 psi nitrogen charge in a new unit tank by opening the gas (vapor) valve on the tank. Vent the pressure to the atmosphere ; then close the valve. 29. Evacuate the unit tank. NOTE The unit tank must be filled with refrigerant before the Robinair unit is ready for use. The Robinair accessory kits 1/2 inch Acme to low side adapter may be needed. The capacity of the unit tank is 50 lb (23 kg). Some tanks have slightly different valve configurations. Be sure to connect the 96 inch blue low side hose to the liquid valve on the source (supply) tank. This valve may be red on some tanks and blue on others.

REFRIGERANT - R134A

30. Connect the 96 inch blue (low) side hose to the liquid valve fitting on a source (supply) tank. NOTE To discontinue tank fill at any time, press HOLD/CONT on Robinair control panel. 31. On the Robinair control panel, press at the same time SHIFT/RESET and ENTER.

NAVAIR 17-1-573
01 MARCH 2009

009 00
Page 8 of 12

32. Press 2. The Robinair unit will begin transferring refrigerant from the source (supply) tank to the unit tank. 33. The display will flash CPL when the Robinair unit automatically stops indicating the unit tank is filled with approximately 30 lbs of refrigerant. 34. The Robinair unit is now ready for use. 3.1 DISCHARGE/RECOVERY OF REFRIGERANT USING ROBINAIR UNIT.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Set indoor thermostat system switch to OFF and fan switch to AUTO. NOTE Environmental Protection Agency regulations require that refrigerants not be discharged into the atmosphere. A refrigerant recovery unit must be used whenever discharging the refrigerant system. Operation of the recovery/recycling unit must be by personnel with EPA certification IAW OPNAVINST 5090.2. 3. Ensure Robinair unit was setup for use; refer to Setup Of Robinair Unit, this WP. 4. Verify there is vacuum pump oil in the Robinair vacuum pump. Oil should be even with the line on the vacuum pump reservoir sight glass. 5. Remove lower rear service panel IAW WP 013 00 to access ECU refrigeration assembly compressor and tubing.

REFRIGERANT - R134A

6. Refer to Figure 5. Unscrew protective caps from ECU refrigeration assembly suction (lowpressure) service valve and discharge (high-pressure) service valve. CAUTION Do not use a refrigerant recovery and recycle unit if it has been used, or is suspected of having been used, with R-22, or any other refrigerant. Cross-contaminated refrigerant can cause damage to or failure of ECU. NOTE This procedure is written for use with the Robinair Recovery and Recycling Unit, part number 17800B. Consult the Robinair vendor manual if any conditions arise with operation of the Robinair unit not covered in this WP. 7. Place Robinair unit near the ECU from which refrigerant is to be discharged/recovered.

NAVAIR 17-1-573
01 MARCH 2009

009 00
Page 9 of 12
High Side Port (RED hose) Low Side Port (BLUE hose) Lockout Door

To Reversing Valve

Suction Service Valve (low side) BLUE Hose

ECU Compressor

Discharge Service Valve (high side) RED Hose

Figure 5. Connection of Robinair to ECU Refrigeration Assembly for Discharge/Recovery. 8. Connect the 96-inch long blue hose with 1/4 inch flare fittings from Robinair unit low side port to ECU suction service valve (low side). (Figure 5). 9. Connect the 96-inch long red hose with 1/4 inch flare fittings from Robinair unit high side port to ECU discharge service valve (high side). (Figure 5). 10. On the Robinair control panel, verify both the high and low side valves are open (Figure 3). 11. Verify both valves on the Robinair units tank are open. NOTE If an extension cord must be used, use a No. 14 AWG minimum and keep cord length 25 feet or less in length. 12. Plug Robinair unit into 110-120 VAC outlet. 13. Turn on the MAIN POWER switch. The display on Robinair unit will indicate R12 because the lockout door is set for use of the 1/4 inch flare fittings. NOTE There must be at least 6 pounds and no more than 30 pounds of R-134A refrigerant in the unit tank for the Robinair unit to operate correctly. If the unit tank contains too little or too much refrigerant the display will indicate CHECK REFRIGERANT. 14. Verify unit tank weight. On the Robinair control panel, press at the same time SHIFT/RESET and ENTER. FUNC appears on the display.

NAVAIR 17-1-573
01 MARCH 2009

009 00
Page 10 of 12

15. Press 7. The weight of the unit tank is displayed. If the weight is at least 6 pounds and no more than 30 pounds proceed with discharge/recovery. 16. On the Robinair control panel, press SHIFT/RESET. 17. Press RECOVER. NOTE If there is no internal pressure in the Robinair unit, recovery of refrigerant from the ECU begins immediately. 18. CL-L shows on the display if there is pressure in the Robinair unit, and a self-clearing process of the components begins. 19. Press HOLD/CONT to bypass clearing if an accurate recovery amount is not required. Otherwise, the Robinair units compressor will start and the CL-L remains on the display. The clearing process takes from 20 seconds to four minutes to complete. When clearing is complete, the Robinair unit automatically begins to recover refrigerant from the ECU. NOTE CH-P appears on the display if the ECU refrigeration assembly pressure is 25 PSI or less. This serves as an alert not to attempt recovery from an empty system. Do not press HOLD/CONT to continue the recovery process unless the ECU refrigeration assembly contains refrigerant. 20. The display shows that the unit is in the RECOVER mode and the AUTOMATIC cycle. Monitor the amount of refrigerant removed from the system by watching the display. 21. The Robinair units compressor shuts off automatically when recovery is complete (at approximately 13 inches of vacuum). The display shows CPL, and then alternately flashes the weight of refrigerant recovered. 22. To assure complete recovery of refrigerant, wait for five minutes and watch the manifold gauges for a rise in pressure above 0 psi. If a rise occurs, press HOLD/CONT. Repeat as needed until the system pressure holds for two minutes. 23. Drain the oil from the separator only after each recovery. Do not completely depressurize the oil separator; immediately close the valve when oil is completely drained in the next step. The lower right corner of the display will indicate OIL (OUNCES) as a reminder. 24. Verify the oil catch bottle is empty, then slowly open the oil drain valve, and drain the oil into the oil catch bottle. This oil was removed from the ECU refrigerant system during recovery. When all the recovered oil has completely drained, immediately close the valve. Dispose of waste oil in an appropriate manner. 25. If the recovery tank fills completely; the compressor will shut off and the digital display shows the message FULL. If this happens, change the unit tank. 26. The refrigeration assembly is now discharged -- empty of refrigerant. Make any needed repairs to the ECU refrigeration assembly and/or replace ECU refrigeration assembly components at this time IAW WP 015 00.

NAVAIR 17-1-573
01 MARCH 2009
4.1 ALTERNATE METHOD FOR DISCHARGE / RECOVERY OF REFRIGERANT.

009 00
Page 11 of 12

4.2 This alternate procedure is for discharging the refrigeration assembly using a charging manifold and recovery and recycling equipment other than the Robinair unit. 4.3 DISCHARGE OF REFRIGERANT FROM REFRIGERATION ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Set indoor thermostat system switch to OFF position and fan switch to AUTO. 3. Remove lower rear panel to access ECU refrigeration assembly components. CAUTION Ensure refrigerant recovery and recycle equipment is for use with R-134A refrigerant. Do not use equipment if it has been used, or is suspected of having been used, with R-22, or any other, refrigerant. Cross contamination of refrigerants can cause damage or operational failure of ECU. NOTE There are several different recovery units in use. Consult the vendor / technical manual of the model being used for specific hookup and operation. Maintenance personnel must be EPA certified IAW OPNAVINST 5090.2.

REFRIGERANT - R134A

4. Unscrew hose connection protective caps from suction (low-pressure) service valve and discharge (high-pressure) service valve (Figure 4). 5. Position charging manifold near ECU compressor. 6. Ensure charging manifold valves are closed. 7. Position recovery and recycling unit near ECU. 8. Connect charging manifold hoses to the manifold and service valves as follows. 9. Connect blue manifold hose to suction service valve (low side) and compound gage of charging manifold. 10. Connect red manifold hose to discharge service valve (high side) and pressure gage of charging manifold. 11. Connect yellow manifold hose to center connection of charging manifold. 12. Connect other end of yellow manifold hose to the recovery and recycling unit. 13. Slowly open the low-pressure service valve on manifold to allow refrigerant gas to flow slowly out of the hose.

NAVAIR 17-1-573
01 MARCH 2009

009 00
Page 12 of 12

14. Slowly open high-pressure service valve to allow refrigerant gas to flow slowly out of the hose. 15. Check the discharge (red) hose for the presence of oil. 16. Disconnect red hose from manifold. 17. Check for presence of oil visually by observing mist for open end of red hose. If oil is present, adjust (close slightly) manifold valves as necessary to prevent oil discharge. 18. Reconnect red hose to manifold. 19. When gas stops flowing (pressure gage reads zero (0) psi), close both service valves. 20. Disconnect recovery-recycling unit from manifold. Leave center hose connected to center port of manifold. 21. The refrigeration assembly is now discharged -- empty of refrigerant. Make any needed repairs to the refrigeration assembly and/or replace refrigeration assembly components at this time IAW WP 015 00.

Pressure Gage

To Discharge Service Valve (High Side) To Suction Service Valve (Low Side)

High Pressure Hose (RED)

Compound Gage

Charging Manifold Low Pressure Hose (BLUE) Discharged Refrigerant (YELLOW Hose)

To Reversing Valve Suction Service Valve (Low Side) BLUE hose Discharge Service Valve (High Side) RED hose

Recovery Recycling Unit

ECU Compressor

Figure 6. Discharging Refrigerant Setup (Using non-Robinair Equipment).

NAVAIR 17-1-573
01 MARCH 2009

010 00
Page 1 of 8

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN EVACUATION ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE WP 008 00 - Leak Test Troubleshooting WP 009 00 Discharge / Recovery WP 011 00 - Charging Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility Management of Ozone Depleting Substances ALPHABETICAL INDEX TITLE WP / Page Number NUMBER NAVAIR 17-1-573 NAVAIR 17-1-573 NAVAIR 17-1-573 NAVAIR 19-25-177 OPNAVINST 5090.2

Alternative Method for Evacuation of ECU Refrigeration Assembly ...........010 00 / 6 Evacuation of Refrigeration Assembly with Robinair Unit...........................010 00 / 3 Introduction..................................................................................................010 00 / 3 SUPPORT EQUIPMENT REQUIRED DESCRIPTION NUMBER

Gloves ........................................................................................................ MIL-G-521 Goggles ...................................................................................................... GG-G-521 Manifold, AC, R134, 4 Valve with Hose Set............................................... 3XL15 Respirator................................................................................................... GGG-M-125 Robinair Recovery, Recycling, and Recharging Unit ................................. 17800B Vacuum Pump............................................................................................ 4Z577

NAVAIR 17-1-573
01 MARCH 2009
MATERIALS REQUIRED NOMENCLATURE NUMBER

010 00
Page 2 of 8

Refrigerant.................................................................................................. R134A

NAVAIR 17-1-573
01 MARCH 2009

010 00
Page 3 of 8

1.1 1.2

INTRODUCTION. This WP provides instructions for evacuating the refrigeration assembly using the Robinair Recovery, Recycling, and Recharging Unit, part number 17800B. An alternate method using a manifold and vacuum pump instead of the Robinair unit for evacuation of the ECU refrigeration assembly refer to, Alternate Method For Evacuation Of ECU Refrigeration Assembly, this WP. EVACUATION OF REFRIGERATION ASSEMBLY WITH ROBINAIR UNIT. The ECU refrigeration assembly must be evacuated and leak tested prior to charging. Evacuation of the refrigeration assembly is accomplished by drawing a vacuum on the compressor low side at the suction line service valve. Proceed as follows.

1.3

2.1 2.2

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. CAUTION Do not use Robinair unit if it has been used, or is suspected of having been used, with R-22, or any other refrigerant. Cross contamination of refrigerants can cause damage to or failure of ECU. NOTE This procedure is written for use with the Robinair Recovery and Recycling Unit, part number 17800B. Operation of the recovery/recycling unit must be by personnel with EPA certification IAW OPNAVINST 5090.2. 2. Set indoor thermostat system switch to OFF and fan switch to AUTO. 3. Verify the Robinair unit is setup as described in, Setup Of Robinair Unit, WP 009 00. 4. Verify there is vacuum pump oil in the vacuum pump.

REFRIGERANT - R134A

5. Verify the Robinair units 96 inch hoses are connected to the ECU refrigeration assemblys service valves: RED hose to discharge service valve (high side) and Blue hose to suction service valve (low side). (Figure 1). 6. On the Robinair control panel, verify the high and low side valves are open. (Figure 2). 7. Verify both valves on the unit tank are open. 8. If needed, plug the Robinair unit into a 110/120 VAC grounded electrical outlet.

NAVAIR 17-1-573
01 MARCH 2009

010 00
Page 4 of 8

9. If needed, on the Robinair control panel, use the main power switch to turn on the Robinair unit. The control panel display may flash R12. (Figure 2). NOTE Fifteen minutes is the default time for evacuation. To run the vacuum pump continuously the programmed time must be changed to 98 minutes and 99 seconds (the maximum setting) 10. Press SHIFT/RESET to toggle the display to show PROGRAM VACUUM MINUTES 15.00. 11. Change the program time to 98.99 by pressing the appropriate keys. 12. Press ENTER, then press VACUUM. The vacuum pump will start and the display will show CON AUTOMATIC VACUUM. To turn the vacuum pump off, press HOLD/CONT then press ENTER. 13. The display counts down the time remaining.

High Side Port (RED hose) Low Side Port (BLUE hose) Lockout Door

To Reversing Valve

Suction Service Valve (low side) BLUE Hose

ECU Compressor

Discharge Service Valve (high side) RED Hose

Figure 1. Connection of Robinair to ECU Refrigeration Assembly for Discharge/Recovery.

NAVAIR 17-1-573
01 MARCH 2009

010 00
Page 5 of 8

Liquid Vapor Indicator Tank Pressure Gage System Oil Indicator Low Side Gage High Side Gage

Tank Temperature Gage High Side Valve Air Purge Valve Display Main Power Switch Low Side Valve Unit Circuit Breaker (17000B Only Oil-less Compressor Protector

Keypad

Expanded View

Figure 2. Robinair Unit Control Panel. NOTE If the message U-HI appears, there is 25 psi or greater of pressure at the inlet. This pressure (refrigerant) must be recovered before evacuation can continue. 14. If necessary, press RECOVER. The display shows the unit is in RECOVER mode and the AUTOMATIC cycle. The Robinaire unit will shut off automatically when recovery is complete and the display will show CPL. Repeat evacuation procedure at step 2.2. Otherwise, proceed as follows. 15. To turn the vacuum pump off, press HOLD/CONT then press ENTER. 16. The vacuum pump automatically shuts off and the display shows CPL when the programmed time has expired. 17. Press any key to exit vacuum mode. 18. The ECU refrigeration assembly is now evacuated and ready for charging with R-134A refrigerant IAW WP 011 00.

NAVAIR 17-1-573
01 MARCH 2009
3.1 3.2

010 00
Page 6 of 8

ALTERNATE METHOD FOR EVACUATION OF ECU REFRIGERATION ASSEMBLY. This alternate procedure is for evacuating the refrigeration assembly using a vacuum pump in place of the Robinair unit.

1. Position vacuum pump near ECU. 2. If charging manifold / hoses are already connected to service valves from discharge procedure then go to step 4. Other wise, do as follows. 3. Unscrew hose connection protective caps from suction (low-pressure) service valve and discharge (high-pressure) service valve (Figure 2). 4. Position charging manifold near ECU compressor. 5. Ensure charging manifold valves are closed. 6. Position vacuum pump near ECU. 7. Connect charging manifold hoses to the manifold and service valves as follows. 8. Connect blue manifold hose to suction service valve (low side) and compound gage of charging manifold. 9. Connect red manifold hose to discharge service valve (high side)) and pressure gage of charging manifold. 10. Open both charging manifold valves. 11. Connect yellow manifold hose to center port of charging manifold. 12. Connect free end of yellow manifold hose to the vacuum pump. 13. Start vacuum pump IAW manufacturers instructions. NOTE Inability to reach 270 to 300 microns may indicate either a leak in the refrigeration assembly or a problem with the vacuum pump. 14. Run the vacuum pump until approximately a 270 to 300-micron vacuum is reached. 15. Close manifold valves and check compound gage. Record reading. 16. Shut vacuum pump off. 17. Let ECU sit for 15 minutes. Observe compound gage reading. 18. If the ECU refrigeration assembly held the vacuum without change of pressure, proceed to step 22. 19. If the vacuum cannot be held for 15 minutes, there may be water vapor in the system or refrigerant in compressor oil. 20. Run vacuum pump for longer period and then repeat procedure from step 5. 21. If vacuum still cannot be held for 15 minutes, there may be a leak in the ECU refrigeration system. Break the vacuum with dry nitrogen and perform troubleshooting leak test (WP 008 00). 22. Close charging manifold valves. 23. Stop vacuum pump. 24. Disconnect vacuum pump from center hose connection.

NAVAIR 17-1-573
01 MARCH 2009

010 00
Page 7 of 8

25. Leave manifold and other hose connections in place if system is to be charged with refrigerant using alternate charging procedure. 26. The ECU refrigeration assembly is now evacuated and ready for charging with R-134A refrigerant IAW WP 011 00.

Pressure Gage

To Discharge Service Valve (High Side) To Suction Service Valve (Low Side)

High Pressure Hose (RED)

Compound Gage

Charging Manifold Low Pressure Hose (BLUE) Discharged Refrigerant (YELLOW Hose)

To Reversing Valve Suction Service Valve (Low Side) BLUE hose Discharge Service Valve (High Side) RED hose

Recovery Recycling Unit

ECU Compressor

Figure 3. Alternate Evacuation Setup (Non-Robinair Unit).

