Installation Guide for Artic Air 24 Volt R134A Air Conditioner

Transcription

1 Installation Guide for Artic Air 24 Volt R134A Air Conditioner Rev 004 April 20, 2014 There are five objectives to installing the Artic Air unit: 1) The primary wiring from the battery, 2) The controller and controller cable, 3) The condenser air exhaust, 4) The condensate drain, 5) Secure tie down. The first step is to review the Artic Air Information and Installation Guide and Digital Control Operations Manual. See section below. Step 1: Primary wiring A #6 MIL-W-22759/16-6 wire is installed as the primary power source to the air conditioner. This power source comes directly from the battery and is protected by a 60 amp circuit breaker installed adjacent to the battery. The Skybolt kit includes a protective housing (AC-2109) to be installed with the circuit breaker. For the Beech Baron, the easiest routing is along the right side of the fuselage and cabin to the aft baggage area. This routing requires the least amount of side panels or floor removal. When routing the primary wire also plan to route the controller cable. The controller cable is shielded and should not be cut or spliced. We recommend a longer control cable than standard. Request a 20 or 35 foot cable with your unit to allow the best possible panel location of the controller on the instrument panel. 60 Amp Breaker with AC-2109 Protector located in Baron nose baggage compartment just aft of battery. The primary wiring and controller wiring is routed beneath the aft baggage compartment floor to the left side of the fuselage. Allow sufficient length of wire to be able to remove the baggage compartment floor enough for maintenance and inspections. The controller

2 cable can be disconnected from the air conditioner and easily removed through the floor. The cannon plug cannot be removed as the plug socket flange is positioned on top of the floor in order to be certain the plug connector will fully engage to the opposing floor socket connector. Thus, once the cannon plug is installed, the floor can only be removed for inspections or maintenance to the extent of extra primary wire length you allow. The Skybolt kit includes a heavy-duty military Amphenol cannon connector (AC-2100 Set). It is a two-connecter plug with solder in each connector for field installation of the wire. The toughest trick is to map out the assembly sequence of all the components in the plug set. Be especially careful that you feed the wire through the various components prior to soldering the wire. The AC-2100 socket has 4 mounting screws to be attached to the rear baggage compartment floor. Before installing the plug, complete step 3 Preparation of the Baggage Compartment Floor). Once the plug is installed, the floor is basically attached to the airframe to the limit of the extra length wire allowed in your installation. If you tackled the primary wire as the first step in installation, before drilling the connecter hole and the controller cable hole and soldering the socket side of the plug, proceed to the next steps first as you must remove the floor to locate the wiring holes, the condensate drain holes, and the tie-down track. Step 2: Condenser Air Exhaust To keep this installation as simple as possible and maintain the portable nature of the Artic Air unit, the condenser air is ducted directly into the aft fuselage to be discharged in the aft tail section. Thus, depending on the unit (one or two ducts) holes in the aft bulkhead must be cut. When the unit is installed, the duct(s) are positioned through bulkhead hole(s). One of the first steps in the installation is to set the Artic unit in the baggage compartment and locate the condenser duct

3 discharge hole(s). Plan to position the unit approximately 2 aft of the front edge of the compartment floor. This should allow about 4-6 inches of spacing from the aft bulkhead to the back of the air conditioner. Once the air conditioner is removed, cut the required hole(s) in the aft bulkhead. Step 3: Preparation of the Baggage Compartment Floor Remove the air conditioner and remove the aft baggage compartment floor. Note that the condensate drain is on the aft right side of the unit. Determine the best routing of the condensate drain hose to the Skybolt bulkhead drain fitting (AC-2125). The combination of fittings should eliminate any chance of the hose kinking or any low spot between the floor fitting (AN833-8D) and the skin bulkhead fitting. The approximate location of the floor hole for the AN833-8D fitting should be determined based on positioning of the air conditioner and the tie-down track. Trace out the base of the air conditioner such that it is approximately 2 aft of the front of the floor (allow for clearance of the protective lip) and in the center. Now determine the location for both tiedown tracks. Plan on approximately 1 clearance from the edge of the track to the side of the floor in order to have access to the floor hold-down screws. Run the track parallel to the cabin wall (floor edge). This will maximize the clearance for the tie down ratchets (AC-2128). Before committing to the exact location of the tracks, check that the backing strip is clear of any airframe structure beneath the floor. Drain Fitting Based on the location of the tracks, now determine a more precise location of the primary wire cannon plughole, the controller cable hole, and the condensate drain hole. Allow as much clearance as possible away from the estimated location of the tie-down ratchets. Drill all necessary holes for the cannon plug, controller cable and drain fitting. Note that the cannon plug mounting screw holes are close to the body of the plug, thus, drill this hole only big enough to mount the plug and no more. Drill 4 each plug socket mounting holes. You may find it easier to solder the primary and ground #6 wires before mounting the plug socket to the floor. Locate each hole in the carpet so that holes can be cut in the carpet.

4 Drill ¼ mounting holes (6 each) for each track and arrow ends. Note: The track, backing strip, and ends are drilled as a set and may be slightly off if the backing strips are interchanged or turned around. Once the track is positioned and the screws inserted, you can determine the end or side that best fits the track and ends. It is your option as to mounting the tracks and cutting the carpet or mounting the tracks over the carpet. If you mount the tracks over the carpet as shown, plan on installing the track after the cannon plug is installed. Note: This is where extra length wire is a good thing to allow the floor to be removed far enough for inspection and to install the track. Position the floor and check for adequate clearances. Step 4: Condensate Drain - Based on the location of the floor drain fitting (AN833-8D), determine the ideal location for the fuselage skin bulkhead fitting (AC-2125). The drain hose is long enough to allow tightening of each fitting with the floor lifted enough for access. Drill and install fitting such that the drain mast chamfer is facing aft. We use an Oring on the outer surface and use LocTite Red to secure the fitting nut. Before you attach the hose from the belly fitting to the floor fitting, solder and install the cannon plug. Step 5: Final Installation of Cannon Plug Route the primary wire through the floor. Properly assemble the plug socket components, including the heat shrink onto the wire before soldering. Solder the primary and ground wires to the plug socket. Do the same for the air conditioner primary and ground leads noting that the plug can only be positioned one way such that the ground mates to the ground and primary to the primary. Complete the process for the heat shrink and clamp the plug ends securely. Now, mount the plug socket to the floor with the hardware included. Prepare a ground wire and fasten to the airframe. Step 6: Final Installation of Baggage Compartment Floor Position the carpet then attach the tie-down track. Position the floor and secure the condensate drain hose below the floor. Check for any FOD, rags, or tools in and around the baggage floor. Secure the baggage floor to the airframe. Note: The tie down is only as good as the floor is fastened to the airframe.

5 Step 7: Condensate Connection - Install the air conditioner. Install AC-2122 straight fitting onto the AN833-8D bulkhead fitting that is attached to the floor (remove the B nut portion of the fitting). Cut the vinyl condensate drain hose to length such that the end is pushed solidly onto the AC-2122 fitting. A slight amount of lubricant will help. Safety wire the vinyl hose end to the fitting. Note: For air conditional removal, simply loosen and disconnect the fitting. Step 8: Controller Location and Installation This step will be unique to every aircraft based on panel availability. The key is to have plenty of controller cable length. We recommend at least 20 (35 feet maximum) feet as any shorter length may restrict your options. Step 9: Ground Use Only - Prepare two labels, one for the controller head and one to be placed on the air conditioner adjacent to the connection plug: FOR GROUND USE ONLY.

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