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MAINTENANCE MANUAL, SA S92A-AMM-000

3. COMPONENT DESCRIPTION

A. Compressor Assembly

10 20

100 100 NICA


ITALY
OTEC
MICR
TORINO

60
90 60

90

10
20

SINGLE COMPRESSOR DUAL COMPRESSOR OPTION

70
50

40

30

80 110 B RM21020_3
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 3 OF 14)

B Compressor Pallet 10 Compressor No. 1 (No. 2 Option)

20 Support Assembly 30 Compressor Pressure Switch

40 Compressor Discharge Sensor 50 Compressor Suction Sensor

60 Refrigerant Inlet from Cabin Evapo- 70 Refrigerant Outlet to Cabin


rator Evaporator

80 Refrigerant Sight Gage 90 Refrigerant Inlet from Filter/Dryer

100 Refrigerant Outlet to Filter/Dryer 110 Flash Tank

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Compressor pallet components consist of a flash tank with refrigerant sight glass, support assembly, No. 1
compressor, and optional No. 2 compressor. The compressor converts the refrigerant coming from the evapo-
rator (a low-pressure gas) into a high-pressure gas. This high-pressure gas is sent to the condenser where it
is converted into a liquid. If the optional second compressor is installed, the support assembly is removed.

In the two compressor configuration, the compressors work in parallel when operating, with each compressor
pumping refrigerant to both the cabin and cockpit evaporators simultaneously. At start up, the Digital Temper-
ature Control Unit (DTCU) will alternate the start of the compressors and most of the time operates with one
compressor.

On the ground with APU power on, the DTCU will engage only one compressor and one condenser fan. With
the ground power cart, the DTCU will turn on the second compressor if the necessary load conditions are
met.

The positive displacement compressor is a hermetic or air tight, scroll-type pump that consists of two inter-
locking elements. An ac motor drives the pump. As the pump operates, vapor is trapped by the motion of the
scrolls and is compressed as it goes from the inlet to discharge ports.

Two pressure sensors provide indications to the DTCU of compressor suction and discharge pressures.

A high-pressure switch, located in the discharge of the compressor, provides a signal to the DTCU for com-
pressor control. If the compressor output pressure exceeds 435 6 29 psig, the DTCU causes the compres-
sors to shut down. When the pressure drops to less than 363 6 29 psig, the switch reopens.

The flash tank, mounted aft of the compressor and support assembly, allows the vaporization of part of the
liquid refrigerant between the condenser and evaporator assemblies. This provides a surge volume for fluid
volume changes caused by changes in system temperature and pressure. On the input line to the flash tank,
a fixed orifice controls the flow rate of coolant entering the flash tank.

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MAINTENANCE MANUAL, SA S92A-AMM-000

B. Cabin Evaporator Assembly

130

MICROTECNICA

MICROTECNICA
150

140 120
C RM21020_4
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 4 OF 14)

C Cabin Evaporator Assembly 120 Cockpit Evaporator Pressure


Regulating Valve

130 Cabin Evaporator Pressure 140 Fin Temperature Sensor


Regulating Valve

150 Outlet Air Temperature Sensor

The Cabin Evaporator Assembly is provided with a pallet and is secured to the top deck of the helicopter with
four captivated bolts. Two connectors for electrical interface are provided: one connector for power supply of
the electrical fan and one interface connector for the temperature sensors.

The cabin assembly contains:

c Heat exchangers

c Thermal expansion valve

c Two pressure regulating valves (one for the cabin and one for the cockpit)

c Fan

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c Air temperature sensor

c Fin temperature sensor

c Electronic shutoff valve

c Two shutoff valves (one for cabin and one for cockpit

The heat exchanger converts the refrigerant coming from the condenser (a high-pressure liquid) into a low-
pressure gas. This process absorbs heat from the cockpit/cabin air causing the air to cool down.

Two separate evaporators are used in the cooling system, one for the cabin and one for the cockpit. Each
unit contains a heat exchanger, a thermal expansion valve, a pressure regulating valve, fan, and temperature
control sensors.

The thermal expansion valves control the refrigerant flow through the evaporators to maintain a constant su-
perheating at the evaporator discharge. The superheating raises the refrigerant approximately 5° C (10° F)
above the saturation temperature of the evaporator to guarantee the gas leaving the evaporator does not
contain a significant amount of liquid.