NAVAIR 17-1-573
01 MARCH 2009

010 00
Page 8 of 8

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 1 of 18

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN CHARGING ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 005 00 - Preparation for Use, Storage, and Shipment ...................... NAVAIR 17-1-573 WP 008 00 - Leak Test............................................................................. NAVAIR 17-1-573 WP 009 00 - Discharge / Recovery.......................................................... NAVAIR 17-1-573 WP 010 00 - Evacuation........................................................................... NAVAIR 17-1-573 WP 011 00 - Charging.............................................................................. NAVAIR 17-1-573 WP 013 00 - Indoor Thermostat, Panels, and Covers ............................. NAVAIR 17-1-573 WP 015 00 - Refrigeration Assembly ....................................................... NAVAIR 17-1-573 WP 016 00 - Control Box Assembly......................................................... NAVAIR 17-1-573 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................................ NAVAIR 19-25-177 Management of Ozone Depleting Substances ........................................ OPNAVINST 5090.2 ALPHABETICAL INDEX TITLE WP / Page Number

Adding Additional Refrigerant to Charged Refrigeration Assembly Using Gas Fill Method.....................................................................................011 00 / 16 Adding Refrigerant to Robinair Units Tank.................................................011 00 / 7 Alternate Methods for Charging ECU Refrigeration Assembly ...................011 00 / 8 Liquid Fill Charge of Evacuated ECU Refrigeration Assembly ................011 00 / 8 Gas Charge of Evacuated ECU Refrigeration Assembly.........................011 00 / 12 Charging of ECU Refrigeration Assembly with Robinair Unit .....................011 00 / 4 Correcting an Incomplete Transfer..............................................................011 00 / 6 Introduction..................................................................................................011 00 / 3

NAVAIR 17-1-573
01 MARCH 2009
ALPHABETICAL INDEX (continued) TITLE

011 00
Page 2 of 18

WP / Page Number

Recycling the Refrigerant in Robinairs Unit Tank ......................................011 00 / 3 SUPPORT EQUIPMENT REQUIRED DESCRIPTION NUMBER

Digital Thermometer................................................................................... - Gloves ........................................................................................................ MIL-G-521 Goggles ...................................................................................................... GG-G-521 Manifold, AC, R134, 4 Valve with Hose Set............................................... 3XL15 Respirator................................................................................................... GGG-M-125 Robinair Recovery, Recycling, and Recharging Unit ................................. 17800B Scale........................................................................................................... - MATERIALS REQUIRED NOMENCLATURE NUMBER

Refrigerant.................................................................................................. R-134A

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 3 of 18

1.1 1.2

INTRODUCTION This WP provides instructions for charging the refrigeration assembly using the Robinair Recovery, Recycling, and Recharging Unit, part number 17800B. For alternate methods (not using the Robinair unit) for charging of the ECU refrigeration assembly refer to, Alternate Methods for Charging ECU Refrigeration Assembly, this WP. RECYCLING THE REFRIGERANT IN ROBINAIRS UNIT TANK. Before charging the ECU refrigeration system with R-134A refrigerant it is necessary to perform the recycling sequence in order to remove any non-condensable gases in the tank.

1.3

2.1 2.2

1. Verify the Robinair unit is setup as described in, Setup Of Robinair Unit, WP 009 00. 2. Ensure both valves on the Robinair units tank are open. 3. On the Robinair control panel, press and hold SHIFT/RESET, then press 1 to start the recycling process. (Figure 1).
Liquid Vapor Indicator Tank Pressure Gage System Oil Indicator Low Side Gage High Side Gage

Tank Temperature Gage High Side Valve Air Purge Valve Display Main Power Switch Low Side Valve Unit Circuit Breaker (17000B Only Oil-less Compressor Protector

Keypad

Expanded View

Figure 1. Robinair Unit Control Panel (Expanded View of Keypad).

NAVAIR 17-1-573
01 MARCH 2009
NOTE If the Robinair Units unit tank is full, the display will show FULL. 4. If display shows Full, press HOLD/CONT to resume operation.

011 00
Page 4 of 18

5. After 5 minutes of recycling, read temperature of refrigerant on the tank temperature gage. Use this temperature and pressure/temperature chart above Robinair control panel to determine the correct pressure for the R-134A refrigerant. 6. Compare pressure read from the chart to the pressure shown on the tank pressure gage. 7. If gage pressure exceeds the chart (target) pressure by more than 10 psi, open the air purge valve on the control panel for approximately 30 seconds to release non-condensables from the tank. Check tank pressure gage again. Repeat as needed until chart and gage pressures are the same. 8. Close tanks LIQUID valve to stop recycling. The unit will pull into a vacuum and shut off automatically. Press any key on the control panel key pad to exit the recycle mode. 9. The Robinair unit is now ready for charging the ECU refrigeration assembly. 3.1 3.2 CHARGING OF ECU REFRIGERATION ASSEMBLY WITH ROBINAIR UNIT. After successful evacuation of the refrigeration assembly and recycling of the Robinair unit tank, the ECU refrigeration assembly can be charged with R-134A refrigerant.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. CAUTION Do not use Robinair unit if it has been used, or is suspected of having been used, with R-22, or any other refrigerant. Cross contamination of refrigerants can cause damage to or failure of ECU. NOTE This procedure is written for use with the Robinair Recovery and Recycling Unit, part number 17800B. Operation of the recovery/recycling unit must be by personnel with EPA certification IAW OPNAVINST 5090.2. Consult the Robinair vendor manual if any conditions arise with operation of the Robinair unit not covered in this WP 2. Set indoor thermostat system switch to OFF and fan switch to AUTO. NOTE The Robinair will not function and CHECK REFRIGERANT will be displayed on the control panel if there are less than 6 pounds of refrigerant in the tank.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 5 of 18

REFRIGERANT - R134A

3. Check weight of refrigerant in the tank. Press and hold SHIFT/RESET, then press ENTER to access the diagnostic mode. Press 7 to display the weight of refrigerant in the tank. 4. If there are less than 15 pounds in the Robinair units tank refer to, Adding Refrigerant To Robinair Units Tank, this WP. 5. Press SHIFT/RESET again to exit the diagnostic mode. 6. Verify the Robinair units 96 inch high and low side hoses are connected to the ECU refrigeration assemblys service valves: RED hose to discharge service valve (high side) and Blue hose to suction service valve (low side). (Figure 2). High Side Port (RED hose) Low Side Port (BLUE hose) Lockout Door

To Reversing Valve

Suction Service Valve (low side) BLUE Hose

ECU Compressor

Discharge Service Valve (high side) RED Hose

Figure 2. Connection of Robinair to ECU Refrigeration Assembly for Charging. 7. On the Robinair control panel, open the high-side valve and, if allowable, the low side valve 8. Press SHIFT/RESET until the message CHG appears on the display. NOTE The A/E32C-45A ECU requires 7 pounds 5 ounces of R-134A refrigerant. 9. Press CHG and using the key pad enter the weight of the refrigerant to be charged. Seven (7) pounds 5 ounces are required, enter as 7.42 charge pounds. 10. Press ENTER. The display will flash to indicate that the charge amount has been recorded in the Robinairs memory.

NAVAIR 17-1-573
01 MARCH 2009
11. Press CHG again to begin the charging process. 12. The display will show the message AUTOMATIC and the amount programmed for recharging. The display counts down to zero as charging proceeds.

011 00
Page 6 of 18

NOTE If the unit beeps continuously, the transfer of refrigerant has stopped before the charging procedure was completed. 13. When charging is complete, the display shows the message CPL. If unit beeps to indicate transfer of refrigerant stopped before charging was complete, refer to, Correcting An Incomplete Transfer, this WP. 14. Close the high and low-side valves on the control panel.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 15. Turn on MF circuit breakers to restore power to ECU IAW NAVAIR 19-25-177. 16. On indoor thermostat, place fan switch to AUTO and system switch to COOL, set target temperature to 60 to ensure ECU will start and continue running. Turn off the ECU and disconnect the high-side hose from it. 17. Start the ECU, and open both the high and low-side valves. This pulls the portion of the programmed charge that is trapped in the hoses into the low side of the A/C-R system. 18. At the lowest recommended operating pressure, close the low-side valve and turn off the A/CR system and disconnect the low-side hose from the system. 19. Close the high-side valve, and turn off the MAIN POWER switch. 4.1 CORRECTING AN INCOMPLETE TRANSFER. NOTE If the scale value does not change for 30 seconds, the unit beeps continuously to indicate that the transfer of refrigerant was not completed. There are two reasons for an incomplete transfer of refrigerant. One, the pressure in the ECU refrigeration assembly is equal to the pressure in the Robinair units tank. Or, two, there is not enough refrigerant in the Robinair units tank. 4.2 4.3 INCOMPLETE TRANSFER DUE TO EQUAL PRESSURE. Proceed as follows if the pressure in the ECU refrigeration system is equal to the pressure in the Robinair units tank (the unit will produce an audible signal and show the remaining weight needed to complete the transfer). Otherwise, refer to, Adding Refrigerant To Robinair Units Tank, this WP, if the display shows the message CHECK REFRIGERANT because there is not enough refrigerant in the tank.

1. Close the high-side valve on the control panel. 2. Disconnect the high-side hose from the ECU system. 3. Continue with step 14, refer to, Charging of Refrigeration Assembly With Robinair Unit, this WP.

NAVAIR 17-1-573
01 MARCH 2009
4.4

011 00
Page 7 of 18

INCOMPLETE TRANSFER DUE TO INSUFFICIENT REFRIGERANT IN ROBINAIR UNIT TANK. Proceed as follows if an incomplete transfer is noted by the display showing the message CHECK REFRIGERANT because there is not enough refrigerant in the tank.

4.5

1. Press HOLD/CONT to interrupt the transfer. 2. Verify both valves on the tank are closed, then disconnect and remove the tank from the unit. Replace it with a tank containing additional refrigerant. 3. Press HOLD/CONT again to resume the transfer. 5.1 5.2 ADDING REFRIGERANT TO ROBINAIR UNIT TANK. It is necessary for the quantity (weight) of the refrigerant in the Robinair units tank to exceed the quantity required to charge the ECU. Proceed as follows to add refrigerant to the Robinair units tank from a disposable supply tank.

1. Ensure the 96 inch blue hose is connected to the Robinair units low-side port. NOTE Disposable refrigeration supply tanks have only one valve and must be turned upside down to transfer liquid. If using a disposable supply tank follow the instructions on the side of the tank to obtain a liquid supply. 2. Open the valve on the disposable supply tank. 3. Close the high-side valve, and open the low-side valve on the Robinair units control panel (Figure 1.) 4. Open both valves on the Robinair units tank. 5. Press SHIFT/RESET and ENTER at the same time to access the diagnostic mode. The display shows FUNC. NOTE It takes about 45 minutes to add refrigerant to the Robinair units tank. The process can be interrupted by pressing HOLD/CONT once. Press HOLD/CONT again to resume. Press SHIFT/RESET to end process. The transfer of new refrigerant to the Robinair units tank is limited by weight to leave space (about 6 pounds of refrigerant) in the unit tank for recovery purposes. 6. Press 2 to begin transferring refrigerant. The display shows ADD for about two seconds, then shows the amount of refrigerant transferred. 7. Transfer stops automatically and the display shows CPL when the source tank is empty or the weight of the refrigerant in the Robinair units tank reaches 37 pounds. 8. Turn disposable supply tank right side up. 9. Close the supply valve on the disposable supply tank. 10. Carefully disconnect the 96-inch blue hose from the disposable supply tank valve.

NAVAIR 17-1-573
01 MARCH 2009
NOTE If the blue hose is only partially clear, the unit will display CH-P.

011 00
Page 8 of 18

11. Press RECOVER. The blue hose will be pulled into a partial vacuum and the unit will turn off automatically. If a partially clear message is displayed press HOLD/CONT to finish clearing the hose. 12. Close the low-side valve on the Robinair control panel (Figure 1). 13. Connect the 96-inch red hose to the Robinair units high-side port. 14. Perform the recycling process, refer to, Recycling The Refrigerant In Robinair Units Tank, this WP. 6.1 6.2 ALTERNATE METHODS FOR CHARGING ECU REFRIGERATION ASSEMBLY. There are two alternative methods of charging the refrigeration assembly using a manifold gage set, charging hose set and a disposable supply tank of R-134A refrigerant in place of the Robinair Recovery/Recycling/Recharging Unit. These alternative methods are the liquid fill charge and the gas charge method. LIQUID FILL CHARGE OF EVACUATED REFRIGERATION ASSEMBLY. The liquid fill charge method is the preferred alternative method for introducing a full charge to an evacuated refrigeration assembly.

6.3 6.4

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. NOTE If hoses and manifold did not remain connected to ECU service valves after evacuation, then they must be purged with R-134A before connecting to service valves prior to charging refrigeration assembly. 2. If charging manifold hoses are already connected to service valves from evacuation procedure (WP 010 00) then go to step 4. Other wise, do as follows.

REFRIGERANT - R134A

3. Unscrew hose connection protective caps from suction (low-pressure) service valve and liquid fill valve charging port. (Figure 2). 4. Position charging manifold near ECU compressor. Use manifold hanger to hang manifold. 5. Ensure charging manifold valves are closed.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 9 of 18

6. Connect charging manifold hoses to the manifold and purge hoses with R-134A refrigerant before connecting to service valves as follows. 7. Connect blue manifold hose to suction service valve and compound gage of charging manifold. 8. Connect red manifold hose to liquid fill valve charging port and pressure gage of charging manifold. 9. Remove left side bottom service panel (WP 015 00) to expose liquid charge valve. (Figure 3). 10. Connect red hose from manifold to charging port on liquid fill valve prior to evacuating unit. 11. Connect one end of yellow manifold hose to R-134A refrigerant cylinder valve. 12. Purge yellow hose with gas (open and close cylinder valve). 13. Position R-134A refrigerant cylinder in upside down position on scale so cylinder valve is nearest ground and cylinder is resting on handles. CAUTION Never introduce liquid refrigerant into the low-pressure (suction) service valve. Severe damage to equipment may occur. 14. Use wrench to remove brass cap from end of liquid fill valve to expose valve seat, if needed to pull in additional charge. (Figure 4). 15. Open R-134A cylinder valve slightly. Liquid refrigerant will flow into evacuated refrigeration assembly. 16. Refrigeration assembly will charge quickly. Observe scale for 7 lbs 5 oz change in weight. 17. Close R-134A cylinder valve. Open Liquid fill valve if closed (to draw in additional charge). 18. Use hex wrench to close liquid fill valve.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 19. Connect power to ECU. Turn on ECU circuit breakers in MF Circuit Breaker / Power Distribution Panel IAW 19-25-177. 20. Set fan switch to AUTO and system switch on indoor thermostat to COOL. Adjust desired temperature to 60 degrees or lower to ensure ECU will continuously run in cooling mode. 21. Check pressure gage. Pressure should be IAW WP 013 00. 22. After 15 minutes of ECU run time, observe the liquid sight glass / indicator (Figure 6) on left bottom of unit.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 10 of 18

Figure 2. Refrigerant Charging Setup Liquid Fill Charging.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 11 of 18

Liquid Fill Charge Valve

Figure 3. Location of Liquid Fill Charge Valve.

2 Charging Port

1 Valve Seat (Under Brass Cap)


Figure 4. Liquid Fill Valve.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 12 of 18

NOTE An occasional bubble in the refrigerant is normal when the refrigeration assembly is fully charged. 23. Clear bubble-free liquid around the center means the refrigeration assembly is fully charged. If fully charged then check indicator in center of sight glass. 24. Green indicator means the refrigerant moisture content is acceptable. Go to step 27. 25. Yellow indicator means there is too much moisture in the system. The refrigeration system must be must be discharged and recovered (WP 009 00), the filter dryer replaced (WP 015 00), leak tested (WP 008 00) evacuated (WP 010 00) and charged (this WP). 26. Milky white or bubbly liquid means the system has a low charge. If this is the case, add more refrigerant using the gas charging procedure on the low side, refer to, Adding Additional Refrigerant To Charged Refrigeration Assembly Using Gas Fill Method, this WP. 27. Use digital thermometers to check ECU for proper cooling. There should be at least a 15F temperature difference between evaporator discharge air and intake air. 28. Turn system switch on indoor thermostat to OFF and fan switch to AUTO. 29. Remove charging manifold hoses. 30. Install service valve protective caps. 31. Install ECU access covers. 32. The ECU is ready for use. 6.5 6.6 GAS CHARGE OF EVACUATED REFRIGERATION ASSEMBLY. The gas charge method is best used to add additional refrigerant to an already charged refrigeration assembly, refer to, Adding Additional Refrigerant To Charged Refrigeration Assembly Using Gas Fill Method, this WP. To fully charge an evacuated ECU refrigeration assembly using the gas charge alternative method proceed as follows. NOTE Hoses and manifold remain connected to ECU service valves after evacuation. If not, hoses and manifold must be purged with R-134A before connecting to service valves prior to charging refrigeration assembly. 1. If charging manifold hoses are already connected to service valves from alternative method evacuation procedure (WP 010 00) then go to step 9. Otherwise do as follows.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 2. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 13 of 18

REFRIGERANT - R134A

3. Unscrew hose connection protective caps from suction (low-pressure) service valve and liquid fill valve charging port. (Figure 2). 4. Position charging manifold near ECU compressor. Use manifold hanger to hang manifold. 5. Ensure charging manifold valves are closed. 6. Connect charging manifold hoses to the manifold and purge hoses with R-134A refrigerant before connecting to service valves as follows. Refer to Figure 5. 7. Connect blue manifold hose to suction service valve and compound gage of charging manifold. 8. Connect red manifold hose to discharge service valve and pressure gage of charging manifold.

R134

Figure 5. Refrigerant Charging Setup Gas Charging. NOTE Position the R-134A cylinder in an upright position. This ensures only gas will be used for charging. The R-134A cylinder is prone to freezing up during the gas charging procedure. Place the cylinder is a warm water bath to prevent it from freezing. Remove from bath periodically to place on scales.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 14 of 18

9. Connect the center hose (yellow) from the charging manifold to a well-charged cylinder of R-134A, or a charging cylinder. 10. Loosen the hose connection to the center of charging manifold. 11. Open the R-134A or charging cylinder valve slightly to allow a small amount of refrigerant to purge air from the hose. Tighten the hose connection at the charging manifold. 12. Using scales, measure and record the weight of the charged R-134 cylinder. 13. Fully open the R-134A cylinder valve. 14. Open the low-pressure valve of the charging manifold. Allow refrigerant gas to enter the system until the system pressure has equalized.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 15. Connect power to ECU. Turn on ECU circuit breakers in MF Circuit Breaker / Power Distribution Panel IAW 19-25-177. 16. It may be necessary to jumper low-pressure switch if unit cycles rapidly on its low pressure switch. To jumper the low press switch (S2), which is located on side of control box, remove the (2) two wires from the switch (quick-connect terminals) and connect the two wires with a small piece of wire inserted into the quick connect terminals, or other suitable mean to connect the two wires electronically. 17. Set fan switch to AUTO and system switch on indoor thermostat to COOL. Adjust temperature setting to 60 degrees to ensure ECU will continuously run in cooling mode throughout the gas charging procedure. 18. Monitor the weight of the refrigerant cylinder as the ECU compressor pulls additional refrigerant gas into the refrigeration assembly until a full 7 lbs, 5 oz. charge is obtained. 19. When the system is fully charged, immediately close the refrigerant cylinder valve, and the charging manifold low-pressure (suction) service valve. 20. Continue to run the ECU in COOL mode. Note time. 21. After 15 minutes, observe the liquid sight glass / indicator (Figure 6) on left bottom of unit. NOTE An occasional bubble in refrigerant is normal when the refrigeration assembly is fully charged. 22. Clear bubble-free liquid around the center means the refrigeration assembly is fully charged. If fully charged then check indicator in center of sight glass. 23. Green indicator means the refrigerant moisture content is acceptable. Go to step 27. 24. Yellow indicator means there is too much moisture in the system. The refrigeration system must be must be discharged (WP 010 00), the filter dryer replaced (WP 016 00), leak tested (WP 009 00) evacuated (WP 011 00) and charged (this WP). 25. Milky white or bubbly liquid means the system has a low charge. 26. If needed, add additional refrigerant gas by opening the R-134A cylinder valve and the manifold low-pressure valve

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 15 of 18

27. Observe sight glass. When bubbles clear close the R-134A cylinder valve and the manifold low-pressure valve. Go to step 19 above. 28. Use digital thermometers to check ECU for proper cooling. There should be at least a 15F temperature difference between evaporator discharge air and intake air. 29. Turn system switch on indoor thermostat to OFF. 30. Remove charging manifold hoses. 31. Install service valve protective caps. 32. Secure service valve access covers.

