HONEYWELL NORMALAIR-GARRETT LIMITED
ENVIRONMENTAL CONTROL UNIT
PART No. 5010C000-002
ABBREVIATED COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
PUBLICATION No. 2742
Statement of Initial Certification
This manual obeys British Civil Airworthiness
Requirements, Section A, Chapter A5-3
Signed ..........................................................
11 Apr 2001
Date ............................................................
C.A.A. Approval No. G02026/00352
NOTE: This approval cannot be used for changes put in this
manual which are not approved by the Equipment Manufacturer.
Changes made by other authorities must each be approved by
that authority and a record made on other record sheets.
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HONEYWELL NORMALAIR-GARRETT LIMITED
Equipment designed and manufactured by Honeywell NormalairGarrett Ltd. is protected by British and foreign patents
All business is governed by the Company’s
Standard Conditions; copies available on request
Printed and published by
Honeywell Normalair-Garrett Ltd.
Yeovil, Somerset, England
© Honeywell Normalair-Garrett Limited 2001
HONEYWELL NORMALAIR-GARRETT LIMITED
ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
1
Description, Operation and Data
The environmental control unit supplies cold air to the aircraft air conditioning system.
Environmental Control Unit - General View
Figure 1
This manual has been written to Honeywell Normalair-Garrett Limited Drawing Office Instruction,
DOI 5010C000 Issue 29.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
A
Description (Fig 1 and 2)
The environmental control unit contains a cooling turbine, a jet pump, a combined heat
exchanger and water condenser, a modulating and shut-off valve assembly, a butterfly valve
and an economy mode solenoid valve.
The cooling turbine has an inward flow radial turbine which turns an axial flow fan through a
shaft. The unit has a turbine wheel enclosed in a nozzle assembly and a torus, a turbine
bearing housing, a fan bearing housing, and a fan enclosed in an inlet assembly.
The air to air heat exchanger is a single pass, cross flow, plate and fin type of unit. It is a
welded/brazed assembly made from aluminium alloy material. It has a core-assembly, a
charge inlet pan assembly and a charge outlet pan assembly.
A cooling air outlet duct assembly is attached below the heat exchanger which contains the
cooling turbine. The jet pump is attached to the cooling turbine and the cooling air outlet duct
assembly. The modulating and shut-off valve assembly is installed on the side of the heat
exchanger. Associated pipework connects the economy mode solenoid valve and the
butterfly valve.
B
Operation
High pressure bleed air supplied by the engine is ducted to the environmental control unit
where it enters the primary heat exchanger and water condenser. Cool ambient air is helped
through the heat exchanger by the cooling turbine fan which releases the air to ambient.
In the primary heat exchanger, bleed air cools to near ambient air temperature. As the bleed
air passes through the reheater/condenser section of the heat exchanger it is cooled more
by re-circulated conditioned air. Because of the high pressure and moderate temperature in
the reheater/condenser, the bleed air is cooled below its dew point, and moisture condenses
from the air. The condensed water is sprayed onto the cool air inlet of the heat exchanger
through the water injector. This reduces the temperature of the cool ambient air as it enters
the heat exchanger. Cool high pressure bleed air goes from the reheater/condenser through
the cooling turbine. This decreases the air temperature more. The pressure of the bleed air
drives the cooling turbine.
Primary air from the cooling turbine goes through the ejector nozzle of the jet pump where
secondary airflow is added from two sources. The first is air from the reheater/condenser.
The second is air returned from the cabin.
When the maximum cooling capacity of the environmental control unit is not necessary, the
economy mode is operated, which decreases engine fuel consumption. The economy mode
solenoid valve is energised, which operates the butterfly valve and decreases the bleed
airflow through the unit and also decreases cabin supply airflow.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
1
Environmental control unit
10 Temperature control duct
(customer furnished equipment)
2
Heat exchanger
11 Jet pump
3
Water injector
12 Cooling turbine
4
Reheater condenser
13 Check valve
5
Water separator
14 Modulating and shut-off valve assembly
6
Relief valve
7
Butterfly valve
8
Temperature sensor
9
Economy mode solenoid valve
Schematic diagram
Figure 2
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
C
Data
Dimensions
Length
Width
Height
521 mm (20.50 in)
273 mm (10.75 in)
484 mm (19.05 in)
Mass
13.15 kg (29.0 lb)
Installation
Two flanges on heat exchanger with
four .250-28 UNF floating achor nuts,
298 mm (11.735 in) and 101.6 mm (4 in)
centres.
Unit to be installed with the heat exchanger
at the top and cooling turbine axis horizontal.