The Evaporator Pressure Regulating (EPR) valve controls pressure in the evaporator. By controlling the pres-
sure of the refrigerant, control of refrigerant temperature is also maintained. Refrigerant temperature is raised
or lowered to decrease or increase cooling capacity.

Each evaporator has three temperature sensors that provide indications to the DTCU of return air tempera-
ture, evaporator air outlet temperature, and supply air temperature used for cockpit and cabin temperature
control.

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C. Cabin Evaporator Fan

160

FLOW

D
RM21020_5
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 5 OF 14)

D Cabin Duct Assembly 160 Cabin Evaporator Fan

The cabin evaporator fan maintains airflow across the evaporator heat exchangers. The fan has a three-
phase, 400 Hz, 115 vac, 3.5 amp motor with a rotation sensor and temp-switch monitored by the DTCU.

When the cooling system is secured, the evaporator fan can be operated by the ventilation system.

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MAINTENANCE MANUAL, SA S92A-AMM-000

D. Filter/Dryer Assembly

170

180

190

170

E RM21020_6
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 6 OF 14)

E Condenser/Flashtank Plumbing 170 Filter/Dryer Assembly

180 Filter/Dryer 190 High-Pressure Service Valve

The filter/dryer assembly, mounted on the aft cabin right side bulkhead at FS-480 on the line between the
condenser and the flash tank, removes contaminants and entrapped moisture from the refrigerant. The high-
pressure service valve is used for system servicing and maintenance.

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MAINTENANCE MANUAL, SA S92A-AMM-000

E. Cockpit Evaporator Assembly

240
ON
TI
TA

AI
RO

R
FL
OW

200
220
230

NO STEP

210

200
RM21020_7
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 7 OF 14)

F Cockpit Evaporator Assembly 200 Fan/Fresh Air Valve Assembly

210 Cockpit Fresh Air Valve 220 Cockpit Evaporator Fan

230 Fin Temperature Sensor 240 Cockpit Outlet Temperature Sen-


sor

The cockpit evaporator assembly components function the same as the cabin assembly components.

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MAINTENANCE MANUAL, SA S92A-AMM-000

Five connectors for electrical interface are provided: one connector for fan power supply, one for the fan
speed sensor, one for the fresh air valve, one for the fin temperature sensor and one for the air temperature
sensor on the outlet duct.

The cockpit evaporator assembly contains:

c Heat exchangers

c Thermal expansion valve

c Fan

c Air temperature sensor

c Fin temperature sensor

c Fresh Air Valve

F. Fresh Air Valve


FLOW

250

FLOW

G RM21020_8
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 8 OF 14)

G Cabin Fresh Air Intake Vent Assem- 250 Cabin Fresh Air Valve
bly

The fresh air valve for the cockpit is located on the inlet of the cockpit evaporator assembly, whereas, the
cabin fresh air valve is located upstream of the cabin evaporator.

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The fresh air valve modulates ambient fresh airflow with return air by position of the valve element.

The valve consists of a 28 vdc electrical motor, end-of-travel switches, mid-travel switch, and valve element.
The DTCU controls the three positions of the valve. The valve positions are:

c Normal air conditioning position 20° 6 5°

c Vent position (fully open) 90° 6 3°

c Recirculation position (fully closed) 0° 6 3°

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G. AC Distribution Units

260

270

J RM21020_9
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 9 OF 14)

H No. 1 AC Power Distribution Unit J No. 2 AC Power Distribution Unit

260 K3 Bus Tie Contactor (Dual Com- 270 K5 Dual Generator Loss Relay
pressor Option)

With either main generator operating, relay K5 is energized. This allows the DTCU to receive inputs from the
environmental control panel.

Relay K3 is used with the dual compressor option. If external power or the Auxiliary Power Unit (APU) is sup-
plying aircraft electrical power, K3 energizes and removes a signal to the DTCU. This will disable dual com-
pressor operation.

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If the APU is the only source of electrical power while in-flight, K3 energizes and removes a 28 vdc input to
the DTCU and energizes relay K55. When K55 energizes it s normally closed contacts open and removes 28
vdc from relay K21 deenergizing all compressor operations.