Liquid Sight Indicator (Sight Glass)

Figure 6. Liquid Sight Indicator.

NAVAIR 17-1-573
01 MARCH 2009
6.7

011 00
Page 16 of 18

ADDING ADDITIONAL REFRIGERANT TO CHARGED REFRIGERATION ASSEMBLY USING GAS FILL METHOD.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove service panels IAW WP 013 00 as needed to access refrigeration assembly components.

REFRIGERANT - R134A

3. Unscrew hose connection protective caps from suction (low-pressure) service valve and liquid fill valve charging port (Figure 2). 4. Position charging manifold near ECU compressor. Use manifold hanger to hang manifold. 5. Ensure the charging manifold valves are closed. Connect the hoses from the manifold to the service valves. Connecting the hoses opens the service valves. 6. Connect blue manifold hose to suction service valve and compound gage of charging manifold. Purge hose by loosening hose connection at manifold. 7. Connect red manifold hose to discharge service valve and pressure gage of charging manifold. Purge hose by loosening hose connection at manifold. NOTE Connect the R-134A cylinder so that only gas will be used for pressurization. That is, place R134A cylinder in an upright position. 8. Connect a cylinder of R-134A refrigerant to the center hose (yellow) connection of the charging manifold. 9. Open the charging manifold blue valve. 10. Open the R-134A refrigerant cylinder valve slightly and adjust as needed to control flow of refrigerant gas into system.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 11. Connect power to ECU (Turn on ECU circuit breakers in MF Circuit Breaker / Power Distribution Panel IAW 19-25-177). 12. Set system switch on indoor thermostat to COOL. 13. Adjust desired temperature at very low temperature setting (60 degrees) to ensure ECU will continuously run in cool mode throughout the gas charging procedure.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 17 of 18

14. Observe sight glass. When bubbles clear immediately close the refrigerant cylinder valve, and the charging manifold low-pressure (suction) valve. 15. Use digital thermometers to check ECU for proper cooling. There should be at least a 15F temperature difference between evaporator discharge air and intake air. 16. Turn system switch on indoor thermostat to OFF. 17. Remove charging manifold hoses. 18. Install service valve protective caps. 19. Secure service valve access covers. 20. ECU is ready for use. Perform preparation for use procedures IAW WP 005 00.

NAVAIR 17-1-573
01 MARCH 2009

011 00
Page 18 of 18

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

012 00
Page 1 of 4

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN PRESSURE TEST ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 006 00 - Operation............................................................................. NAVAIR 17-1-573 WP 007 00 - Testing and Troubleshooting............................................... NAVAIR 17-1-573 WP 011 00 - Charging.............................................................................. NAVAIR 17-1-573 WP 015 00 -Refrigeration Assembly ........................................................ NAVAIR 17-1-573 ALPHABETICAL INDEX TITLE WP / Page Number

Introduction..................................................................................................012 00 / 3 Pressure Testing .........................................................................................012 00 / 3 SUPPORT EQUIPMENT REQUIRED DESCRIPTION NUMBER

Charging Manifold with Hose Set............................................................... 3XL15 MATERIALS REQUIRED NOMENCLATURE NUMBER

Mask, Air Filtering....................................................................................... 4240-01-152-3555 Gloves ........................................................................................................ MIL-G-12223 Goggles ...................................................................................................... GG-G-521 Respirator................................................................................................... GGG-M-125

NAVAIR 17-1-573
01 MARCH 2009
1.1 1.2 INTRODUCTION.

012 00
Page 2 of 4

This WP provides instructions for testing the pressure of the refrigerant charge in the refrigeration assembly. Pressure testing is accomplished after charging the refrigeration assembly (WP 011 00) and when directed by troubleshooting procedures (WP 007 00). PRESSURE TESTING. NOTE If an alternate charging method was used, hoses and manifold should remain connected to ECU service valves after charging. If not, hoses and manifold must be purged with R134A before connecting to service valves prior to charging refrigeration assembly.

2.1

1. If charging manifold hoses were left connected to ECU refrigeration assembly service valves from charging procedure (WP 011 00) then go to step 9. Otherwise, do as follows.

REFRIGERANT - R134A

2. Unscrew hose connection protective caps from suction (low-pressure) service valve and discharge (high-pressure) service valve (Figure 1). 3. Position charging manifold near ECU compressor (3). Use manifold hanger to hang manifold near compressor. 4. Ensure charging manifold valves are closed. 5. Connect charging manifold hoses to the manifold, refer to Figure 1. 6. Connect blue manifold hose to suction service valve (low pressure) and compound gage of charging manifold. 7. Connect red manifold hose to discharge service valve (high pressure) and pressure gage of charging manifold. 8. Purge hoses with R134A refrigerant by opening quickly then closing the discharge and suction hose connections at the charging manifold. 9. Ensure manifold valves are closed. 10. Set ECU system switch on indoor thermostat to COOL and fan switch to AUTO. 11. Set temperature to 60 degrees or lower to ensure ECU unit will turn on and run during this procedure. 12. With the ECU operating, allow manifold gages to stabilize. Record reading of compound and pressure gages. 13. Compare gage readings with the normal range of system pressure as shown in Table 1. If pressure is within appropriate range, go to step 15. Otherwise, proceed as follows. 14. Check for and clear any blockage of air. 15. If needed add refrigerant (WP 015 00). 16. Go to troubleshooting (WP 007 00). 17. Turn off ECU by setting system switch to OFF and fan switch to AUTO.

NAVAIR 17-1-573
01 MARCH 2009

012 00
Page 3 of 4

REFRIGERANT - R134A

18. Disconnect manifold hoses/gages. Remove manifold. 19. Install service valve caps. 20. Install service panels. 21. Go to WP 006 00 for operation of ECU.

Table 1. Normal Temperature Pressure Relationships. Temperatures Outdoor Ambient Evaporator Intake 90F (32C) Air to Unit (Dry Bulb) 80F (27C) Air to Unit (Dry Bulb) Pressure Range (PSIG) 50F (10C) 26-33 Suction 90114 Discharge 23-30 Suction 85105 Discharge 75F (24C) 34-40 Suction 130-158 Discharge 30-38 Suction 120-149 Discharge 100F (38C) 40-47 Suction 190-227 Discharge 38-43 Suction 180-214 Discharge 120F (52C) 55-27 Suction 270-300 Discharge 43-50 Suction 247-288 Discharge

Figure 1. Pressure Testing Setup.

NAVAIR 17-1-573
01 MARCH 2009

012 00
Page 4 of 4

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

013 00
Page 1 of 10

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN INDOOR THERMOSTAT, PANELS, AND COVERS ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

Technical Manual, Maintenance Instructions (Organizational and Intermediate Level), Support Equipment (Cleaning, Preservation, and Corrosion Control) .................................................................................... NAVAIR 17-1-125 Technical Manual, Preoperational Checklist, Mobile Facility Program Environmental Control Unit A/E32C-45A ................................................. NAVAIR 17-600-762-6-1 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................................ NAVAIR 19-25-177 ALPHABETICAL INDEX TITLE WP / Page Number

Covers and Panels ......................................................................................013 00 / 6 Installation, Covers and Panels................................................................013 00 / 7 Removal, Covers and Panels...................................................................013 00 / 6 Installation, Model 8425 Indoor Thermostat................................................013 00 / 5 Introduction..................................................................................................013 00 / 3 Maintenance and Repair of Panels and Covers .........................................013 00 / 9 Removal, Model 8425 Indoor Thermostat...................................................013 00 / 3 SUPPORT EQUIPMENT REQUIRED DESCRIPTION NUMBER

Continuity Tester ........................................................................................ - Multimeter................................................................................................... 77AN

NAVAIR 17-1-573
01 MARCH 2009
MATERIALS REQUIRED NOMENCLATURE NUMBER

013 00
Page 2 of 10

3M Scotch-Grip High Performance Contact Adhesive............................... 1357 (CAGEC 94959) Edge Seal for Insulation ............................................................................. - Refrigerant.................................................................................................. R134A

NAVAIR 17-1-573
01 MARCH 2009

013 00
Page 3 of 10

1.1

INTRODUCTION.

1.2 This WP provides instructions for removal and replacement of the indoor thermostat from the MF and ECU. This WP also provides instruction for removal and installation of ECU service panels and covers from the ECU frame. 1.3 2.1 2.2 The A/E32C-45A ECU uses the Robertshaw model 8425 indoor thermostat. REMOVAL OF MODEL 8425 INDOOR THERMOSTAT. Remove Model 8425 indoor thermostat as follows.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Place indoor thermostat system switch (emer-heat-off-cool) in OFF position and fan switch in AUTO position. (Figure 1).

Figure 1. Indoor Thermostat: System Switch and Fan Switch Settings.

NAVAIR 17-1-573
01 MARCH 2009

013 00
Page 4 of 10

3. The thermostat has an interlocking cover secured by tabs at the top. Use flat thin object to depress tabs and remove cover. (Figure 2). 4. Tag then remove wires from thermostat terminals. (Figure 3). 5. Remove two mounting screws (located in mounting holes) and detach thermostat base from wall. (Figure 4).

Figure 2. Removal of Indoor Thermostat Cover.

Figure 3. Wiring Connections For Indoor Thermostat to Control Box Terminal Board 3 (TB3).

NAVAIR 17-1-573
01 MARCH 2009

013 00
Page 5 of 10

Figure 4. Indoor Thermostat Mounting Holes.

3.1 3.2

INSTALLATION OF MODEL 8425 THERMOSTAT. Install model 8425 thermostat as follows.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. The thermostat has an interlocking cover secured by tabs at the top. Use coin or screw driver to remove cover. (Figure 2). CAUTION Ensure internal switches are set to correct position. 3. Set ELEC GAS switch to ELEC. Set NON HP HP switch to HP. (Figure 5). 4. Align thermostat base with mounting bracket on MF wall and feed wires through opening. 5. Secure base to wall with supplied screws. 6. Connect the ECU electrical wiring to thermostat base. Insert wire tips into terminal strip IAW Figure 3 and match wire label (tags) to terminals. 7. Install thermostat cover. 8. Place indoor thermostat system switch (emer-heat-off-cool) in OFF position and fan switch in AUTO position. (Figure 1) 9. Operational Check. When indoor thermostat installation is completed, operate the system through at least one full cycle of heating and/or cooling, refer to Preoperational Checklist, NAVAIR 17-600-762-6-1.

NAVAIR 17-1-573
01 MARCH 2009

013 00
Page 6 of 10

Figure 5. Indoor Thermostat (cover removed): ELEC GAS Switch and Non HP HP Switch. 4.1 4.2 COVERS AND PANELS. Refer to Table 1 and Figure 6 for identification of service panels and covers. NOTE The rear lower panel must be removed before the rear upper panel can be removed. All other panels can be removed independently. The side extension panels allow removal of side panels without having to pull the ECU away from the wall of the MF. Some panels are lined with a flexible duct liner. Do not remove this liner unless to replace it. Take care not to damage the liner when removing or installing panels.

4.3

REMOVAL OF PANELS AND COVERS.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove panels and covers by unfastening self-tapping hex head screws that the secure panels and covers to frame / chassis. 3. Remove only those panels needed to access the area where maintenance or servicing is being performed.

NAVAIR 17-1-573
01 MARCH 2009
4.4 INSTALLATION OF PANELS AND COVERS.

013 00
Page 7 of 10

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. CAUTION Exercise care when installing panels to prevent damage to tubing and wiring. 2. Replace panels and covers in the reverse order they were removed. NOTE There are two sizes of self-tapping, hex head screws used to secure the panels, 1032x7/16 and 10-32x7/8.

3. Use correct size screws when fastening panel to frame (Table 1).

Figure 6. ECU Service Panels and Covers (Refer to Table 1 for Index).

NAVAIR 17-1-573
01 MARCH 2009

013 00
Page 8 of 10

Table 1. Panels and Covers (See Figure 6). Index No. 1 2 Panel or Cover Cover Top Removable Panel Assembly (Fresh Air Vent Assembly) Panel, Upper Rear Panel, Lower Rear Panel, Upper Side Panel, Lower Side Part Number Location Attaching Screw Size 10-32x7/16 multiple Self-Tapping Hex Head Screw p/n 1559AS427-2 multiple Screw Qty 2 multiple

1559AS580-1 1559AS556-1

Top of unit On exterior (outdoor) side of upper rear panel

3 4

1559AS557-1 1559AS579-1

Rear (outdoor), top Rear (outdoor), bottom left and right upper sides left and right side above slide side panels left and right bottom side over ECU mounting slides left and right side indoor corners of control box of control box

10-32x7/16 10-32x7/8

1559AS427-2 1559AS427-3

2 6

5 6

1559AS574-1 1559AS575-1

10-32x7/8

1559AS427-3

Panel, Side, Slide

1559AS605-1

10-32x7/16

1559AS427-2

Panel, Side Extension Control Box Assembly Cover

1559AS607

10-32x7/16

1559AS427-2

NAVAIR 17-1-573
01 MARCH 2009
4.5 MAINTENANCE AND REPAIR OF PANELS AND COVERS.

013 00
Page 9 of 10

4.6 Maintenance and repair of panels and covers consists of the following: Corrosion control IAW NAVAIR 17-1-125, straightening bent or warped covers and panels, replacing missing hardware, and cleaning of the duct liner (insulation) when needed.

COMPRESSED AIR

1. Clean the surface of duct liner with a dry cleaning method such as contact vacuuming with a shop-vac, compressed air, or brush. 2. Remove and replace damaged or missing duct liner (insulation). 3. Cut new insulation to size for the effected panel. Use old insulation and panel as template. 4. Coat any cut edges exposed to air flow with an edge treatment product. 5. Apply adhesive to panel surface IAW manufacturers directions and attach duct liner.

NAVAIR 17-1-573
01 MARCH 2009

013 00
Page 10 of 10

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 1 of 14

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN CHASSIS ASSEMBLY ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 013 00 - Indoor Thermostat, Panels and Covers .............................. NAVAIR 17-1-573 WP 016 00 - Control Box Assembly......................................................... NAVAIR 17-1-573 WP 017 00 - Indoor Blower Assembly ..................................................... NAVAIR 17-1-573 WP 019 00 Unit Wiring Inspection, Test, Repair and Installation ......... NAVAIR 17-1-573 Technical Manual, Preoperational Checklist, Mobile Facility Program Environmental Control Unit A/E32C-45A ................................................. NAVAIR 17-600-762-6-1 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................................ NAVAIR 19-25-177 ALPHABETICAL INDEX TITLE WP / Page Number

Control Box Assembly .................................................................................014 00 / 7 Installation, Control Box Assembly...........................................................014 00 / 8 Removal, Control Box Assembly..............................................................014 00 / 7 Heater Cutout Switch (S4)...........................................................................014 00 / 14 Installation, Heater Cutout Switch ............................................................014 00 / 14 Removal, Heater Cutout Switch ...............................................................014 00 / 14 Heating Element (HR1, HR2, HR3, HR4) ...................................................014 00 / 12 Installation, Heating Element ...................................................................014 00 / 13 Removal, Heating Element ......................................................................014 00 / 12 Indoor Blower Assembly..............................................................................014 00 / 3 Installation, Indoor Blower Assembly .......................................................014 00 / 6 Removal, Indoor Blower Assembly ..........................................................014 00 / 3 Introduction..................................................................................................014 00 / 3

ALPHABETICAL INDEX (continued)

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 2 of 14

TITLE

WP / Page Number

Motor and Fan Assembly ............................................................................014 00 / 9 Installation, Motor and Fan Assembly ......................................................014 00 / 11 Removal, Motor and Fan Assembly .........................................................014 00 / 9 SUPPORT EQUIPMENT REQUIRED DESCRIPTION Continuity Tester ......................................................................................... Multimeter.................................................................................................... Tool Kit, General Mechanics ....................................................................... MATERIALS REQUIRED NOMENCLATURE NUMBER NUMBER -77AN 5180-00-699-5273

Silicon Sealant............................................................................................ - -

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 3 of 14

1.1 1.2

INTRODUCTION. This WP provides instruction for removal and installation of the following chassis assembly components: Indoor Blower Assembly, Control Box Assembly, Motor and Fan Assembly (Outdoor), Heating Element (HR1, HR2, HR3, HR4), and Heater Cutout Switch (S4). INDOOR BLOWER ASSEMBLY. REMOVAL OF INDOOR BLOWER ASSEMBLY.

2.1 2.2

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. NOTE Lower rear panel must be removed before upper rear panel can be removed. 2. Remove lower rear panel, upper rear panel, and control box cover IAW WP 013 00. 3. Tag and disconnect indoor fan motor electrical wires from the indoor fan motor relay (K2) in control box. (Figure 1).

K2 Relay

Figure 1. Location of Indoor Fan Motor Relay (K2) in Control Box.