Connections
Bleed air inlet
Flare per MS33584 to suit
38.1 mm (1.5 in) dia tube
Cool air inlet
Rectangular area, flanges on longer sides
with twelve .1640 x 32 UNJC floating anchor
nuts.
Condenser cold air inlet
Single bead 38.1 mm (1.5 in) dia duct
similar to MS33660-24, style A
Conditioned air outlet
Single bead 76.2 mm (3.0 in) dia duct
similar to MS33660-48, style A
Cabin return air inlet
Single bead 63.5 mm (2.5 in) dia duct
similar to MS33660-40, style A
Cool air outlet
Single bead 101.6 mm (4.0 in) dia duct
similar to MS33660-64, style A
Ambient temperature range
Ground operation
Flight operation
Maximum normal pressure and
temperature of bleed air
-62 deg C to +74 deg C
-54 deg C to +52 deg C
3.65 bar (52.9 psi) at 314 deg C
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HONEYWELL NORMALAIR-GARRETT LIMITED
ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
2
Testing and Fault Isolation
A
Test Equipment
Refer to Table 1 for the equipment necessary to test the environmental control unit.
NOTE:
Equivalent alternatives can be used for these items.
TE No
Part No
Description
Vendor
1/1
-
Flowmeters, 0 to 5.5 kg/min (0 to 12 lb/min), 2 off
CFE
1/2
-
Pressure gauge
0 to 3.5 bar (0 to 50 psi)
CFE
1/3
-
Temperature gauges
0 to 250 deg C, 2 off
CFE
1/4
-
Temperature gauge
-10 to +100 deg C
CFE
1/5
-
Temperature selector
CFE
1/6
5673K000
Ducting with orifice
HNGL
1/7
-
Clean, dry air supply
0 - 3.5 bar (0 to 50 psi)
and temperature 0 - 250 deg C
CFE
Power supply 27 - 29 V dc
CFE
1/8
Test Equipment
Table 1
B
Functional Test
(1)
Connect the unit to the test circuit shown in Fig 3, with the cabin return air inlet blanked.
Make sure the modulating and shut-off valve is de-energised.
(2)
Energise the economy mode solenoid valve.
(3)
Apply an air pressure of 2.25 to 2.40 bar (32.7 to 34.7 psia) at a temperature of 200 to
210 deg C to the bleed air inlet. Keep these conditions constant.
(4)
Apply an air temperature of 31.2 to 36.2 deg C at the cool air inlet. Keep this condition
constant.
(5)
Make sure the air temperature at the sensor is 0 deg C maximum. The bleed air inlet
airflow must be 5.035 kg/min (11.1 lb/min) maximum and the outlet airflow must be
4.58 kg/min (10.1 lb/min) minimum.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
Test Circuit
Figure 3
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
(6)
De-energise the economy mode solenoid valve.
(7)
Make sure the bleed air inlet airflow has decreased to 0.907 to 1.814 kg/min
(2.0 to 4.0 lb/min). The air temperature at the sensor must be less than -1.1 deg C.
Decrease the cool air inlet temperature to get the temperature at the sensor.
(8)
Adjust the temperature selector to the full cold position and energise the modulating
and shut-off valve.
(9)
Make sure the air temperature at the sensor has increased to 0 to 3.3 deg C.
(10) While at these conditions, feel around all pipe joints to make sure there is no leakage.
(11) Adjust the temperature selector to the full hot position.
(12) When the conditions become stable make sure the air temperature at the sensor is
77 to 88 deg C.
(13) Decrease the bleed air inlet and cool air inlet pressure and temperature to ambient.
De-energise the modulating and shut-off valve.
(14) Remove the unit from the test circuit.
C
Fault Isolation
Defect
Possible Cause
(1) Cool air temperatures at
sensor too high
(a) Heat exchanger blocked
or damaged
Clean and check heat
exchanger
(b) Cooling turbine faulty
Reject unit
(a) Loose duct connections
Examine connections and
tighten as necessary
(b) Heat exchanger blocked
Clean heat exchanger
(2) Flow through the unit
too low
Recommended Procedure
Fault Isolation
Table 2
3
Disassembly
A
General
The procedure that follows gives instructions for the removal of the heat exchanger.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
B
Procedure (Ref IPL Fig 1)
(1)
Loosen the two clamps (10) which connect pipework from the cooling turbine (110) to
the heat exchanger (250).
NOTE:
The sleeves (20) between the clamps and pipework are assembled to the
pipework with RTV 732 sealant.
(2)
Disconnect the pipework from the tee (150) which houses the relief valve assembly
(160).
(3)
Remove the screw (30) and washer (40) which attach the pipework from the
modulating and shut-off valve assembly to the cooling turbine (110).