H. Digital Temperature Control Unit

K20 K21
−X2 +X1
A1 A2 −X2 +X1

B1 B2
A1 A2
F
B1 B2
C1 C2
C1 C2
300
300
MICROTECNICA

P4
COMPRESSOR
NO. 1

P5
COMPRESSOR
FW NO. 2 P4
280 D

K 300 DUAL COMPRESSOR


OPTION
K20 K21
280

290

SINGLE COMPRESSOR
P4
280 RM21020_10
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 10 OF 14)

K Digital Temperature Control Unit Pal- 280 Digital Temperature Control Unit
let Assembly

290 Digital Temperature Control Unit 300 Compressor Relay, K21 No. 1,
(DTCU) K22 No. 2 Optional Compressor

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The DTCU controls the cockpit and cabin cooling system operations. The DTCU receives inputs from the
various temperature sensors and sends command control signals to the compressors, condenser fans,
evaporator pressure regulating valves, and fresh air intake valves.

The compressor power relay (K21) is mounted to and controlled by the DTCU. When energized, K21 con-
nects the compressor motor to the No. 1 ac primary bus.

I. Miscellaneous Contactor Pallet

310

320

L
RM21020_11
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 11 OF 14)

L Miscellaneous Contactor Pallet 310 K19 (Cockpit)

320 K18 (Cabin)

The miscellaneous contactor pallet contains relays K18 and K19. These relays are controlled by the DTCU.
When energized, they connect the condenser fans to the No. 1 and No. 2 ac primary buses, respectively.

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MAINTENANCE MANUAL, SA S92A-AMM-000

J. Condenser Assembly

FW
D

370

360

350
330

340
M
RM21020_12
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 12 OF 14)

M Condenser Assembly 330 Condenser Fans

340 Burst Fuse 350 Condenser Outlet

360 Condenser Inlet 370 Heat Exchanger

The condenser assembly converts the refrigerant coming from the compressor (a high-pressure gas) into a
high-pressure liquid for the evaporator. A single condenser heat exchanger, mounted in the right sponson, is
used by both cabin and cockpit cooling systems.

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Two three-phase, 115 vac, 16 amp fans operate in parallel on the air exhaust side of the condenser heat ex-
changer. These fans provide a continuous airflow from outside the aircraft across the condenser heat ex-
changer. Each fan has a temp-switch and rotation sensor monitored on the DTCU.

High-pressure liquid leaving the condenser passes by a temperature sensitive burst fuse. Since pressure is
temperature dependent for all refrigerant liquids, this burst fuse acts as a safety device at high pressures,
protecting the system and aircraft if all other safety devices fail. The burst fuse releases the entire refrigerant
to the atmosphere if refrigerant temperature reaches 100° C (212° F).

K. Environmental Control Panel

(VIP HELICOPTERS 0009 AND SUBSEQUENT)


D
FW
380 380

(HELICOPTERS PRIOR TO 0009)


(HELICOPTERS 0011 AND SUBSEQUENT)
380
380 RM21020_13
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 13 OF 14)

N Overhead Console 380 Environmental Control Panel

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Temperature Selection. The Environmental Control Panel (ECP), located on the overhead console, contains
controls for both heating and cooling of the aircraft. The control relevant to the cooling system is the MAS-
TER control switch.

Helicopters prior to 0009. The MASTER control switch is used to provide either outside ambient (VENT) air
or conditioned (ECS) air to the cabin and cockpit. the MASTER switch has seven positions.

MASTER Control Switch Position:

c OFF - System is secured

c VENT, CKPT - Routes outside air to the cockpit

c VENT, CABIN - Routes outside air to the cabin

c VENT, BOTH - Routes outside air to both the cockpit and the cabin

c ECS, CKPT - Energizes the ECS and routes conditioned air to the cockpit

c ECS, CABIN- Energizes the ECS and routes conditioned air to the cabin

c ECS, BOTH - Energizes the ECS and routes conditioned air to both the cockpit and cabin

Helicopters 0011 and Subsequent and VIP Helicopters 0009 and Subsequent. The selection of the requested
temperature in the compartment is achieved by the rotation of the potentiometer for each compartment (cabin
and cockpit). The selectable temperature range is from 60°F to 80°F. The selected temperature of 60°F cor-
responds to the position of the potentiometer in fully counterclockwise position while 80°F corresponds to the
fully clockwise position. During the ACS operation, the control operated by the DTCU try to obtain the tem-
perature requested on the control panel by comparing the air temperature at the compartment outlet.