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 4 of 14

NOTE The fan motor wires pass through a bushing in the fan shelf. The bushing is filled with silicon sealant. Do not discard the bushing. 4. Pull wires through hole in control box panel and through bushing on fan shelf. Cut wire ties, silicon sealant and bushing as needed to remove the fan motor wires (Figures 2 and 3). CAUTION Support indoor blower assembly to prevent it from falling when screws and bolts attaching it to the indoor coil drain pan are removed. 5. Remove screws from blower mounting angles on both sides of the two indoor fan housings (total of 12 screws) (Figure 4). 6. Remove two screws securing front of each blower housing to drain pan flanges (total of 4 screws) (Figure 5). 7. Remove four bolts and washers securing motor bracket to motor mount. Leave motor mount fastened to drain pan. 8. Remove indoor blower assembly (motor, two fan blower housings) from ECU. 9. Refer to WP 017 00 for maintenance on the indoor blower assembly.

Fan Shelf Indoor Fan Blower Electrical Wires

Control Box Assembly

Figure 2. Indoor Blower Assembly Electrical Wires (View from Indoor Side).

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 5 of 14

Indoor Fan Blower Electrical Wires

Bushing with Silicon Sealant in Fan Shelf

Figure 3. Detail of Indoor Blower Assembly Electrical Wires Passing Through Fan Shelf.

Drain Pan

Figure 4. Location of Screws Securing Side Flanges of Fan Blower Housings.

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 6 of 14

Drain Pan

Figure 5. Location of Screws Securing Front Flange of Fan Blower Housings and Motor Bracket. 2.3 INSTALLATION OF INDOOR BLOWER ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove lower rear panel, upper rear panel, and control box cover IAW WP 013 00. 3. Fasten motor bracket to motor mount using four bolts and washers. (Figure 5) CAUTION Support indoor blower assembly until it is securely fastened to the indoor coil drain pan. 4. Fasten fan blower housings to drain pan by installing three screws in each blower mounting angle on both sides of the two indoor fan housings (total of 12 screws) and through holes in outdoor side of the indoor fan housings (total of 4 screws). (Figures 4 and 5). 5. Route indoor blower motor electrical wires through bushing in fan shelf and into control box assembly. 6. Connect electrical wires to indoor fan relay (K2) in control box assembly. (Figure 1). 7. Install wire ties to indoor blower electrical wires. 8. Seal bushing in fan shelf with silicon sealant to prevent air leakage to/from indoor air section to compressor/control box section of ECU. 9. Install control box cover, upper rear panel and lower rear panel IAW WP 013 00.

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 7 of 14

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 10. Connect ECU power (plugs/cables) and turn on circuit breakers in MF IAW MF pub. 11. Operational Check. Perform preoperational checklist NAVAIR 17-600-762-6-1. Operate the ECU through at least one full cycle of heating and/or cooling to ensure indoor fan blower operates properly. 3.1 3.2 CONTROL BOX ASSEMBLY. REMOVAL OF CONTROL BOX ASSEMBLY.

1. For minor repairs and removal/replacement of individual components refer to WP 016 00.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 2. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 3. Remove lower panel right side, upper rear panel, lower rear panel, and control box assembly cover IAW WP 013 00. 4. Tag and disconnect electrical wiring from control box components and control box assembly. Refer to WP 019 00. 5. Open clamp on defrost sensor bulb and remove bulb from outdoor coil. (Figure 6). NOTE The LPCO and HPCO switches are independent assemblies but their respective mounting brackets share a screw for mounting to the outside of the control box. 6. Remove three screws securing LPCO and HPCO switches mounting brackets to control box assembly (Figure 7). CAUTION Exercise care when moving LPCO and HPCO away from control box to prevent bending capillary tubing. Do not disconnect LPCO and HPCO tubing or refrigerant may be discharged and refrigeration assembly will require complete servicing. 7. Take care not to bend the capillary tubing, move the LPCO and HPCO switches away from the control box (Figure 7). Do not disconnect capillary tubing from LPCO or HPCO switches. 8. Remove four screws that secure flanges of control box to compressor shelf. 9. Slide control box assembly out of chassis / compressor control box section.

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 8 of 14

Defrost Sensor Bulb

Figure 6. Defrost Sensor Bulb.

Mounting Brackets and Screws

Control Box Assembly LH side

LPCO and HPCO Switches

Capillary Tubing

Figure 7. LPCO and HPCO Switches on Control Box Assembly. 3.3 INSTALLATION OF CONTROL BOX ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove lower panel right side, lower rear panel, and upper rear panel IAW WP 013 00. 3. Slide control box assembly into chassis / compressor control box section. 4. Position control box assembly flanges over holes in compressor shelf and fasten control box assembly to shelf with four screws.

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 9 of 14

NOTE The LPCO and HPCO switches are independent assemblies but their respective mounting brackets share a screw for mounting to the control box. 5. Attach mounting brackets for LPCO and HPCO switches to control box assembly using screws. Take care not to bend the capillary tubing. (Figure 7). 6. Clamp defrost sensor bulb to outdoor coil. (Figure 6). 7. Connect electrical wiring to control box components. 8. Install control box assembly cover, upper rear panel, lower rear panel, and lower right side panel IAW WP 013 00.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 9. Connect ECU power (plugs/cables) and turn on circuit breakers in MF IAW MF pub. 10. Operational Check. Perform preoperational checklist NAVAIR 17-600-762-6-1. Operate the ECU through at least one full cycle of heating and/or cooling to ensure indoor fan blower operates properly. 4.1 4.2 OUTDOOR FAN MOTOR AND FAN ASSEMBLY. REMOVAL OF OUTDOOR FAN MOTOR AND FAN ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove ECU from MF IAW NAVAIR 19-25-177. CAUTION Ensure ECU is on a stable surface to preclude it from falling over when working on fan motor and fan assembly. 3. Remove lower rear panel, lower side panels (as needed), and control box cover IAW WP 013 00.

WARNING
Capacitor may contain charge. Electrical shock hazard with potential injury to personnel may exist. 4. Before disconnecting wiring, use an instrument with insulated handle to discharge outdoor fan motor capacitor, C1, (1, Figure 8) by causing a short across capacitor leads

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 10 of 14

Figure 8. Outdoor Fan Motor Electrical Components in Control Box Assembly. 5. Tag then disconnect motor leads to capacitor C1 (1) and outdoor fan relay K3 (2). Cut tie straps as needed and remove wires from control box. 6. Remove ground wire from fan shroud. 7. Remove fan support (1, Figure 9) with motor (5) and fan propeller (6) from fan shroud (11) by removing six screws (2), flat washers, (3) and lock washers (4). CAUTION Carefully handle fan propeller blades, they have sharp edges. 8. Loosen two setscrews that secure fan propeller to motor shaft and remove fan propeller (10) from motor (5). 9. Loosen nut (9), washers (7 and 8), and screw (6) in fan support (1). 10. Remove motor (5) from fan support (1).

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 11 of 14

12

11

Figure 9. Outdoor Fan Motor and Fan Assembly. 4.3 INSTALLATION OF OUTDOOR FAN MOTOR AND FAN ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. As needed, remove ECU from MF IAW NAVAIR 19-25-177. CAUTION Ensure ECU is on a stable surface to preclude it from falling over when working on fan motor and fan assembly. NOTE Replace fan propeller if fan propeller blades are bent or twisted. 3. Install fan propeller (10, Figure 9) on motor (5) shaft, positioning it so there is only 1/4 inch clearance from motor. Do not tighten setscrews. 4. Position motor (5) in fan support (1) as follows. Clamp must be 180 degrees from motor leads. Distance from end of motor (end without shaft) to bracket of fan support must be 2 inches. Secure using screw (6), washers (7 and 8), and nut (9). 5. Install fan support (1) with motor (5) so that motor leads are on the bottom. Secure with screws (2), lock washer (4), and flat washers (3). 6.

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 12 of 14

NOTE Ensure fan propeller set screws will contact flat section of motor shaft at 90-degree angle. 7. Position fan propeller (10) for a 1/2 inch clearance between blades and condenser coil (12). Tighten setscrews against flat section of motor shaft. 8. Manually rotate fan propellers (10) to check clearance and reposition on shaft if necessary. 9. Insert motor leads into control box and connect leads to capacitor C1 (1, Figure 8) and to outdoor fan relay K3 (2). Install wire ties as needed. 10. Connect ground wire to fan shroud. 11. Install control box cover, side panels (as needed) and lower rear panel IAW WP 013 00. 12. Install ECU in MF IAW NAVAIR 19-25-177.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 13. Connect ECU power (plugs/cables) and turn on circuit breakers in MF IAW MF pub. 14. Operational Check. Perform preoperational checklist NAVAIR 17-600-762-6-1. Operate the ECU through at least one full cycle of heating and/or cooling to ensure outdoor fan motor and assembly operates properly. 5.1 5.2 HEATING ELEMENT (HR1, HR2, HR3, AND HR4). REMOVAL OF HEATING ELEMENT (HR1, HR2, HR3, HR4).

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove ECU from MF IAW NAVAIR 19-25-177. CAUTION Ensure ECU is on a stable surface to preclude it from falling over when working on heating element. 3. Remove top cover, upper right side panel, lower rear panel, upper rear panel and control box cover IAW WP 013 00. 4. Remove bracket assembly (1, Figure 10) by removing screws (2). 5. Remove screws (3) holding heating element (4) to evaporator closeout bracket (5). 6. Remove four screws (6) holding heating element (4) to chassis assembly. 7. Remove heating element (4) from indoor air section. 8. Tag and disconnect wires from heating element (4).

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 13 of 14

3 2

8 6 2 1

7 5

Figure 10. Heating Element and Heater Cutout Switch Removal and Installation 5.3 INSTALLATION OF HEATING ELEMENT (HR1, HR2, HR3, HR4).

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove ECU from MF IAW NAVAIR 19-25-177. CAUTION Ensure ECU is on a stable surface to preclude it from falling over when working on heating element. 3. Position heating element (4) into indoor air section. 4. Secure heating element (4) to chassis using four screws (6). 5. Attach heating element (4) to evaporator closeout bracket (5) using screw (3). 6. Connect electrical wires to heating element (4) and remove tags. 7. Install bracket assembly (1) with screws (2). 8. Install control box cover, upper rear panel, lower rear panel, upper RH side panel, and top cover IAW WP 013 00. 9. Install ECU in MF IAW NAVAIR 19-25-177.

NAVAIR 17-1-573
01 MARCH 2009

014 00
Page 14 of 14

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 10. Connect ECU power (plugs/cables) and turn on circuit breakers in MF IAW MF pub. 11. Operational Check. Perform preoperational checklist NAVAIR 17-600-762-6-1. Operate the ECU through at least one full cycle of heating and/or cooling to ensure ECU operates properly. 6.1 6.2 HEATER CUTOUT SWITCH (S4). REMOVAL OF HEATER CUTOUT SWITCH (S4).

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove MF front panel IAW NAVAIR 19-25-177. 3. Remove LH upper side panel IAW WP 013 00. 4. Remove bracket assembly (1, Figure 10) by removing screws (2). 5. Remove screws (7) and switch (8). 6. Tag and disconnect wire leads from bracket assembly (1). 6.3 INSTALLATION OF HEATER CUTOUT SWITCH (S4).

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Connect wire leads then remove tags. 3. Install switch (8) to bracket (1) using screws (7). 4. Attached bracket assembly (1) with screws (2). 5. Install panel (9) using screws (10). 6. Install MF Front Panel IAW NAVAIR 19-25-177.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 7. Connect ECU power (plugs/cables) and turn on circuit breakers in MF IAW MF pub. 8. Operational Check. Perform preoperational checklist NAVAIR 17-600-762-6-1. Operate the ECU through at least one full cycle of heating and/or cooling to ensure ECU operates properly.

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 1 of 22

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN REFRIGERATION ASSEMBLY ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 008 00 Leak Test............................................................................... NAVAIR 17-1-573 WP 009 00 Discharge .............................................................................. NAVAIR 17-1-573 WP 010 00 Evacuation............................................................................. NAVAIR 17-1-573 WP 011 00 Charging ................................................................................ NAVAIR 17-1-573 WP 013 00 Indoor Thermostat, Panels and Covers ................................ NAVAIR 17-1-573 WP 014 00 Chassis Assembly ................................................................. NAVAIR 17-1-573 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................................ NAVAIR 19-25-177 ALPHABETICAL INDEX TITLE WP / Page Number

Accumulator Assembly................................................................................015 00 / 18 Installation, Accumulator Assembly .......................................................015 00 / 18 Removal, Accumulator Assembly ..........................................................015 00 / 18 Compressor.................................................................................................015 00 / 15 Installation, Compressor ........................................................................015 00 / 15 Removal, Compressor............................................................................015 00 / 15 Filter-Dryer ..................................................................................................015 00 / 6 Installation ..............................................................................................015 00 / 7 Removal .................................................................................................015 00 / 6 High-Pressure Cutout Switch ......................................................................015 00 / 19 Installation, High-Pressure Cutout Switch..............................................015 00 / 19 Removal, High-Pressure Cutout Switch.................................................015 00 / 19 Indoor Coil Assembly ..................................................................................015 00 / 12 Installation, Indoor Coil Assembly ..........................................................015 00 / 13

NAVAIR 17-1-573
01 MARCH 2009
Removal, Indoor Coil Assembly .............................................................015 00 / 12 Introduction..................................................................................................015 00 / 4 Low-Pressure Cutout Switch .......................................................................015 00 / 20 Installation, Low-Pressure Cutout Switch ..............................................015 00 / 21 Removal, Low-Pressure Cutout Switch..................................................015 00 / 20 Outdoor Coil Assembly................................................................................015 00 / 10 Installation, Outdoor Coil Assembly .......................................................015 00 / 11 Removal, Outdoor Coil Assembly ..........................................................015 00 / 10 Reversing Valve Assembly..........................................................................015 00 / 13 Installation, Reversing Valve Assembly .................................................015 00 / 14 Removal, Reversing Valve Assembly ....................................................015 00 / 13 Rotolock and Coupling Nuts Fittings ...........................................................015 00 / 4 Assembly................................................................................................015 00/ 5 Disassembly ...........................................................................................015 00/ 5 Tube Assemblies.........................................................................................015 00 / 8 Installation, Tube Assemblies ................................................................015 00 / 8 Removal, Tube Assemblies ...................................................................015 00 / 8 SUPPORT EQUIPMENT REQUIRED DESCRIPTION NUMBER

015 00
Page 2 of 22

Tool Kit, General Mechanics ...................................................................... 5180-00-699-5273 5/16 socket ............................................................................................ - Tool Kit, Service, Refrigeration Unit ........................................................... 5180-00-596-1474 Tool Kit, Refrigeration Equipment .............................................................. SC5180-90-CL-n18 Recovery and Recycle Unit, Refrigerant .................................................... - Lifting Device.............................................................................................. - Mask, Air Filtering....................................................................................... 4240-01-152-3555 Gloves ........................................................................................................ MIL-G-12223 Goggles ...................................................................................................... GG-G-521 Respirator................................................................................................... GGG-M-125 Multimeter................................................................................................... 77AN ECU Torque Tool Set ................................................................................. none Wrench, Crowfoot, 1/2 DR 1-3/8 ........................................................... 1TEK4 (Grainger/MCMC) Wrench, Crowfoot, 1/2 DR 5/16 ............................................................ J5330CF (Grainger/MCMC) Wrench, Crowfoot, 1/2 DR 1-1/4 ........................................................... J5340CF (Grainger/MCMC) Wrench, Crowfoot, 1/2 DR 1-1/8 ........................................................... J5336CF (Grainger/MCMC)

NAVAIR 17-1-573
01 MARCH 2009
DESCRIPTION NUMBER

015 00
Page 3 of 22

Wrench, Crowfoot, 3/8 DR 5/8 .............................................................. 1UDR8 (Grainger/MCMC) Wrench, Crowfoot, 3/8 DR 3/4 .............................................................. 1UDT1 (Grainger/MCMC) Wrench, Crowfoot, 3/8 DR 7/16 ............................................................ 1UDR5 (Grainger/MCMC) Wrench, Torque, 1/2 DR 10-150 ........................................................... 5274A13 (Grainger/MCMC) Adapter, 1/2 DR, 1/2F x 3/8M ............................................................... 3ZB37 (Grainger/MCMC) Adapter, 3/8 DR, 3/8F x 1/2M ............................................................... 3ZB25 (Grainger/MCMC) Manifold, AC R134 4 valve.................................................................... 3XL15 (Grainger/MCMC) MATERIALS REQUIRED NOMENCLATURE NUMBER

3M Sealant Corrosion Inhibitor................................................................... - Filter-Dryer ................................................................................................. - Nitrogen ...................................................................................................... 6830-00-292-0732 Rotolock Gasket, (Teflon Ring) large ......................................................... - Rotolock Gasket, (Teflon Ring) small......................................................... - Teflon Tape ................................................................................................ - -

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 4 of 22

1.1 1.2

INTRODUCTION. This WP provides instruction for repair, removal, and installation of refrigeration assembly components, including rotolock fittings. There is no brazing / debrazing of refrigeration assembly tubes with the A/E32C-45A ECU. A key feature of the A/E32C-45A ECU that is different from legacy ECUs is the use of rotolock fittings instead of brazing to connect component parts to the refrigeration assembly. Use of rotolock fittings eliminates the requirement to purge the refrigeration assembly after maintenance and/or prior to charging it with refrigerant. ROTOLOCK AND COUPLING NUTS FITTINGS. There are five rotolock/coupling nut fittings used instead of brazing to assemble refrigeration components into the refrigeration assembly (Figures 1 and 2). Four of these fittings have a 1 3/8 inch nut, the fifth fitting has a 1/1/8 inch coupling nut. A Teflon seal is used in the fitting to provide a leak free seal. These gaskets must be replaced each time the fitting is opened. Proper assembly / disassembly of the rotolock / coupling nut fittings is essential to maintaining the refrigeration assembly. 1 1/8 inch Coupling Nut

1.3

2.1 2.2

1 3/8 inch Rotolocks Figure 1. Rotolock and Coupling Nut Fittings (Accumulator / Reversing Valve View).

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 5 of 22

1 3/8 inch Rotolocks Figure 2. Rotolock and Coupling Nut Fittings (Compressor View). 2.3 DISASSEMBLY OF ROTOLOCK FITTINGS. NOTE Always use two wrenches to disassemble rotolock fittings. One wrench is used to stabilize the fitting while the other wrench is used to break the fitting by turning the nut. Rotolock fittings may be coated with 3M Sealant corrosion inhibitor. Use wrench or other tool to remove coating if needed to fit wrench onto fitting. 1. Place one wrench on non-moving part of rotolock fitting to stabilize the joint and adjacent tubing. 2. Place second wrench on moving part of rotolock fitting and turn nut counterclockwise to loosen. 2.4 ASSEMBLY OF ROTOLOCK FITTINGS. NOTE Every time a rotolock fitting is disassembled, the rotolock gasket must be replaced. 1. Remove used rotolock gasket and replace it with a new gasket. 2. Align rotolock components and hand tighten by turning moving component clockwise. NOTE Always use two wrenches to assemble rotolock fittings. One wrench is used to stabilize the fitting while the other wrench is used to tighten the fitting by turning the nut. Rotolock assemblies must be torqued to a minimum value to achieve a leak-free seal. Tightening beyond this minimum torque valve is allowed if needed to preclude leaks.