(4)
Disconnect the connector on the pipework from the heat exchanger (250) to the
modulating and shut-off valve assembly.
(5)
Remove the two bolts (60) and washers (70) which attach the modulating and shut-off
valve assembly to the heat exchanger (250).
(6)
Remove the modulating and shut-off valve assembly, butterfly valve and connected
pipework from the heat exchanger (250) and cooling turbine (110). Remove and
discard the packing (50) from the cooling turbine (110).
(7)
Remove the twelve screws (90) and washers (100) which attach the cooling air outlet
duct assembly (80) to the heat exchanger (250). Remove the duct assembly, complete
with cooling turbine (110), from the heat exchanger.
NOTE:
This joint is assembled with RTV 732 sealant.
(8)
Loosen nut (140) and remove tee (150) together with relief valve assembly (160) from
the heat exchanger pipework. Remove and discard the packing (170).
(9)
Remove the screw (180) and washer (190) which attach the loop clamp to the heat
exchanger (250).
(10) Loosen the hose clamp (200) and remove the hose from the end of the heat exchanger
(250).
(11) Remove the three screws (220) and washers (230) which attach the temperature
sensor (210) to the reheat condenser duct assembly. Carefully remove the
temperature sensor. Remove the gasket (240).
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
4
Cleaning
A
Materials required
NOTE:
Equivalent alternatives can be used for these items.
ML No
Description
Specification
Vendor
3/1
Hydrocarbon solvent
-
CFM
3/2
Lint free material
-
CFM
3/3
Liquid detergent
MIL-D-16791E
CFM
Cleaning Materials
Table 3
B
General Procedure
WARNING:
C
CLEANING MATERIALS CAN BE DANGEROUS TO PERSONS. USE
ONLY IN AN AREA WITH A GOOD FLOW OF AIR. KEEP AWAY FROM
SOURCES OF IGNITION. PREVENT SKIN CONTACT. PUT ON
PROTECTIVE CLOTHING AND EYE PROTECTION.
(1)
Clean all items externally with lint free material (ML No 3/2) made moist with
hydrocarbon solvent (ML No 3/1).
(2)
Dry the items with clean dry lint free material (ML No 3/2).
Heat Exchanger
(1)
Pressure clean the unit internally (through the bleed air and cool air sides) with a 2%
solution of liquid detergent (ML No 3/3) and water.
(2)
Clean the unit externally with lint free material (ML No 3/2) made moist with the
solution.
(3)
Flush the unit internally and externally with clean cold water.
(4)
Drain the unit.
(5)
Dry the unit in an air circulating oven for 1 hour at 120 deg C.
(6)
Put a flow of dry air through the bleed air and cool air sides and make sure the unit is
fully dry.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
5
Check
A
B
C
General
(1)
Examine all screw threads for damage.
(2)
Make sure there is no corrosion and cracks.
Heat Exchanger
(1)
Examine the heat exchanger core, as far as possible, for blockage and damage.
(2)
Visually examine the unit for cracks. If cracks are found reject the unit.
(3)
Examine the pan assemblies and pipes for dents. Do not try to remove the dents.
Examine small sharp dents for cracks. If cracks are found reject the unit.
(4)
Make sure that the anchor nuts are attached correctly and that the threads are
serviceable.
(5)
Examine the pipe end connections for damage and distortion.
Cooling Turbine Lubrication (Ref IPL Fig 1)
This procedure may be done without the removal of the cooling turbine (110) from the cooling
air outlet duct assembly (80)
NOTE:
Equivalent alternatives can be used for these items.
ML No
Description
Specification
Vendor
4/1
Lubricating oil
MIL-L-23699
CFM
4/2
Lockwire, 0.5 mm dia
AS 44725-1
CFM
Materials
Table 4
(1)
Make sure that the area around both oil plugs (120) is clean.
(2)
Cut the lockwire and remove the oil plug (120) adjacent to the cooling turbine pipe
flanges. Remove and discard the O-ring seal (130).
(3)
With the help of a funnel pour approximately 20 ml of oil (ML No 4/1) into the cooling
turbine (110). Allow five minutes for the oil to be absorbed.
(4)
Turn the unit so that the oil hole is at the bottom. Let the oil drain.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
(5)
Do steps (3) and (4) until oil drains.
NOTE:
Capacity of cooling turbine is 80 ml. Do not use more than this quantity of
oil.
(6)
Let the unit drain for 10 minutes.
(7)
Assemble a new O-ring seal (130) on the oil plug (120) and install the oil plug in the
cooling turbine (110).