CABIN MASTER Control Switch Position:

c OFF - all the components of the ACS but the DTCU are switched OFF.

c VENT - the relevant evaporator fan is switched ON (the Switch ON of the evaporator fan is actuated di-
rectly by the control panel). in that position the DTCU commands the FAV in the OPEN position.

c HEAT - position, the relevant evaporator fan is switched ON (the switch ON of the evaporator fan is actu-
ated directly by the control panel). In that position the DTCU commands the FAV in the CLOSED position.

c HT & VT - , the relevant evaporator fan is switched ON (the switch ON of the evaporator fan is actuated
directly by the control panel). In that position the DTCU commands the FAV in the MID position.

c MAX AC - The operation of the ACS when MAX AC is selected is the same of the AC position except the
FAV is commanded in closed position in order to speed up the cool down of the compartment.

c AC - the relevant evaporator fan is switched ON (the switch ON of the evaporator fan is actuated directly
by the control panel). In that position the DTCU commands the FAV in the MID position. The selection of
the AC position in the control panel directly commands the relevant refrigerant SOV to open.

CABIN TEMP digital panel, RMT CABIN CONT SELECTED switch, and CABIN CNTR switch.

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The VIP Helicopter ECS CONT PANEL has in addition to the above controls the following:

c Digital Display - Provides a readout in Fahrenheit or Centigrade of the cabin return air temperature sensor
output.

c CABIN CNTR switch - The switch allows the pilot or crewman to over ride the Cabin control. The pilot can
than select temperature and mode operation.

c RMT CABIN CONT SELECTED - A Green light indicates the CABIN CNTR switch is in the NORM mode.
This indicates that the cabin compartment has full control of mode and temperature selection.

L. Subcooler

390

RM21020_14
SA

AIR CONDITIONING SYSTEM - COMPONENT LOCATION (SHEET 14 OF 14)

O Subcooler 390 Subcooler

The subcooler is located in the top deck of the helicopter. The function of the subcooler is to cool down the
liquid arriving from the flash tank before the inlet in the thermostatic expansion valve in order to avoid pres-
ence of refrigerant gas at the valve inlet. The cooling of the liquid is obtained by using the cold refrigerant
gas coming from the evaporator.

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4. OPERATION

REFRIGERANT CIRCULATION

The cooling system uses a single, closed-loop refrigeration circuit that includes two parallel evaporator
circuits and one compressor. The refrigerant acts as a heat transfer fluid, either absorbing heat from the
cockpit or cabin air via the evaporators or radiating heat overboard via the condenser and condenser air
system.

Starting at the output of the compressor, the refrigerant is a high-pressure gas. This gas passes through
the high-pressure shutoff switch to the condenser where heat is removed from the gas by the air blowing
over the condenser heat exchanger. As the refrigerant cools down, it is converted to a high-pressure liq-
uid. The liquid leaving the condenser passes by the burst fuse, through the filter/dryer and into the flash
tank. Part of the liquid is flashed into vapor creating an equilibrium pressure condition that is maintained.
The refrigerant leaves the flash tank via one of two outlet lines: the compressor economizer supply line
located at the top or the evaporator thermal expansion valve line located at the bottom.

The flash tank allows the separation of the liquid phase from the vapor phase of the refrigerant. The va-
por phase is sent to the compressor economizer while the liquid phase is sent to the thermostatic valves
of the evaporators.

The economizer supply line supplies low-pressure gas to the compressor. The thermal expansion valves
convert the high-pressure liquid into superheated low-pressure liquid/gas before it passes through the
evaporator pressure regulator valves. The position of the regulator valve is controlled by the DTCU as
determined by the temperature control system.

Heat is removed from the cockpit/cabin air in the evaporator heat exchanger and transferred to the refrig-
erant. This raises the pressure and temperature of the refrigerant. The refrigerant lines that leave the
evaporators combine into a common line which goes to the compressor assembly.

In the compressor assembly, the flow passes through a compressor inlet check valve, past a compressor
suction pressure sensor, and mixes with the gas extracted directly from the flash tank. The compressors
raise the pressure of the gas. After leaving the compressors, the high-pressure refrigerant gas passes a
high-pressure discharge pressure sensor, through a compressor discharge check valve, and to the con-
denser input where the refrigerant cycle starts again.