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 6 of 22

3. Use ECU torque wrench tools and tighten rotolock fitting to minimum torque of 60 lb ft or as specified in applicable procedure. 4. Apply 3M Sealant corrosion inhibitor to all exposed areas of rotolock fittings and exposed adjacent tubing. 3.1 FILTER-DRYER. NOTE The filter-dryer must be removed and replaced with a new filter-dryer every time the refrigeration assembly is opened for repair / replacement of a component.

Figure 3. Filter Dryer. 3.2 REMOVAL OF FILTER DRYER.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove service panels as needed IAW WP 0013 00. 3. Discharge refrigerant from ECU as needed IAW WP 008 00.

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 7 of 22

NOTE Always use two wrenches to disassemble filter dryer flare nut fittings. One wrench is used to stabilize the fitting while the other wrench is used to break the fitting by turning the nut. Filter dryer flare nut fittings may be coated with 3M Sealant corrosion inhibitor. Use wrench or other tool to remove 3M coating if needed to fit wrench onto fitting. 4. Disconnect the flare nut (2, Figure 3) from each end of the filter dryer (3) as follows. Use a 3/4 inch wrench on the filter dryer hex fitting (1) and a 15/16 inch wrench on the flare nut (2). Hold filter dryer hex fitting and turn flare nut counterclockwise. 5. Remove the screw (4), washer (5), standoff (6), and clamp (7) securing the filter dryer (3) to the outdoor fan housing assembly (8). 3.3 INSTALLATION OF FILTER DRYER.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Apply Teflon tape to threads of filter dryer hex fitting. Place the tape on top of the threads and hold the tape down with index finger and roll the fitting in a clockwise direction. Wrap the Teflon tape 3 times around the fitting, then hold down on the threads with your thumb and pull on the tape roll to 'cut' the tape. 4. Align flare nuts (2) to each end of the filter dryer (3) and hand tighten flare nuts onto threaded part of filter dryer hex nut. NOTE Always use two wrenches to assemble filter dryer flare nut fittings. One wrench is used to stabilize the fitting while the other wrench is used to tighten the fitting by turning the nut. Do not over tighten fitting. You can damage the threads or destroy the Teflon tape seal. Tighten fitting up to two turns with a wrench. Do not force the fitting if it wants to stop before two turns. 5. Tighten fitting up to two turns with a 3/4 inch wrench on the filter dryer hex fitting (1) and a 15/16 inch wrench on the flare nut (2). 6. Place the clamp (7) over the filter dryer (3). Secure the clamp (3) to the outdoor fan housing assembly (8) with the standoff (6), washer (5), and screw (4). 7. Perform the leak test after repairs IAW WP 008 00. 8. Evacuate refrigeration assembly IAW WP 0010 00. 9. Charge refrigeration assembly IAW WP 0011 00. 10. Apply 3M Sealant corrosion inhibitor to all exposed areas of flare nut fittings and exposed adjacent tubing. 11. Install service panels IAW WP 013 00. 12. Perform other maintenance as needed to return ECU to service.

NAVAIR 17-1-573
01 MARCH 2009
4.1 4.2 TUBE ASSEMBLIES. REMOVAL OF TUBE ASSEMBLIES.

015 00
Page 8 of 22

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove service panels IAW WP 013 00. 3. Discharge refrigeration assembly IAW WP 009 00. 4. Remove tube clamps, attaching hardware and insulation from tube as necessary. 5. Remove tube sections from unit by disassembling rotolock fittings, refer to, Disassembly Of Rotolock Fittings, this WP. 6. Cover tube ends to prevent moisture and foreign particles from entering refrigerant system. 4.3 INSTALLATION OF TUBE ASSEMBLIES.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Remove protective covering from tube end sections and position replacement tube. 4. Install and connect tube sections by assembling rotolock fittings, refer to, Assembly Of Rotolock Fittings, this WP. NOTE The filter-dryer must be replaced after any refrigeration system component is replaced. 5. Replace filter-dryer, refer to, Filter Dryer, this WP. 6. Perform leak test after repairs IAW WP 008 00. 7. Evacuate refrigeration assembly IAW WP 010 00. 8. Charge system IAW WP 011 00. 9. Apply 3M Sealant corrosion inhibitor to exposed areas of flare nut fittings and exposed adjacent tubing. 10. Install service panels IAW WP 013 00. 11. Perform other maintenance as needed to return ECU to service.

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 9 of 22

Figure 4. Refrigeration Assembly.

NAVAIR 17-1-573
01 MARCH 2009
5.1 5.2 OUTDOOR COIL ASSEMBLY. REMOVAL OF OUTDOOR COIL ASSEMBLY.

015 00
Page 10 of 22

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove ECU from Mobile Facility IAW NAVAIR 19-25-177. CAUTION Ensure ECU is on flat level surface to minimize possibility it could fall over during maintenance. 3. Remove lower rear, lower sides (left and right) side, side slide panels (left and right), and side extension (left side) service panels IAW WP 013 00. 4. Discharge refrigeration assembly IAW WP 009 00. 5. Remove side brace (1, Figure 5) from left side (compressor side) of frame assembly.

Figure 5. Frame Assembly Removal of Outdoor Coil.

NAVAIR 17-1-573
01 MARCH 2009
6. Remove LH back angle (2) from frame assembly.

015 00
Page 11 of 22

7. Disconnect outdoor coil (28, Figure 4) from tubing by disassembling rotolock fitting, refer to, Disassembly Of Rotolock Fittings, this WP. NOTE Always use two wrenches to disassemble flare nut fittings. One wrench is used to stabilize the fitting while the other wrench is used to break the fitting by turning the nut. 8. Disconnect flare nut at top of sight glass as follows. Use a 3/4 inch wrench on the sight glass hex fitting and a 15/16 inch wrench on the flare nut. Hold hex nut and turn flare nut counterclockwise. 9. Remove Teflon tape from threaded part of sight glass hex nut. 10. Cover tube ends to prevent moisture and foreign material from entering refrigerant system. 11. Remove clamp on tube above sight glass. 12. Detach defrost termination switch sensor bulb from side of outdoor coil (28) and position it where it will not interfere with removal of outdoor coil. 13. Remove eight screws (29) securing condenser coil (28) to outdoor fan shroud assembly. 14. Remove outdoor coil (28) from ECU by pulling / sliding it towards side where frame brace (1, Figure 5) and LH side angle (2) were removed. 5.3 INSTALLATION OF OUTDOOR COIL ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. CAUTION Ensure ECU is on flat level surface to minimize possibility it could fall over during maintenance. 3. Slide replacement outdoor coil (28, Figure 4) in to ECU from side where frame brace (1, Figure 5) and LH side angle (2) were removed. 4. Secure outdoor coil to outdoor fan shroud assembly with screws (29, Figure 4). 5. Attach defrost termination switch sensor bulb to outdoor coil (28). 6. Remove protective coverings from tube end sections. 7. Apply Teflon tape to sight glass hex nut threads. Place the tape on top of the threads and hold the tape down with index finger and roll tape around the fitting in a clockwise direction. Wrap the Teflon tape 3 times around the fitting, then hold down on the threads with your thumb and pull on the tape roll to 'cut' the tape. 8. Align flare nut on tubing above sight glass with sight glass hex nut and hand tighten.

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 12 of 22

NOTE Always use two wrenches to assemble flare nut fittings. One wrench is used to stabilize the fitting while the other wrench is used to tighten the fitting by turning the nut. Do not over tighten fitting. You can damage the threads or destroy the Teflon seal. Tighten fitting up to two turns with a wrench. Do not force the fitting if it wants to stop before two turns. 9. Tighten fitting up to two turns with a 3/4 inch wrench on the hex fitting (1) and a 15/16 inch wrench on the flare nut (2). 10. Install clamp on tube above sight glass. 11. Connect outdoor coil to tubing by assembling rotolock fitting , refer to, Assembly Of Rotolock Fittings, this WP. NOTE The filter-dryer must be replaced after any refrigeration assembly component is removed and replaced. 12. Replace filter-dryer, refer to, Filter Dryer, this WP. 13. Install LH back angle from frame assembly (2, Figure 5) 14. Install side brace on left side (compressor side) of frame assembly (1). 15. Perform leak test after repairs IAW WP 008 00. 16. Evacuate refrigeration assembly IAW WP 010 00. 17. Charge system IAW WP 011 00. 18. Apply 3M Sealant corrosion inhibitor to all exposed areas of rotolock and flare nut fittings and exposed adjacent tubing. 19. Install service panels IAW WP 013 00. 20. Perform other maintenance as needed to return ECU to service. 6.1 6.2 INDOOR COIL ASSEMBLY. REMOVAL OF INDOOR COIL ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Discharge refrigeration assembly ECU IAW WP 010 00. 4. Remove heating element IAW WP 014 00. 5. Disconnect indoor coil (7, Figure 4) from tubing by disassembling rotolock fitting, refer to, Disassembly Of Rotolock Fittings, this WP. 6. Cover tube ends to prevent moisture and foreign material from entering refrigeration assembly.

NAVAIR 17-1-573
01 MARCH 2009
7. Remove screws (32) securing bracket (31). 8. Remove screws (8) securing indoor coil (7). 9. Lift and remove indoor coil from ECU. 6.3 INSTALLATION OF INDOOR COIL ASSEMBLY.

015 00
Page 13 of 22

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Remove protective coverings from tube end sections. 4. Position replacement indoor coil (7) in ECU. 5. Install heating element IAW WP 014 00. 6. Secure indoor coil in ECU with screws (8). 7. Install bracket (31) and secure with screws (32). 8. Connect indoor coil to tubing by assembling rotolock fitting, refer to, Assembly Of Rotolock Fittings, this WP. NOTE The filter-dryer must be replaced after any refrigeration assembly component is replaced. 9. Replace filter-dryer (22) Refer to, Filter Dryer, this WP. 10. Perform the leak test after repairs IAW WP 008 00. 11. Evacuate refrigeration assembly IAW WP 010 00. 12. Charge refrigeration system IAW WP 011 00. 13. Install service panels IAW WP 013 00. 14. Install Mobile Facility Front Panel IAW NAVAIR 19-25-177. 15. Perform other maintenance as needed to return ECU to service. 7.1 7.2 REVERSING VALVE ASSEMBLY. REMOVAL OF REVERSING VALVE ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove service panels IAW WP 0013 00.

NAVAIR 17-1-573
01 MARCH 2009
3. Discharge refrigeration assembly IAW WP 009 00. 4. Remove solenoid retaining screw and slide off solenoid from reversing valve. 5. Cut foil and cork tape to expose expansion valve sensing bulb. 6. Remove two clamps to release expansion valve bulb from tubing.

015 00
Page 14 of 22

7. Disconnect reversing valve from refrigeration assembly tubing by disassembling rotolock fittings, refer to, Disassembly Of Rotolock Fittings, this WP. 8. Remove reversing valve from ECU. 9. Cover tube ends to prevent moisture and foreign material from entering refrigeration assembly. 7.3 INSTALLATION OF REVERSING VALVE ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Remove protective covering from tube ends. 4. Connect reversing valve assembly to refrigeration assembly tubing by assembling rotolocks , refer to, Assembly Of Rotolock Fittings, this WP. Tighten rotolock fittings to 50 to 60-foot pounds for the three suction connections and 40 to 50 foot pounds for the discharge connection of compressor. NOTE The filter-dryer must be replaced after any refrigeration system component is replaced. 5. Replace filter-dryer, refer to, Filter Dryer, this WP. 6. Install expansion valve sensing bulb to tubing with two clamps. 7. Wrap expansion valve sensing bulb and tube with cork tape and foil. 8. Perform the leak test after repairs IAW WP 008 00. 9. Evacuate refrigeration assembly IAW WP 010 00. 10. Charge refrigeration assembly IAW WP 011 00. 11. Install service panels IAW WP 013 00. 12. Perform other maintenance as needed to return ECU to service.

NAVAIR 17-1-573
01 MARCH 2009
8.1 8.2 COMPRESSOR. REMOVAL OF COMPRESSOR.

015 00
Page 15 of 22

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove service panels IAW WP 0013 00. NOTE Remove reversing valve assembly, this WP, prior to removing compressor. 3. Remove service panels IAW WP 013 00. 4. Discharge refrigeration assembly IAW WP 009 00. 5. Remove cover from compressor terminal box, tag, then disconnect compressor electrical wiring from terminals T1, T2, and T3. Cut wire ties as needed. (Figure 6). 6. Remove exterior crankcase heater belly band from compressor (located approximately 1 inch above base of compressor) by loosening adjusting screw and disconnecting ground wire from ECU. (Figure 7).

T1

T2

T3

Figure 6. Compressor Terminal Box Terminals T1, T2 and T3.

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 16 of 22

Compressor Crankcase Heater. Figure 7. Crankcase Heater on Compressor.

5
Figure 8. Attaching Hardware -- Compressor-to-Compressor Shelf.

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 17 of 22

7. Disconnect compressor from tubing by disassembling rotolock fittings at compressor suction (larger diameter) port and discharge (smaller diameter) port. 8. Remove nuts (1, Figure 8), washer (2), and upper elastomeric washer (3). 9. Carefully lift compressor from compressor shelf weldment and remove from ECU. Cover tube ends to prevent moisture and foreign particles from entering refrigeration assembly. 8.3 INSTALLATION OF COMPRESSOR.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Remove protective covering from tube end sections and position compressor. 4. Replace compressor-mounting hardware if damaged or worn. 5. Install compressor on mounts. Secure with washers (2, 3) and nuts (1). 6. Install exterior crankcase heater belly band (Figure 7) on compressor approximately 1 inch above base of compressor. Tighten adjustment screw and attach ground wire to ECU. CAUTION Compressor wiring at T1, T2 and T3 must be phased matched for proper operation of compressor. Improper phasing will result in noticeably noisy compressor operation. If not corrected it will result in failure of compressor. 7. Connect electrical wiring from compressor to terminals T1, T2, and T3 of relay (Figure 6). 8. Install new rotolock gaskets on compressor suction and discharge rotolock fittings. 9. Connect compressor to refrigeration assembly tubing by assembling rotolock fittings, refer to, Assembly Of Rotolock Fittings, this WP. Tighten fittings to 50-60 foot pounds for the suction connection and 40-50 foot pounds for the discharge connection. NOTE The filter-dryer must be replaced after any refrigeration assembly component is replaced. 10. Replace filter-dryer, refer to, Filter Dryer, this WP. 11. Perform the leak test after repairs IAW WP 009 00. 12. Evacuate refrigeration assembly IAW WP 011 00. 13. Charge refrigeration assembly IAW WP 012 00. 14. Install service panels IAW WP 013 00. 15. Install Mobile Facility Front Panel IAW NAVAIR 19-25-177. 16. Perform other maintenance as needed to return ECU to service.

NAVAIR 17-1-573
01 MARCH 2009
9.1 9.2 ACCUMULATOR ASSEMBLY. REMOVAL OF ACCUMULATOR ASSEMBLY.

015 00
Page 18 of 22

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove service panels IAW WP 0013 00. 3. Discharge refrigeration assembly IAW WP 009 00. 4. Remove expansion-sensing tube by disconnecting flare nut from accumulator tubing. 5. Disconnect low-pressure switch flare nut and expansion valve equalizer tubing flare nut from accumulator tubing. 6. Disconnect accumulator tubing from compressor and reversing valve tubing by disassembling rotolock fittings, refer to, Disassembly Of Rotolock Fittings, this WP. 7. Remove nut (5, Figure 4) and washer (6) from bottom of accumulator mounting stud and remove accumulator assembly (26) from ECU. 9.3 INSTALLATION OF ACCUMULATOR ASSEMBLY.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Remove protective covering from tube end sections. 4. Install rotolock gaskets on accumulator tubing fittings. 5. Position accumulator (26, Figure 4) and connect it to the refrigeration assembly by assembling rotolock fittings, refer to, Assembly Of Rotolock Fittings, this WP. 6. Connect low-pressure switch flare nut and expansion valve equalizer tubing flare nut to accumulator tubing fittings. 7. Install expansion-sensing tube by connecting flare nut to accumulator tubing. 8. Secure accumulator (26) with washer (6) and nut (5). NOTE The filter-dryer must be replaced after any refrigeration system component is replaced. 9. Replace filter-dryer (22), refer to, Filter Dryer, this WP. 10. Perform the leak test after repairs IAW WP 009 00. 11. Evacuate refrigeration assembly IAW WP 010 00.

NAVAIR 17-1-573
01 MARCH 2009
12. Charge refrigeration assembly IAW WP 011 00. 13. Install service panels IAW WP 013 00. 14. Perform other maintenance as needed to return ECU to service. 10.1 HIGH-PRESSURE CUTOUT SWITCH. 10.2 REMOVAL OF HIGH-PRESSURE CUTOUT SWITCH.

015 00
Page 19 of 22

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Discharge refrigeration assembly IAW WP 009 00. 4. Tag and disconnect the high-pressure cutout (HPCO) switch electrical wires number 13, 15, and 16. (Figure 9). 5. Disconnect HPCO switch tubing flare nut from compressor discharge tubing. NOTE HPCO and LPCO switches are mounted adjacent to one another on the control box using three screws one screw specific to each switch and the third screw shared between the two switches. 6. Remove mounting screw specific to HPCO switch and loosen shared mounting screw. 7. Remove HPCO switch from ECU. 10.3 INSTALLATION OF HIGH-PRESSURE CUTOUT SWITCH.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Mount HPCO switch, S1, next to LPCO switch, S2, on exterior of control box. Secure with HPCO specific mounting screw and mounting screw shared with LPCO switch. 4. Connect HPCO switch tubing to fitting on compressor discharge tubing with flare nut. 5. Connect HPCO switch electrical wires 13, 15 and 16 (Figure 9).

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 20 of 22

NOTE The filter-dryer must be replaced after any refrigeration system component is replaced. 6. Replace filter-dryer, refer to, Filter Dryer, this WP. 7. Perform the leak test after repairs IAW WP 008 00. 8. Evacuate refrigeration assembly IAW WP 010 00. 9. Charge system IAW WP 011 00. 10. Install service panels IAW WP 013 00. 11. Install Mobile Facility Front Panel IAW NAVAIR 19-25-177. 12. Perform other maintenance as needed to return ECU to service.