(8)
Find the second oil plug (120), which is at 90 degrees to the first oil plug. Cut the
lockwire and remove the oil plug. Remove and discard the O-ring seal (130).
(9)
Do steps (3) to (7) for the second oil hole. Make sure that no more than 80 ml of oil in
total is used. If the addition of a total of 80 ml of oil fails to produce any oil from the
drain, reject the unit.
CAUTION:
EXCESS OIL IN THE COOLING TURBINE SUMP MAY RESULT IN
SEEPAGE, AND THE BEARINGS OVERHEATING IN HIGH-SPEED
RUNNING CONDITIONS. IT IS ESSENTIAL, THEREFORE, THAT
ANY FREE OIL IS ALLOWED TO DRAIN FROM THE SUMP FOR AT
LEAST 10 MINUTES BEFORE THE DRAIN PLUG IS REFITTED.
(10) Use lockwire (ML No 4/2) to lock the two oil plugs (120) to the adjacent cooling turbine
flange.
NOTE:
6
After lubrication the cooling turbine must be kept with the shaft axis
horizontal.
Repair
There are no permitted repair procedures for the environmental control unit.
7
Assembly (Ref IPL Fig 1)
A
General
(1)
All replacement parts must be either those given in the Illustrated Parts List, or
approved alternatives.
(2)
After assembly the unit must be tested as given in Testing and Fault Isolation.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
B
Materials
NOTE:
Equivalent alternatives can be used for these items.
ML No
Description
Specification
5/1
Silastic 732 RTV adhesive,
clear
MIL-A-46106
5/2
Self adhesive PVC tape
-
Vendor
Dow Cornings Ltd
Avco House
Castle Street
Reading
Berks RG1 7DZ
ENGLAND
CFM
Assembly Materials
Table 5
D
Procedure
(1)
Assemble the gasket (240) and temperature sensor (210) on the reheat condenser
duct assembly and attach with three screws (220) and washers (230).
(2)
Assemble the hose connected to the water injector, to the small connection at the end
of the heat exchanger (250) and attach with the hose clamp (200).
(3)
Attach the loop clamp on the hose, to the heat exchanger (250) with the screw (180)
and washer (190).
(4)
Assemble a new packing (170) to the tee (150) and attach the tee, together with relief
valve assembly (160), to the heat exchanger pipework. Tighten the nut (140).
WARNING:
732 RTV - ACETIC ACID IS RELEASED DURING THE CURING PROCESS,
WHICH MAKES AN IRRITANT TO EYES, SKIN AND MUCOUS
MEMBRANES WHEN MIXED WITH MOIST AIR. WEAR PROTECTIVE
CLOTHING, RUBBER GLOVES AND EYE PROTECTION. USE IN A WELL
VENTILATED AREA.
(5)
Apply a continuous film of 732 RTV adhesive (ML No 5/1) to the outside of the flanges
of the heat exchanger (250) which mate with the cooling air outlet duct assembly (80).
Assemble the cooling air outlet duct assembly (80), complete with cooling turbine
(110), to the heat exchanger (250). Attach the parts with 12 screws (90) and washers
(100).
(6)
Install a new packing (50) in the groove of the cooling turbine (110) duct.
(7)
Put the modulating and shut-off valve assembly, butterfly valve and connected
pipework in position on the heat exchanger (250).
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
(8)
Apply a continuous film of 732 RTV adhesive (ML No 5/1) around the inside, at each
end of the two sealing sleeves (20). Assemble the two sleeves (20) and coupling
clamps (10) to the pipework/heat exchanger and pipework/cooling turbine joints. Make
sure the other pipework connections are aligned before the clamps (10) are fully
tightened.
NOTE:
(9)
The clamps must be tightened before there is a surface film on the adhesive
(approximately 10 minutes).
Loosely attach the modulating and shut-off valve assembly to the heat exchanger
(250) with two bolts (60) and washers (70).
(10) Attach the heat exchanger pipework connector to the modulating and shut-off valve
assembly.
(11) Attach the pipework from the modulating and shut-off valve assembly to the cooling
turbine (110) with the screw (30) and washer (40).
(12) Attach the pipework to the tee (150) which houses the relief valve assembly (160).
(13) Fully tighten the two bolts (60).
(14) After testing, assemble the protective caps (260, 270, 280, 290, 300) to the unit. Attach
protective cover (310) to the heat exchanger (250) with adhesive tape (ML No 5/2).
8
Fits and Clearances
Fits and clearances are not applicable to the environmental control unit.
9
Special Tools, Fixtures and Equipment
A
Special Tools and Fixtures
There are no special tools or fixtures necessary for the environmental control unit.