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MAINTENANCE MANUAL, SA S92A-AMM-000

CABIN FRESH
AIR INLET
FROM
CONTROLLER TO
CONTROLLER
TO
TO CONTROLLER FROM
CONTROLLER CONTROLLER TO
32 CONTROLLER
11 17 33 17 14
FROM 37 20 12
3 22 29 FROM
TO CONTROLLER 18B 28 17 15 27 13
1B 17 5B CONTROLLER
CONTROLLER 18B TO
18A 1A CONTROLLER
FTPV
7
E

EVAPORATOR
P

FLASH
P

TANK
EV 38 T COCKPIT
P AP
P DTCU OR FRESH AIR
6 T

T
AT 5A INTAKE
OR
T 4
23A 17 26
23B T E
24B 24A 31 T
17
WATER DRAIN
WATER CABIN TO OVBD
TO RETURN AIR COCKPIT
DRAIN TO
CONTROLLER
CABIN TO OVBD 34 CONDITIONED
CONTROLLER COCKPIT
8 AIR
CONDITIONED 8 RETURN
AIR FROM H AIR
CONTROLLER 21
25 ELECTRIC
S.O.V.
P.S. H
FWD

BULKHEAD
TO COMPRESSION POWER FROM CONTROL
19 2 PANEL
CABIN 34 COCKPIT
DRYER/
FILTER

TO FROM
CONTROLLER CONTROLLER
10
FROM
CONTROLLER
35
LEGEND

HIGH PRESSURE GAS


LOW PRESSURE GAS
HIGH PRESSURE LIQUID
OVERBOARD LOW PRESSURE LIQUID / GAS
ELECTRICAL LOGIC
47 10 P PRESSURE SENSOR
9 36
30 T TEMPERATURE SENSOR
P, S PRESSURE SWITCH

E ELECTRICAL ACTUATOR
H ELECTRIC HEATER
AIR CONDITIONING SYSTEM - FLOW BLOCK DIAGRAM
RM21019A
SA

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MAINTENANCE MANUAL, SA S92A-AMM-000

AIR CONDITIONING SYSTEM COMPONENTS

1 Compressor with Electric Drive Motor 2 Filter/Dryer

3 Flash Tank 4 Subcooler

5 Thermostatic Expansion Valve (2) 6 Cabin Fresh Air Valve

7 Cockpit Fresh Air Valve 8 Evaporator Pressure Regulator (EPR)


Valve (2)

9 Condenser 10 Condenser Fan (2)

11 Digital Temperature Control Unit 12 Cabin Evaporator Fan


(DTCU)

13 Cockpit Evaporator Fan 14 Cabin Evaporator

15 Cockpit Evaporator 16 Electronic SOV

17 Temperature Sensor (6) 18 Pressure Sensor (2)

19 High- Pressure Switch 20 Flash Tank Pressurization Valve

21 Cabin SOV 22 Fixed Orifice

23 Check Valve 24 Check Valve - Included in Compressor

25 Cockpit SOV 26 Cockpit Top Deck Return Duct

27 Cockpit Evaporator Inlet Header 28 Cockpit Evaporator Outlet Header

29 Cockpit Top Deck Supply Duct 30 Condenser Transition Ducting

31 Cabin Return Duct 32 Cabin Evaporator Inlet Header

33 Cabin Evaporator Outlet Header 34 Low-Pressure Service Valve

35 High-Pressure Service Valve 36 Burst Fuse

37 Compressor Power Relay (K21) 38 Condenser Fan Relay (K20)

39 Compressor Relay (K20) 40 Compressor Relay (K21)

41 Condenser Fan Relay (K19)

CONDENSER AIR CIRCULATION

Ambient air enters the condenser through the right wheel well in the aft section of the sponson. It then
passes through a Foreign Object Damage (FOD) screen before it enters the condenser heat exchanger. The
air acts as a heat sink for the cooling system, cooling the high-pressure gas output of the compressors and

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MAINTENANCE MANUAL, SA S92A-AMM-000

converting the gas to a liquid in the condenser. After passing through the heat exchanger, the air passes
through the condenser transition duct and passes through two condenser fans which discharge the air over-
board through another FOD screen.

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