Figure 9. Wiring for HPCO Switch (S1) and LPCO (S2) Switch. 11.1 LOW-PRESSURE CUTOUT SWITCH. 11.2 REMOVAL OF LOW-PRESSURE CUTOUT SWITCH.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat.

Control Box

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 21 of 22

1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove service panels IAW WP 0013 00. 3. Discharge refrigeration assembly IAW WP 009 00. 4. Tag and disconnect low-pressure cutout (LPCO) switch, S2, electrical wires number 14 and 16 (Figure 9). 5. Disconnect LPCO switch flare nut from accumulator tubing. NOTE HPCO and LPCO switches are mounted adjacent to one another on the control box using three screws one screw specific to each switch and the third screw is shared between the two switches. 6. Remove mounting screw specific to LPCO switch and loosen mounting screw shared with HPCO switch. 7. Remove LPCO switch from ECU. 11.3 INSTALLATION OF LOW-PRESSURE CUTOUT SWITCH.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. If needed, remove service panels IAW WP 0013 00. 3. Mount LPCO switch, S2, next to HPCO switch, S1, on exterior of control box. Secure with LPCO specific mounting screw and mounting screw shared with HPCO switch. 4. Connect LPCO switch flare nut to fitting of accumulator tubing. 5. Connect LPCO switch electrical wires number 14 and 16 (Figure 9). NOTE The filter-dryer must be replaced after any refrigeration system component is replaced. 6. Replace filter-dryer, refer to, Filter Dryer, this WP. 7. Perform the leak test after repairs IAW WP 008 00. 8. Evacuate refrigeration assembly IAW WP 010 00. 9. Charge system IAW WP 011 00. 10. Install service panels IAW WP 013 00. 11. Install Mobile Facility Front Panel. Refer to NAVAIR 19-25-177. 12. Perform other maintenance as needed to return ECU to service.

NAVAIR 17-1-573
01 MARCH 2009

015 00
Page 22 of 22

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

016 00
Page 1 of 6

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN CONTROL BOX ASSEMBLY ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 013 00 Indoor Thermostat, Panels, and Covers ............................ NAVAIR 17-1-573 WP 019 00 - Unit Wiring: Inspection, Test, Repair, and Installation ........ NAVAIR 17-1-573 NAVAIR 19-25-177 Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................................ ALPHABETICAL INDEX TITLE WP / Page Number

Control Box Assembly .................................................................................016 00 / 2 Installation of Control Box Electrical Components ......................................016 00 / 6 Introduction..................................................................................................016 00 / 2 Removal of Control Box Electrical Components .........................................016 00 / 3

NAVAIR 17-1-573
01 MARCH 2009

016 00
Page 2 of 6

1.1 1.2 2.1 2.2

INTRODUCTION. This WP provides maintenance instructions for the control box assembly. CONTROL BOX ASSEMBLY. Repair of the control box assembly (Figure 1) is limited to replacement of defective electrical components (Table 1). Components are attached to the interior of the control box assembly with self-tapping screws.

Figure 1. Control Box Electrical Components.

NAVAIR 17-1-573
01 MARCH 2009

016 00
Page 3 of 6

Table 1. Control Box Electrical Components. COMPONENT Terminal Board, Power In Electric Heat 1 Terminal Board. Power In Heat Pump Terminal Board, Room Thermostat 3 Relay, Compressor Motor Relay, Indoor Fan Motor Relay, Outdoor Fan Motor LABEL TB1 TB2 TB3 K1 K2 K3 COMPONENT Relay, Electric Heaters Stage 1 Relay, Electric Heaters Stage 2 Capacitor, Outdoor Fan Motor Transformer, 24 VAC Control Circuit Switch, 2d Stage Heater Thermostat Defrost Control LABEL K4 K5 C1 TR S5 DC

2.3

REMOVAL OF CONTROL BOX ELECTRICAL COMPONENTS.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove lower service panel IAW WP 013 00. 3. Remove control box cover IAW WP 013 00. 4. Tag and disconnect electrical wires to component(s) to be removed. Refer to Figures 2 and 3 and WP 019 00 for control box wiring details. 5. Prior to removal of defrost control loosen clamp holding defrost switch sensor bulb. NOTE The defrost termination thermostat is part of defrost control and is replaced as complete assembly. 6. Detach selected component from control box assembly by removing self-tapping screws. 7. Remove selected component from control box assembly.

NAVAIR 17-1-573
01 MARCH 2009

016 00
Page 4 of 6

Figure 2. Control Box Electrical Wiring 24VAC Control.

NAVAIR 17-1-573
01 MARCH 2009

016 00
Page 5 of 6

Figure 3. Control Box Electrical Wiring High Voltage Power.

NAVAIR 17-1-573
01 MARCH 2009
2.4 INSTALLATION OF CONTROL BOX ELECTRICAL COMPONENTS.

016 00
Page 6 of 6

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. As needed, remove lower service panel and control box cover IAW WP 013 00. 3. Prior to installation of defrost control install defrost switch sensor bulb and tighten clamp. 4. Attach selected component to control box with self-tapping screws. 5. Connect electrical wires to component(s). Refer to Figures 2 and 3 and WP 019 00 for control box wiring details. 6. Install control box cover IAW WP 013 00. 7. Install lower service panel IAW WP 013 00. 8. Perform other maintenance as needed to return ECU to service.

NAVAIR 17-1-573
01 MARCH 2009

017 00
Page 1 of 4

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN INDOOR BLOWER ASSEMBLY ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 014 00 - Chassis Assembly............................................................... NAVAIR 17-1-573 ALPHABETICAL INDEX TITLE WP / Page Number

Indoor Blower Assembly..............................................................................017 00 / 2 Assembly of Indoor Blower Assembly....................................................01700 / 3 Cleaning of Indoor Blower Assembly .....................................................017 00 / 2 Disassembly of Indoor Blower Assembly ...............................................017 00 / 2 Visual Inspection of Indoor Blower Assembly ........................................017 00 / 2 Introduction..................................................................................................017 00 / 2 MATERIALS REQUIRED NOMENCLATURE NUMBER

Cleaning Compound, Solvent, Detergent................................................. Simple Green Cleaning Solvent ...................................................................................... MIL-PRF-680 Type III Cloth, Wiping, Lint Free............................................................................ DDD-R-30 Detergent, Liquid ...................................................................................... MIL-D-16791

NAVAIR 17-1-573
01 MARCH 2009

017 00
Page 2 of 4

1.1 1.2

INTRODUCTION. This WP provides maintenance instructions for disassembly, cleaning, inspection, and assembly of the indoor blower assembly after it is removed from the ECU. INDOOR BLOWER ASSEMBLY. Refer to WP 014 00 for instructions on removal and installation of the indoor blower assembly from / into the ECU. DISASSEMBLY OF THE INDOOR BLOWER ASSEMBLY.

2.1 2.2

2.3

1. Remove screws (2, Figure 1) to detach the two inlet flanges (1) from each of the two fan housings (3). 2. Remove outer inlet flange from each side. 3. Remove each fan housing (3) by sliding it over its respective fan impeller (4 and 5). 4. Tag impellers LH and RH. 5. Align access hole in each impeller with its impeller set screw. Insert long (10-inch) hex wrench through access hole to engage set screw. Loosen set screws to release impeller from motor (6) shaft. 6. Slide each impeller (4 and 5) off its respective shaft. 7. Remove inner inlet flange from motor side of respective fan housing. 2.4 CLEANING OF THE INDOOR BLOWER ASSEMBLY.

CLEANING SOLVENT, MIL-PRF-680 TYPE III

GENERAL PURPOSE DETERGENTS, MIL-D-16791

1. Clean all parts with cleaning solvent, MIL-PRF-680, Type III or detergent, MIL-D-16791, water cleaning to eliminate dirt, oil, and other contaminants that cause, promote, or mask corrosion. 2. Wipe with clean, lint-free cloth. 2.5 VISUAL INSPECTION OF THE INDOOR BLOWER ASSEMBLY.

1. Inspect all parts for damage, cracks, corrosion, and excessive wear. 2. Inspect motor (6) for free rotation and evidence of overheating. 3. Inspect capacitor for overheating. 4. Inspect wiring for chafing and deterioration.

NAVAIR 17-1-573
01 MARCH 2009
5. Inspect terminals for security and corrosion. 6. Inspect fan impellers (4 and 5) for damage or distortion. 2.6 ASSEMBLY OF THE INDOOR BLOWER ASSEMBLY.

017 00
Page 3 of 4

1. Assembly an inlet flange (1) to the motor side of the each fan housing (3). 2. Slide fan housings (3) over their respective motor shafts. 3. Remove tags and slide LH and RH fan impellers (4 and 5) into respective fan housing (3) over motor shaft 4. Working through exhaust port in fan housing, align access hole in each impeller with its impeller set screw. Insert long (10-inch) hex wrench through access hole to engage set screw. Tighten set screws to securely attach impeller to motor (6) shaft. 5. Install inlet flanges (1) in the outside of RH and LH fan housings (3). Secure with screws (2).

NAVAIR 17-1-573
01 MARCH 2009

017 00
Page 4 of 4

Figure 1. Indoor Blower Assembly.

NAVAIR 17-1-573
01 MARCH 2009

018 00
Page 1 of 4

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN FRAME ASSEMBLY ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

Maintenance Instructions (Organizational and Intermediate, Levels) Support Equipment Cleaning Preservation, and Corrosion Control ........ NAVAIR 17-1-125 WP 020 00 - Illustrated Parts Breakdown ................................................ NAVAIR 17-1-573 ALPHABETICAL INDEX TITLE WP / Page Number

Frame Assembly .........................................................................................018 00 / 2 Introduction..................................................................................................018 00 / 2

NAVAIR 17-1-573
01 MARCH 2009

018 00
Page 2 of 4

1.1 1.2

INTRODUCTION. This WP provides maintenance instructions for corrosion repair and replacement of missing hardware for the frame assembly, part number 1559AS401. FRAME ASSEMBLY. Maintenance of the frame assembly (Figure 1) is limited to corrosion control IAW NAVAIR 171-125 and replacement of missing parts / hardware. Refer to the IPB, (WP 020 00) to identify parts. Table 1 lists the significant structural members of the frame assembly. Exercise care when installing frame parts to prevent damage to tubing and wiring.

2.1 2.2

Figure 1. Frame Assembly.

NAVAIR 17-1-573
01 MARCH 2009

018 00
Page 3 of 4

Table 1. Frame Assembly Structural Members (Refer to Figure 1). Component Pan, Bottom Angle, Back, LH Angle, Back, RH Angle, Front, LH Angle, Front, RH Bracket, EVAP, LH Label 1 2 3 4 5 6 Component Bracket, EVAP, RH Shelf. Fan Weldment, Shelf, Compressor Weldment Pan Drain Shroud, Fan Brace, Side Label 7 8 9 10 11 12

NAVAIR 17-1-573
01 MARCH 2009

018 00
Page 4 of 4

THIS PAGE INTENTIONALLY BLANK.

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 1 of 10

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN UNIT WIRING INSPECTION, TEST, REPAIR, AND INSTALLATION ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

Technical Manual, Operation and Intermediate Maintenance With Illustrated Parts Breakdown, Mobile Facility ............................ NAVAIR 19-25-177 ALPHABETICAL INDEX TITLE WP / Page Number

Introduction..................................................................................................019 00 / 2 Repair of Unit Wiring ...................................................................................019 00 / 3 Replacement of Unit Wiring ........................................................................019 00 / 3 Test of Unit Wiring.......................................................................................019 00 / 2 Visual Inspection of Unit Wiring ..................................................................019 00 / 2 SUPPORT EQUIPMENT REQUIRED DESCRIPTION NUMBER

Heat Shrink Tubing..................................................................................... Multimeter................................................................................................... 77AN

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 2 of 10

1.1 1.2

INTRODUCTION. This WP provides maintenance instructions for visual inspection, test, repair, and replacement of ECU electrical wiring. Refer to Table 1, Wire List, for wire number, labels (from / to) wire size (AWG), wire color, type of end-to-end connections, length of wire, and remarks. Refer to Figures 1, 2 and 3 for wiring schematic diagrams. VISUAL INSPECTION OF UNIT WIRING.

1.3

1.4 2.1

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Visually inspect all installed wiring for cracked or frayed insulation. Pay particular attention to wires routed around sharp edges. 3. Repair unserviceable wiring, refer to, Repair Of Unit Wiring, this WP, or replace unserviceable wiring, refer to, Replacement Of Unit Wiring, this WP. Remove wire bands / ties as required to remove damaged wire. Determine wire gauge and length from Table 1 4. Inspect terminal screws, compression terminal, and quick-connect terminals for tightness and good electrical conductance. 5. Replace damaged connectors. 3.1 TEST OF UNIT WIRING.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Test for continuity of wiring using multimeter. 3. Touch the test probes of a multimeter set on low-resistance range to ends of wire and/or corresponding pin of connector. 4. If continuity is not indicated, repair wire, refer to, Repair Of Unit Wiring, this WP, or replace wire, Replacement Of Unit Wiring, this WP.

NAVAIR 17-1-573
01 MARCH 2009
4.1 REPAIR OF UNIT WIRING.

019 00
Page 3 of 10

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Remove the insulation to expose 1/2 inch of bare wire on each side of break or damaged insulation. 3. Insert the wire ends into a splice-connector, splice, and crimp the connector to make firm electrical contact. Alternatively, heat-shrink tubing may be slipped over one end of the wire before splicing, and then heated after the splice is made and soldered, so as to cover the spliced area. 4. Be sure that no bare wire or wire strands are exposed after splice is complete. 5. Replace broken or loose terminal lugs with exact duplicates. 6. After repair, check continuity terminal-to-terminal. 5.1 REPLACEMENT OF UNIT WIRING.

WARNING
Severe electrical shock may cause injury or death to personnel. ECU has two (2) power circuits Heat Pump and Electric Heat. 1. Ensure power to ECU is secured by turning off heat pump and electric heat circuit breakers and disconnecting plugs (cables) IAW NAVAIR 19-25-177. 2. Verify all labels on all wire leads prior to removal. Refer to wire list (Table 1. 3. Disconnect all terminals. 4. Carefully remove connectors from unit. 5. Install new labels on new wires. Refer to wire list (Table 1). 6. Verify correct labels on wires and connect all terminals. Refer to schematic diagrams (Figures 1, 2 and 3) and wire list (Table 1). 7. Route new wire and secure in bundle with wire bands.

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 4 of 10

Table 1. Wire List.


WIRE NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 TB3-G TB3-W TB3-Y TB3-B TB3-C TB3-R TB3-R TB3-C TR-24VAC GND K3 COIL K2 COIL K5 COIL DC-HPS DC-LPS DC-LPS S1 DC-CC LABELS FROM TO K2-COIL DC-W DC-Y DC-B DC-C DC-R TR-24VAC TR-24VAC GND K3, COIL K2-COIL K5-COIL K4-COIL S1 S2 S1 S2 K1-COIL WIRE SIZE AWG 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 WIRE COLOR BLUE WHITE YELLOW BLUE BLACK RED RED BLACK BLACK BLACK BLACK BLACK RED BLUE BLACK BLACK RED TYPE OF END TO END CONNECTION #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 SPADE-PIGGY BACK 1559AS281-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE-PIGGY BACK 1559AS281-1 SPADE 1559AS282-1 SPADE-PIGGY BACK 1559AS281-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE-PIGGY BACK SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 LENGTH OF WIRE 12 20 20 20 22 20 6 6 12 7 10 7 17 17 15 5 13 REMARKS

24 VAC CONTROL

18 19

DC-CC DC-FAN

K1-COIL K3-COIL

20 20

BLACK BLUE

11 12

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 5 of 10

Table 1. Wire List.


WIRE NO. 20 21 30 S5 S5 TB1-1 LABELS FROM TO K5-COIL K4-COIL K4-CONTACTS WIRE SIZE AWG 20 20 10 WIRE COLOR BLUE BLUE BLACK TYPE OF END TO END CONNECTION SPADE 1559AS282-1 SPADE-PIGGY BACK 1559AS281-1 #10 RING 1559AS283-3 SPADE 1559AS282-1 SPADE 1559AS282-1 #10 RING 1559AS283-3 LENGTH OF WIRE 7 11 7 CONTROL BOX HIGH VOLTAGE POWER REMARKS

31 32 33 34 35 36 37 38 39 40 41 42 43 50 51 52

TB1-2 TB1-2 TB1-3 TB2-1 TB2-2 TB2-3 K1-L1 K1-L2 K1-L2 K1-L3 K1-T3 K1-T1 C1 DC-RV K1-COIL S4

K4-CONTACTS K5-CONTACTS K5-CONTACTS K1-L1 K1-L2 K1-K3 K2-CONTACTS K2-CONTACTS TR-COM TR-208V K3-CONTACTS K3-CONTACTS K3-CONTACTS RV-COIL RV-COIL TB-3-W

10 10 10 10 10 10 14 14 20 20 14 14 14 20 20 20

RED RED BLUE BLACK RED BLUE BLACK RED BLACK BLUE BLUE BLACK BLACK BLACK BLACK WHITE

#10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 SPADE 1559AS282-1 SPADE 1559AS282-1 #10 RING 1559AS283-3 #10 RING 1559AS283-3 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 #10 RING 1559AS283-3

#10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 SPADE 1559AS282-1 SPADE 1559AS282-1 #10 RING 1559AS283-3 #10 RING 1559AS283-3 SPADE 1559AS282-1 SPADE 1559AS282-1 SPADE 1559AS282-1 #10 RING 1559AS283-3

7 9 9 6 6 6 6 6 11 10 15 17 8 38 32 WIRE LIST CHASSIS

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 6 of 10

Table 1. Wire List.


WIRE NO. 53 54 S4 B1-T1 LABELS FROM TO K4 COIL K1-L1 WIRE SIZE AWG 20 10 WIRE COLOR WHITE BLACK TYPE OF END TO END CONNECTION #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 #10 RING 1559AS283-3 SPADE 1559AS282-1 FLAG COMPRESSOR 1559AS682 FLAG COMPRESSOR 1559AS682 FLAG COMPRESSOR 1559AS682 24 LENGTH OF WIRE REMARKS

55

B1-T2

K1-L2

10

RED

24

56

B1-T3

K1-L3

10

BLUE

24

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 7 of 10

Figure 1. Electrical Wiring 24VAC Control.

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 8 of 10

Figure 2. Electrical Wiring High Voltage Power.