B
Equipment
The equipment necessary for the environmental control unit is given in Table 1.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
ILLUSTRATED PARTS LIST
1.
Introduction
A. General
This Illustrated Parts List (IPL) is for the identification and requisition of replaceable parts.
B. Vendor Codes Index
The Vendor Codes Index gives all Vendor Codes used in the Detailed Parts List and the
names and addresses of the Vendors.
C. Reference Designation Index (when applicable)
The Reference Designation Index gives, in alpha-numerical sequence, designation codes
given to electrical and electronic parts in the equipment. The index gives the figure and item
number where each reference designation is given in the Detailed Parts List.
D. Numerical Index (when applicable)
The Numerical Index gives, in alpha-numerical sequence, all part numbers given in the
Detailed Parts List. The ‘Total Required’ column gives the total quantity required for each
part number at the figure and item entry. An ‘Airline Stock Number’ column is given for airline
use.
E.
Detailed Parts List
The Detailed Parts List includes parts lists and related illustrations. Parts are given in
disassembly sequence where this sequence can be kept. Each item given in the list has an
item number for each installation. The Detailed Parts List is indented to show the assembly
relationship of the item within the list. For example, the description of an item is indented to
the right of the description of its next higher assembly. Attaching parts are listed immediately
after the assembly they attach and are given before any detail parts of the assembly. The
words ‘ATTACHING PARTS’ are given before and the symbol ‘***’ is given after each group
of attaching parts. Effectivity codes, when necessary, are given to identify the next higher
assembly on which an item may be used. For example, code AC shows that an item is used
on assemblies A and C but not on other assemblies. Any part which is not given a code is
not limited in its application and can be used on all the next higher assemblies.
2.
How to Use the Illustrated Parts List
A. When the Part Number is Known
Find the part number in the Numerical Index and use the figure and item number given to find
the part in the related Detailed Parts List illustration and list of parts.
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
B. When the Part Number is not Known
Identify the applicable illustration, find the part on the illustration and use the item number to
find data of the part in the related list of parts.
C. When the Reference Designation is Known
Refer to the Reference Designation Index and find the designator. Use the figure and item
number given to find the part in the related Detailed Parts List illustration and list of parts.
3.
Abbreviations
The abbreviations that follow are used in the IPL:
RF
V
4.
Reference (item)
Vendor (code)
Vendor Codes Index
The vendor codes that follow are in accordance with the United Kingdom Codification Handbook
99-H4-1:
Vendor Code
U1068
Vendor Address
Dowty Seals Ltd
Ashchurch
Tewkesbury
Gloucester GL20 8JS
ENGLAND
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
Unit, Environmental Control
Figure 1 Sheet 1 of 2
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
Unit, Environmental Control
Figure 1 Sheet 2
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
Part No. 5010C000
Fig &
Item
No.
1-1
10
20
30
40
50
60
70
80
Nomenclature
5010C000-002
234-524-9007
664-501-9104
MS27039-1-07
AN960KD10L
M83248-1-124
AN3-3A
AN960KD10L
2202219-1
90
100
MS27039-1-07
AN960KD10L
110
120
130
140
150
160
170
180
190
200
210
1538D000-002
MS9015-02
100-902-2129
AN924-4D
2201002-3
884984-5
M83248-1-904
MS27039-0806
AN960KD8L
211-032-9002
625614-1-1
220
230
MS27039-0809
AN960KD8L
240
250
2202404-1
8585C000
260
270
280
290
300
310
5010C014
3001S03348
3001S03355
3001S03332
3001S03326
5010C013
Eff
Code
Part No.
1234567
Unit, Environmental Control
. Clamp, Coupling
. Sleeve, Sealing
. Screw, Machine
. Washer
. Packing
. Bolt, Machine
. Washer
. Duct Assembly, Cooling Air Outlet
ATTACHING PARTS
. Screw, Machine
. Washer
***
. Turbine, Cooling
. . Plug
. . Seal, O-ring
. Nut, Plain Hexagon
. Fitting Assembly, Orificed Tee
. Valve Assembly, Relief
. Packing
. Screw, Machine
. Washer
. Clamp, Hose
. Sensor, Temperature
ATTACHING PARTS
. Screw, Machine
. Washer
***
. Gasket, Sensor
. Heat Exchanger Assembly
TRANSIT ITEMS
Cap, Protective
Cap, Protective
Cap, Protective
Cap, Protective
Cap, Protective
Cap, Protective
Units
per
Assy
RF
2
2
1
1
1
2
2
1
12
12
(VU1068)
1
2
2
1
1
1
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
- Item Not Illustrated
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