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 9 of 10

LEGEND LABEL B1 B2 B3 C1 CH DC HR1 -- HR4 K1 K2 K3 K4

COMPONENT Compressor Motor* Indoor Fan Motor* Outdoor Fan Motor* Capacitor Outdoor Fan Motor Crankcase Heater Defrost Control Electric Heater Elements Relay Compressor Motor Relay Indoor Fan Motor Relay Outdoor Fan Motor

LABEL K5 RV S1 S2 S3 S4 S5 TB1 TB2 TB3

COMPONENT Relay Elec. Heaters 2d Stg. Reversing Valve High Pressure Cutout Switch Low Pressure Cutout Switch Defrost Termination Thermostat Switch Heater Cutout Switch 2d Stg Heater Thermostat Switch Terminal Board - Power In Electric Heat Terminal Board- Power In Heat Pump Terminal Board - Room Thermostat

Relay Elec. Heaters 1st Stg. TR Transformer 24VAC Control Circuit * Motors B1, B2 and B3 have thermal protection.

Figure 3. Environmental Control Unit Wiring Schematic Diagram.

NAVAIR 17-1-573
01 MARCH 2009

019 00
Page 10 of 10

THIS PAGE INTENTIONALLY LEFT BLANK

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 1 of 34

ORGANIZATIONAL AND INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN ILLUSTRATED PARTS BREAKDOWN ENVIRONMENTAL CONTROL UNIT, A/E32C-45A PART NUMBER 1559AS400-1

REFERENCE MATERIAL TITLE NUMBER

WP 002 00 - Introduction.......................................................................... NAVAIR 17-1-573 ALPHABETICAL INDEX TITLE WP / Page Number

Chassis Assembly .......................................................................................020 00 / 9 Control Box Assembly .................................................................................020 00 / 30 Discharge Tube Assembly ..........................................................................020 00 / 28 ECU Panels and Covers .............................................................................020 00 / 4 Environmental Control Unit .........................................................................020 00 / 2 Expansion Valve Assembly .........................................................................020 00 / 22 Frame Assembly .........................................................................................020 00 / 12 Indoor Blower Assembly..............................................................................020 00 / 14 Introduction..................................................................................................020 00 / 2 Liquid Valve Assembly ................................................................................020 00 / 26 Refrigeration Assembly ...............................................................................020 00 / 16 Removable Panel Assembly .......................................................................020 00 / 7 Reversing Valve Assembly..........................................................................020 00 / 20 Suction Accumulator Assembly...................................................................020 00 / 24

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 2 of 34

1.1 1.2

INTRODUCTION. This WP provides the Illustrated Parts Breakdown (IPB) for the A/E32C-45A ECU and its component assemblies. A detailed introduction to the IPB is provided in WP 002 00.

1.3

Figure 1. Environmental Control Unit, A/E32C-45A, Part Number 1559AS400. (Sheet 1 of 2)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 3 of 34

Figure 1. Environmental Control Unit, A/E32C-45A, Part Number 1559AS400. (Sheet 2 of 2)


INDEX NO. PART NUMBER 1559AS400-1 1 2 3 REF 1559AS474-1 1559AS428-1 DESCRIPTION / CAGE 1 2 3 4 5 6 7 ENVIRONMENTAL CONTROL UNIT (ECU) 3-TON, A/E32C-45A / 0V5R4 ................................. 1 ECU PANELS AND COVERS / 30003 (Breakdown in Figure 2) .......................................... CHASSIS ASSY / 30003 (Breakdown in Figure 4) .......................................... 1 REFRIGERATION ASSY / 30003 (Breakdown in Figure 7).......................................... 1 XAGGG AGGGG UNITS PER ASSY USABLE ON CODE SM&R CODE PEOGG

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 4 of 34

Figure 2. ECU Panels and Covers. (Sheet 1 of 4)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 5 of 34

Figure 2. ECU Panels and Covers. (Sheet 2 of 4)


INDEX NO. PART NUMBER REF 1 2 1559AS580-1 1559AS427-2 1007RW DESCRIPTION / CAGE 1 2 3 4 5 6 7 PANELS AND COVERS / 30003 (NHA in Figure 1) /ATTACHING PARTS/ SCREW, SELF TAPPING, 10-32 X 7/16 / 30003 (not shown) ........................................................... 4 SCREW, SELF TAPPING, 10-32 X 7/16 /Tower Fasteners Corp./ (not shown) ---*--3 1559AS556-1 REMOVABLE PANEL ASSY / 30003 (Breakdown in Figure 3) ....................................... 1 /ATTACHING PARTS/ 4 5 6 MS35207-265 MS51470-03 MS27183-42 SCREW, SELF TAPPING, ZNPL NO. 10-32 X 3/4 / 80205 (not shown) ........................................ 8 NUT, HEX, ZNPL NO. 10-32 / 80205 (not shown) .................................................................. 8 WASHER, FLAT, ZNPL. NO. 10 / 80205 (not shown) .................................................................. 16 ---*--7 8 1559AS557-1 1559AS427-2 1007RW PANEL, UPPER REAR/ 30003............................. 1 /ATTACHING PARTS/ SCREW, SELF TAPPING, 10-32 X 7/16 / Tower Fasteners Corp (not shown).................................. 2 SCREW, SELF TAPPING, 10-32 X 7/16 / 30003 (not shown) ---*--9 10 1559AS579-1 1559AS427-2 1007RW PANEL, LOWER REAR/ 30003 ............................ 1 /ATTACHING PARTS/ SCREW, SELF TAPPING, 10-32 X 7/16 / 30003 (not shown) ........................................................... 6 SCREW, SELF TAPPING, 10-32 X 7/16 / Tower Fasteners Corp (not shown) ---*--11 12 1559AS574-1 1559AS427-2 1007RW PANEL, UPPER SIDE / 30003 ............................. 2 /ATTACHING PARTS/ SCREW, SELF TAPPING, 10-32 X 7/16 / 30003 (not shown) ........................................................... 3 SCREW, SELF TAPPING, 10-32 X 7/16 / Tower Fasteners Corp (not shown) ---*--Continued on next page PAGZZ XBGZZ PAGZZ XBGZZ PAGZZ XBGZZ PAGZZ PAGZZ PAGZZ XBGZZ PAGZZ UNITS PER ASSY REF USABLE ON CODE SM&R CODE

PEOGG XBGZZ

COVER, TOP / 30003........................................... 1

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 6 of 34

Figure 2. ECU Panels and Covers. (Sheet 3 of 4)


INDEX NO. PART NUMBER DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE

13 14

1559AS574-1 1559AS427-2 1007RW

PANEL, LOWER SIDE / 30003............................. 2 /ATTACHING PARTS/ SCREW, SELF TAPPING, 10-32 X 7/16 / 30003 (not shown) ........................................................... 3 SCREW, SELF TAPPING, 10-32 X 7/16 / Tower Fasteners Corp (not shown) ---*-- PANEL, SIDE (SLIDE) / 30003 ............................. 2 /ATTACHING PARTS/ SCREW SELF TAPPING, 10-32 X 7/8 / 30003 (not shown) ........................................................... 2 SCREW SELF TAPPING, 10-32 X 7/8 / Tower Fasteners Corp (not shown) ---*-- PANEL, SIDE EXTENSION /30003 ...................... 2 /ATTACHING PARTS/ SCREW SELF TAPPING, 10-32 X 7/8 / 30003 (not shown) ........................................................... 4 SCREW SELF TAPPING, 10-32 X 7/8 / Tower Fasteners Corp (not shown) ---*-- COVER, CONTROL BOX ASSEMBLY / 30003... 1 /ATTACHING PARTS/ SCREW SELF TAPPING, 10-32 X 7/8 / 30003 (not shown) ........................................................... 4 SCREW SELF TAPPING, 10-32 X 7/8 / Tower Fasteners Corp (not shown) ---*-- INSULATION, FIBERGLASS (1/2 X 47-1/4 X 100 INCHES) /30003 ........................................... AR INSULATION, FIBERGLASS (1/2 X 47-1/4 X 100 INCHES) / 75165 ADHESIVE / 30003............................................... AR ADHESIVE / 3M Corp/

XBGZZ

PAGZZ

15 16

1559AS605-1 1559AS427-3 1007RW

XBGZZ

PAGZZ

17 18

1559AS607-1 1559AS427-3 1007RW

XBGZZ

PAGZZ

19 20

1559AS555-1 1559AS427-3 1007RW

XBGZZ

PAGZZ

21

1559AS272-1 LINACOUSTIC

PAGZZ

22

1559AS267-1 NO. 1357 CONTACT CEMENT

PAGZZ

Continued on next page

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 7 of 34

Figure 2. ECU Panels and Covers. (Sheet 4 of 4)


INDEX NO. PART NUMBER DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE

23

1559AS598-1 ES1559AS598

DECAL, SCHEMATIC DGRM / 30003 (not shown) .................................................................. 1 DECAL, SCHEMATIC DGRM / 0V5R4 (not shown) PLATE, IDENTIFICATION / 30003 (not shown) ... 1 PLATE, IDENTIFICATION / 0V5R4 (not shown) /ATTACHING PARTS/ RIVET, POP / 96906 (not shown) ......................... 4 ---*---

XCGZZ

24

1559AS593-1 ES1559AS593

XBGZZ

25

MS20604AS4T2

PAGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 8 of 34

16

1 14

12

See Exploded View for Vent Installation 2

15 14

1 5 13 5 6 Figure 3. ECU Upper Rear Panel with Linacoustic Insulation Panel. 11

10

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 9 of 34

Figure 3. Removable Panel Assembly, Part Number 1559AS556-1. (Sheet 1 of 2)


INDEX NO. PART NUMBER 1559AS556-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1559AS557-1 1559AS271-1
ES 1559AS271-1

DESCRIPTION / CAGE 1 2 3 4 5 6 7 REMOVABLE PANEL ASSY / 30003 (NHA in Figure 2) PANEL, REMOVABLE / 30003............................... FILTER, AIR / 30003 / ........................................... FILTER, AIR / 0V5R4 PLATE / 30003 ....................................................... /ATTACHING PARTS ITEMS 1, 2, 3, 11, 12 and 13 WASHER / 80205 ................................................... WASHER / 96906 ................................................... WASHER / 96906 ................................................... NUT, HEX / 80205 .................................................. NUT, SELF RETAINING / 30003 ............................ NUT, SELF RETAINING / 72800 SCREW / 80205 ..................................................... SCREW, THUMB / 96906....................................... ---*-- COVER, FRESH AIR INTAKE / 30003 ................... COVER, FRESH AIR INTAKE / 0V5R4 BRACKET ASSY / 30003 ....................................... FRESH AIR DAMPER / 30003 ............................... /ATTACHING PARTS/ ADHESIVE /30003.................................................. ADHESIVE / 3M Corp

UNITS PER ASSY REF 1 1 1 16 1 1 8 1 8 1 1 1 1 AR

USABLE ON CODE

SM&R CODE XBGZZ XBGZZ PAGZZ XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ XBGZZ XBGZZ XBGZZ PAGZZ

1559AS294-1 MS27183-42 MS27183-10 MS35338-44 MS51470-03 1559AS259-1 C7988-1420 MS35207-265 MS21316-36 1559AS265-1
ES1559AS265-1

1559AS262-1 1559AS260-1 1559AS267-1 NO. 1357 CONTACT CEMENT

15

1559AS266-2 1559AS266-1

GASKET, BLACK, RUBATEX R1800-FS, 0125 INCH THICK / 30003............................................... GASKET, BLACK, RUBATEX R1800-FS, 0125 INCH THICK / 30003 INSULATION FIBERGLASS / 30003 ......................

XBGZZ

16

1559AS272-1

AR

PAGZZ

FIBERGLASS DUCT LINER / UNITED REFRIGERATION ........... DUCT LINER X 47-1/4 X 100

AR

PAGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 10 of 34

Figure 4. Chassis Assembly, Part Number 1559AS474-1. (Sheet 1 of 3)

NAVAIR 17-1-573
01 MARCH 2009
Figure 4. Chassis Assembly, Part Number 1559AS474-1. (Sheet 2 of 3)
INDEX NO. PART NUMBER 1559AS474-1 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 1559AS401-1 MS90725-3 MS27183-10 MS35338-44 1559AS548-1 ES7124 2512 AS219WDG-3 MS90725-63 MS27183-10 MS35338-44 MS35649-2252 1559AS250-1 SW4L-010 1559AS543-1 1559AS242-1 20400L2-43 1559AS173-1 1559AS237-1 ES315-002 1559AS253-1 DESCRIPTION / CAGE 1 2 3 4 5 6 7 CHASSIS ASSEMBLY / 30003 (NHA in Figure 1) UNITS PER ASSY REF

020 00
Page 11 of 34

USABLE ON CODE

SM&R CODE XAGGG XBGGG PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ

FRAME ASSEMBLY / 30003 (NHA Figure 4).......................................................... REF SCREW / 96906 ....................................................... 1 WASHER / 96906..................................................... 1 WASHER / 96906..................................................... 1 MOTOR, OUTDOOR/ 30003 .................................... 1 MOTOR, OUTDOOR/ 0V5R4 CLAMP/ 81343 ......................................................... 1 SCREW / 96906 ....................................................... 1 WASHER / 96906..................................................... 1 WASHER / 80205..................................................... 1 NUT / 80205 ............................................................. 1 PROPELLER, FAN / 30003 ...................................... 1 PROPELLER, FAN / LAU INDUSTRIES FAN SUPPORT ASSY (FAN WELDMENT) / 30003........................................................................ 1 SWITCH, THERMOSTATIC (S4) / 30003 SWITCH, THERMOSTATIC (S4) / 82647 BUSHING ELECTRICAL / 30003 ............................. 3 HEATING ELEMENT, ELECTRICAL / 30003........... 1 HEATING ELEMENT, ELECTRICAL / 0V5R4 TUBING, FLEXIBLE, VINYL (57 INCHES) / 30003 1 1

XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ

COMCO VINYL TUBING, FLEXIBLE, VINYL (57 INCHES) / 21916 TUBING SIZE 31 16 17 18 19 20 21 22 23 24 25 26 27 AS21919WDG14 1559AS483-1 1559AS127-2 1559AS538-1 1559AS515-1 1559AS173-1 1339AS952-5 7513K242 1559AS684-3 1559AS176-1 15589AS289-1 1559AS496-1 CLAMP/ 81343 ......................................................... 1 CONTROL BOX ASSY / 30003 (Breakdown in Figure 13).......................................... 1 SCREW, SELF TAPPING, 10-32 X 7/16 / 30003 ..... 24 BRACKET, THERMO / 30003 .................................. 1 INDOOR BLOWER HOUSING ASSY / 30003 (Breakdown in Figure 6)............................................ 2 BUSHING ELECTRICAL / 30003 ............................. 3 NIPPLE, CHASE / 30003 ......................................... 3 LOCKNUT / 30003 ................................................... 3 CRANKCASE HEATER / 30003............................... 1 SLICER, CONDUCTOR / 30003 .............................. 1 INSULATION SLEEVING / 30003 ............................ AR REFRIGERATION LABEL / 30003 ........................... 1 PAGZZ

XBGGG PAGZZ XBGZZ AGGGG PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 12 of 34

Figure 5. Frame Assembly, Part Number 1559AS401-1. (Sheet 1 of 2)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 13 of 34

Figure 5. Frame Assembly, Part Number 1559AS401-1. (Sheet 2 of 2)


INDEX NO. PART NUMBER 1559AS401-1 1 2 3 4 5 6 7 8 9 10 11 12 13 1559AS402-1 1559AS403-1 1559AS404-1 1559AS405-1 1559AS412-1 1559AS413-1 1559AS414-1 1559AS415-1 1559AS416-1 1559AS421-1 1559AS425-1 1559AS608-1 1559AS427-02 1007RW DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE XBGGG XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ PAGZZ

FRAME ASSEMBLY / 30003 (NHA Figure 4)........................................................ REF BRACKET, EVAPORATOR RH / 30003................. 1 BRACKET, EVAPORATOR LH / 30003 ................. 1 SHELF, FAN / 30003.............................................. 1 COMPRESSOR SHELF WELDMENT / 30003....... 1 ANGLE, BACK, LH / 30003 .................................... 1 ANGLE, BACK, RH / 30003 ................................... 1 ANGLE, FRONT, RH / 30003 ................................. 1 ANGLE, FRONT, LH / 30003 ................................. 1 DRAIN PAN WELDMENT / 30003.......................... 1 BOTTOM PAN ASSY / 30003 ................................ 1 FAN SHROUD / 30003........................................... 1 BRACE, SIDE / 30003............................................ 1 /ATTACHING PARTS/ FOR ITEMS 1 THRU 12 SCREW, SELF TAPPING, 10-32 X 7/16 / 30003 ... 54 SCREW, SELF TAPPING, 10-32 X 7/16 / TOWER FASTENERS CORP. ---*---

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 14 of 34

Figure 6. Indoor Blower Assembly, Part Number 1559AS515. (Sheet 1 of 2)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 15 of 34

Figure 6. Indoor Blower Assembly, Part Number 1559AS515. (Sheet 2 of 2)


INDEX NO. PART NUMBER 1559AS515-1 1 1559AS531 ES7461022 2 1559AS427-2 1007RW DESCRIPTION / CAGE 1 2 3 4 5 6 7 INDOOR BLOWER ASSY / 30003 (NHA in Figure 4) FLANGE, INLET / 0V5R4 /ATTACHING PARTS/ SCREW, SELF TAPPING 10-32 X 7/16 / 30003 ...... 16 SCREW, SELF TAPPING 10-32 X 7/16 / TOWER FASTENERS CORP. ---*--3 4 5 6 1559AS521-3 1559AS525-2 ES9500-6355 1559AS525-1 ES9500-6354 1559AS529-1 ES7124 2258 7 8 9 10 11 12 MS90725-3 MS35338-44 MS27183-10 1559AS518-1 1559AS522 1559AS523 HOUSING, INDOOR FAN / 30003 ........................... 2 IMPELLER, FAN, RH / 30003................................... 1 IMPELLER, FAN, RH / 0V5R4.................................. IMPELLER, FAN, LH / 30003 ................................... 1 IMPELLER, FAN, LH / 0V5R4 .................................. MOTOR / 30003 ....................................................... 1 MOTOR / 0V5R4 ...................................................... /ATTACHING PARTS/ SCREW / 96906 ....................................................... 4 WASHER, LOCK / 80205 ......................................... 4 WASHER / 96906..................................................... 4 ---*-- BRACKET ASSY / 30003 ......................................... 1 ANGLE, BLOWER / 30003 ....................................... 2 ANGLE, BLOWER / 30003 ....................................... 2 XBGZZ XBGZZ XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ XBGZZ PAGZZ PAGZZ UNITS PER ASSY REF USABLE ON CODE SM&R CODE AGGGG PAGZZ

FLANGE, INLET / 30003 .......................................... 4

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 16 of 34

Figure 7. Refrigeration Assembly, Part Number 1559AS428. (Sheet 1 of 4)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 17 of 34

View A

Figure 7. Refrigeration Assembly, Part Number 1559AS428. (Sheet 2 of 4)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 18 of 34

Figure 7. Refrigeration Assembly, Part Number 1559AS428. (Sheet 3 of 4)


INDEX NO. PART NUMBER 1559AS428-1 1 2 3 4 5 6 7 8 1559AS401-1 1559AS173-1 1559AS173-3 1559AS469 MS35649-2382 1559AS665 ES9500-E9987 1559AS438 ES105642102 1559AS427-2 1007RW 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1559AS455-1 1559AS171-1 1559AS430-1 ZR72KCE-TF5 MS35649-2312 MS27183-12 1559AS669-1 ES13225E8453 1559AS441-2 1559AS444-1 1559AS664-1 ES9500-E9972 1559AS446 1559AS496 1559AS650 SA-14 1559AS601 HPC-169-HH 1559AS662 1559AS441-1 DESCRIPTION / CAGE 1 2 3 4 5 6 7 REFRIGERATION ASSEMBLY / 30003 UNITS PER ASSY REF USABLE ON CODE SM&R CODE AGGGG AGGGG PAGZZ PAGZZ XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ

FRAME ASSEMBLY / 30003 (Breakdown in Figure 5) . 1 BUSHING / 30003 ..................................................... 1 BUSHING / 30003 ..................................................... 2 SUCTION TUBE ASSY / 30003 ................................ 1 NUT / 96906 .............................................................. 4 WASHER / 96906...................................................... 4 WASHER / 0V5R4 COIL, INDOOR / 30003............................................. 1 COIL, INDOOR / 0V5R4 SCREW, SELF TAPPING / 30003............................. 23 SCREW, SELF TAPPING / TOWER FASTENERS CORP. LIQUID TUBE ASSY / 30003 .................................... 1 INSULATION SLEEVE, THERM 36 INCHES / 30003......................................................................... 1 COMPRESSOR / 30003............................................ 1 COMPRESSOR / 14569 NUT / 96906 (not shown) .......................................... 4 GROMMET / 96906................................................... 4 WASHER, ELASTOMER / 30003.............................. 8 WASHER, ELASTOMER / 0V5R4 LOW PRESSURE CUTOUT SWITCH / 30003.......... 1 REVERSING VALVE ASSEMBLY / 30003 (Breakdown in Figure 8)............................................. 1 MOUNTING SPACER/ 30003 ................................... 4 MOUNTING SPACER/ 0V5R4 LIQUID TUBE ASSY / 30003 .................................... 1 R134A DECAL / 30003 (Far Side) .......................... 1 SIGHTGLASS / 30003............................................... 1 SIGHTGLASS / 78462 FILTER-DRYER / 30003 ........................................... 1 FILTER-DRYER / 78462 EXPANSION VALVE ASSEMBLY / 30003 (Breakdown in Figure 9)............................................. 1 SWITCH, HIGH PRESSURE, CUTOUT / 30003 ....... 1 Continued on next page

XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ XBGZZ PAGZZ XBGZZ XBGZZ PAGZZ

MS21919WDG48 CLAMP / 96906 ......................................................... 1

PAGZZ PAGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 19 of 34

Figure 7. Refrigeration Assembly, Part Number 1559AS428. (Sheet 4 of 4)


INDEX NO. PART NUMBER DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE

25 26 27 28 29 30 31 32 33 34 35 36 37 38

1559AS610-1 1559AS670-1 1559AS604-1 1559AS439-1 ES104227602 MS21044-NO8 1559AS453-1 1559ASAS467-1 1559ASAS171-2 AS21919WDG-8 MS90725-3 MS35338-44 MS27183-10 AS21919WDG-3 1559AS668-1

BRACKET ANGLE / 30003 ....................................... 1 SUCTION ACCUMULATOR ASSEMBLY / 30003 (Breakdown in Figure 10)........................................... 1 LIQUID VALVE ASSEMBLY / 30003 (Breakdown in Figure 11) .................................................................. 1 COIL, OUTDOOR / 30003 ......................................... 1 COIL, OUTDOOR / 0V5R4 NUT, LOCKING #8-32 / 96906 .................................. 1 SUCTION TUBE ASSEMBLY OUTDOOR / 30003 ... 1 TUBING CLOSURE PLATE/ 96906 .......................... 4 INSULATION SLEEVING/ 30003 .............................. 1 CLAMP / 81343 ......................................................... 1 SCREW / 96906 ........................................................ 1 WASHER/ 96906....................................................... 1 WASHER/ 96906....................................................... 1 CLAMP / 81343 ......................................................... 1 DISCHARGE TUBE ASSEMBLY / 30003 (Breakdown in Figure 12)........................................... 1

XBGZZ PAGZZ PAGZZ XBGZZ PAGZZ XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 20 of 34

3 2 9 8 10 4

5 16

11 3 2 13

15

12

14 2

3 Figure 8. Reversing Valve Assembly, Part Number 1559AS444. (Sheet 1 of 2)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 21 of 34

Figure 8. Reversing Valve Assembly, Part Number 1559AS444. (Sheet 2 of 2)


INDEX NO. PART NUMBER 1559AS444 1 1559AS445 ESV6-414080100 2 3 1559AS640 SA04CP 1559AS680-02 AC-7000-024 DESCRIPTION / CAGE 1 2 3 4 5 6 7 REVERSING VALVE ASSEMBLY / 30003 (NHA in Figure 7) VALVE, LINEAR / 0V5R4 STRAIGHT ADAPTER (roto-lock nut) / 30003.......... 3 STRAIGHT ADAPTER (roto-lock nut) / 30003 7/8 INCH DIA. TEFLON SEAL FOR ROTO LOCK NUT / 30003 ............................................................. 1 7/8 INCH TEFLON SEAL FOR ROTO LOCK NUT / AJ WILLIAMS MANUFACTURING CO. JACKSON, MI, TEL 517-784-8383 FLARE FITTING / 30003 .......................................... 1 FLARE FITTING / 41947 ELBOW TUBE (STD) / 30003................................... 1 ELBOW TUBE (ST) / 30003 ..................................... 1 STRAIGHT TUBE / 30003 ........................................ 1 ELBOW TUBE (45) / 30003 .................................... 1 STRAIGHT TUBE / 30003 ........................................ 1 STRAIGHT TUBE / 30003 ........................................ 1 STRAIGHT TUBE / 30003 ........................................ 1 STRAIGHT TUBE / 30003 ........................................ 1 STRAIGHT TUBE / 30003 ........................................ 1 TUBING COPPER (1/2) / 30003............................... 1 ELBOW, TUBE (LONG 90) / 30003 ........................ 1 ELBOW, TUBE (LONG ST) / 30003 ......................... 2 XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ PAGZZ XBGZZ UNITS PER ASSY REF USABLE ON CODE SM&R CODE PAGZZ XBGZZ

VALVE, LINEAR / 30003 .......................................... 1

4 5 6 7 8 9 10 11 12 13 14 15 16

1559AS160-2 A03546 1559AS159-3 1559AS159-4 1559AS462-8 1559AS159-5 1559AS462-14 1559AS462-37 1559AS462-18 1559AS462-46 1559AS462-22 1559AS449 1559AS159-7 1559AS159-6

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 22 of 34

Figure 9. Expansion Valve Assembly, Part Number 1559AS662. (Sheet 1 of 2)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 23 of 34

Figure 9. Expansion Valve Assembly, Part Number 1559AS662. (Sheet 2 of 2)


INDEX NO. PART NUMBER 1559AS662-1 1 2 3 4 5 6 7 1559AS663 EBFJE-C 1559AS142-2 1559AS160-2 1559AS450-1 1559AS470 1559AS169-2 1559AS142-1 DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE PAGGG XBGZZ PAGZZ XBGZZ XBGZZ XBGZZ XBGZZ PAGZZ

EXPANSION VALVE ASSEMBLY / 30003 (NHA in Figure 7) ................................................................. REF EXPANSION VALVE / 30003 ................................. 1 EXPANSION VALVE / 78462 NUT, TUBE COUPLING / 30003 ............................ 1 FLARE FITTING / 30003 ........................................ 1 TUBING, COPPER (FLARED) / 30003 .................. 1 ADAPTER, CAPILLARY TUBE / 30003 ................. 1 TUBING, COPPER (CAP) / 30003 ......................... 1 NUT, TUBE COUPLING / 30003 ............................ 1

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 24 of 34

Figure 10. Suction Accumulator Assembly, Part Number 155AS670. (Sheet 1 of 2)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 25 of 34

Figure 10. Suction Accumulator Assembly, Part Number 155AS670. (Sheet 2 of 2)


INDEX NO. PART NUMBER 1559AS670-1 1 1559AS434-1 A-AS 5 97 2 3 4 5 6 7 8 9 10 11 12 1559AS630-1 1559AS620-2 AD-7000-188 1559AS160-1 1559AS148-1 1559AS159-3 1559AS457-1 1559AS457-2 1559AS159-5 1559AS462-42 1559AS462-24 1559AS680-02 AC-7000-024 DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE

SUCTION ACCUMULATOR ASSEMBLY / 30003 (NHA in Figure 7)....................................................... REF ACCUMULATOR / 30003....................................... 1 ACCUMULATOR / EMERSON CLIMATE TECHNOLOGIES DISTRIBUTION SERVICES ANGLE ADAPTER / 30003 .................................... 1 BRASS ADAPTER / 30003 .................................... 1 BRASS ADAPTER / AJ WILLIAMS MFG CO. FLARE ADAPTER / 30003 ..................................... 2 VALVE, PNEUMATIC / 30003 ................................ 1 ELBOW, TUBE (STD) / 30003................................ 2 TUBING, COPPER (7/8) / 30003............................ 1 TUBING, COPPER (7/8) / 30003............................ 1 ELBOW, TUBE (45) / 30003 ................................. 1 TUBING, COPPER / 30003 .................................... 1 TUBING, COPPER / 30003 .................................... 2 7/8 INCH DIA. TEFLON SEAL FOR ROTO LOCK NUT / 30003 ........................................................... 1 7/8 INCH TEFLON SEAL FOR ROTO LOCK NUT / AJ WILLIAMS MANUFACTURING CO. JACKSON, MI, TEL 517-784-8383

PAGGG XBGZZ

XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ XBGZZ PAGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 26 of 34

Figure 11. Liquid Valve Assembly, Part Number 1559AS606. (Sheet 1 of 2)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 27 of 34

Figure 11. Liquid Valve Assembly, Part Number 1559AS606. (Sheet 2 of 2)


INDEX NO. PART NUMBER 1559AS604 1 1559AS655-2 278397-08 2 3 4 1559AS142-2 1559AS458-1 1559AS450-1 DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE

LIQUID VALVE ASSEMBLY / 30003 (NHA Figure 7).............................................................. REF LIQUID VALVE / 30003 ............................................. 1 LIQUID VALVE / PARKER HANNIFIN CORPORATION NUT, TUBE COUPLING / 30003 ............................... 2 TUBE / 30003 ............................................................ 1 TUBE / 30003 ............................................................ 1

PAGZZ XBGZZ

XBGZZ XBGZZ XBGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 28 of 34

6 3

4 2 1

Figure 12. Discharge Tube Assembly, Part Number 1559AS668. (Sheet 1 of 2)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 29 of 34

Figure 12. Discharge Tube Assembly, Part Number 1559AS668. (Sheet 2 of 2)


INDEX NO. PART NUMBER 1559AS668 1 2 3 1559AS630-1 AA04CP 1559AS680-01 AC-7000-023 DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE

DISCHARGE TUBE ASSEMBLY / 30003 (NHA Figure 7).......................................................... REF ANGLE ADAPTER / 30003 .................................... 1 ANGLE ADAPTER / 5/8 INCH DIA. TEFLON SEAL FOR ROTO LOCK NUT / 30003................................................. 1 5/8 INCH TEFLON SEAL / AJ WILLIAMS MANUFACTURING CO. JACKSON, MI, TEL 517-784-8383 TUBE / 30003 ......................................................... 1 VALVE / 30003 ....................................................... 1 FLARE FITTING / 30003 ........................................ 1

AGGGG XBGZZ PAGZZ

4 5 6

1559AS456-1 1559AS148-1 1559AS160-1

XBGZZ XBGZZ XBGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 30 of 34

Figure 13. Control Box Assembly, Part Number 1559AS483. (Sheet 1 of 4)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 31 of 34

Figure 13. Control Box Assembly, Part Number 1559AS483. (Sheet 2 of 4)

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 32 of 34

Figure 13. Control Box Assembly, Part Number 1559AS483. (Sheet 3 of 4)


INDEX NO. PART NUMBER 1559AS483-1 1 2 3 4 5 6 1559AS201-1 603 GP 03 1559AS202-1 MS3600-03-VF-10 1559AS136-1 MS35489-17 1559AS205-1 CB35-36-C 1559AS490-1 HCC-3XQ02CY 7 8 1559AS199-1 HCT-09J4AG08 1559AS195-1 H230A 9 1559AS503-1 672 GP 06 10 1559AS504-1 MS4400-06-XP-SP 11 12 13 14 1559AS500-1 ES1559AS500 1559AS227-2 HCK-100V370Z 1559AS512-1 20400L2-43 1559AS441-1 P20EB-2C 15 1559AS441-2 P20EB-1C DESCRIPTION / CAGE 1 2 3 4 5 6 7 UNITS PER ASSY USABLE ON CODE SM&R CODE

CONTROL BOX ASSEMBLY / 30003 (NHA in Figure 4) ..................................................... REF TERMINAL BOARD (TB1, TB2) / 30003 .............. 1 TERMINAL BOARD (TB1, TB2) / MARATHON PLATE, DESIGNATION / 30003 ........................... 2 PLATE, DESIGNATION / 9R803 .......................... INSULATION SHEET / 30003............................... 6 GROMMET, RUBBER / 96906 ............................. 6 TERMINAL, LUG (FOR TB1) / 30003 ................... 6 TERMINAL, LUG (FOR TB1) / 06383 ................... RELAY, ELECTROMAGNET (K1) / 30003 ........... 1 RELAY, ELECTROMAGNET (K1) / HARTLAND CONTROLS LLC TRANSFORMER / 30003 ..................................... 1 TRANSFORMER / 80089 ..................................... RELAY, ELECTROMAGNET (K2, K3, K4, K5) / 1 30003 .................................................................... RELAY, ELECTROMAGNET (K1) / 80089 ........... TERMINAL BOARD (TB3) / 30003 (shown in view A) ................................................................ 1 TERMINAL BOARD (TB3) / MARATHON (shown in view A) PLATE, DESIGNATION / 30003 (shown in view A) ........................................................................ 2 PLATE, DESIGNATION / 9R803 (shown in view A) ........................................................................ DEFROST CONTROL (DC) / 30003..................... 1 DEFROST CONTROL (DC) / 0V5R4.................... 1 CAPACITOR, FIXED (C1) / 01002........................ 1 CAPACITOR, FIXED (C1) / 80089........................ 1 BRACKET, CAPACITOR / 30003 ........................ 1 BRACKET, CAPACITOR / 82647 HIGH-PRESSURE CUTOUT SWITCH (HPCO) (S2) / 30003........................................................... 1 HIGH-PRESSURE CUTOUT SWITCH (HPCO) (S2) / 41947........................................................... LOW-PRESSURE CUTOUT SWITCH (LPCO) (S1) / 30003........................................................... 1 LOW-PRESSURE CUTOUT SWITCH (LPCO) (S1) / 41947........................................................... Continued on next page

XBGGG PAGZZ PAGZZ XBGZZ PAGZZ PAGZZ PAGZZ

PAGZZ

PAGZZ

PAGZZ

PAGZZ

PAGZZ PAGZZ XBGZZ

PAGZZ

PAGZZ

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 33 of 34

Figure 13. Control Box Assembly, Part Number 1559AS483. (Sheet 4 of 4)


INDEX NO. PART NUMBER DESCRIPTION / CAGE 1 2 3 4 5 6 7 Continued from previous page 16 17 18 19 1559AS206-1 RC31-1012 1559AS173-1 1559AS173-2 1559AS299-1 2119 20 21 22 23 24 1559AS427-2 1007RW 1559AS427-3 1014RW 1559AS666-1 ES1559AS666 25 26 27 MS35206-246 1559AS555-1 1559AS598-1 ES1559AS598 28 29 1559AS667-1 91010A160 1559AS177-1 PLT1.5M-M 1559AS484-1 SWITCH,THERMOSTATIC (S5) / 30003 .............. 1 SWITCH,THERMOSTATIC (S5) / 80439 .............. 1 BUSHING, ELECTRIC / 30003 ............................. 1 BUSHING, ELECTRIC / 30003 ............................. 2 BUSHING, ELECTRIC / 30003 (shown in view A) ........................................................................ 1 BUSHING, ELECTRIC / 28520 CONTROL BOX / 30003 ....................................... 1 SCREW, SELF TAPPING 10-32 X 7/8 PHILIP HD / 30003 ............................................................ 1 SCREW, SELF TAPPING 10-32 X 7/16 / 30003... 23 SCREW, SELF TAPPING 10-32 X 7/16 / SCREW, SELF TAPPING / 30003 ........................ 6 SCREW, SELF TAPPING / LABEL, DANGER WARNING / 30003 (not shown)................................................................... 1 LABEL, DANGER WARNING / 0V5R4 (not shown) SCREW, MACHINE, 8-32X 3/8 / 80205................ 6 COVER, CONTROL BOX/ 30003 (see figure 2) ... REF WIRING SCHEMATIC (LABEL)/ 30003 (not shown)................................................................... 1 WIRING SCHEMATIC (LABEL)/ 0V5R4 (not shown)................................................................... RIVET, PUSH-IN / 30003 (shown in view A) ...... 2 RIVET, PUSH-IN / BAND, WIRE / 30003 (not shown) ........................ 12 BAND, WIRE / 06383 PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ XBGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ PAGZZ UNITS PER ASSY USABLE ON CODE SM&R CODE

NAVAIR 17-1-573
01 MARCH 2009

020 00
Page 34 of 34

THIS PAGE INTENTIONALLY LEFT BLANK