ZEE Systems, Inc.

SERVICE LETTER Z26-1

I. PLANNING INFORMATION

A. Effectivity: Aircraft equipped with ZEE Systems, Inc. P/N: Z26-89600-Series Motor Compressor
Condenser Assembly or P/N: Z26-8900-Series Motor Compressor Assembly and remote location
Power Condenser Assy.

B. Reason: Provide refrigerant charging instructions for air conditioning systems using the Z26-
89600-Series Motor Compressor Condenser Assembly or P/N: Z26-8900-Series Motor
Compressor Assembly and remote location Power Condenser Assy.

C. Description: Servicing of the air conditioning system is done in 3 phases, 1) Evacuation, 2) Static
Charge, and 3) Running Charge.

D. Compliance: Compliance is mandatory.

E. Manpower: The following is an estimated time only. Facility, knowledge, experience, equipment
and ambient conditions will effect these estimates: 1) Remove Panels: 0.5hrs, 2) Recover
refrigerant: 2.0hrs, 3) Evacuation 7.5hrs, 4) Static Charge: 0.5hrs, 5) Running Charge: 1-4hrs, 2)
Panel installation 0.5hrs. This estimate does not include equipment set up and any other service,
maintenance or repairs that may be required.

F. Material cost and availability: Operator to provide all cost.

G. Tools and Materials:

1. The following special tools are required to perform the maintenance described in this Service
Letter.

ITEM SOURCE

Leak Detector, for HFC-134a Commercially Available.

Power Supply capable of 28VDC, 150 Amps Commercially Available.

For up to 5 hrs continuous duty.

Refrigerant Recovery/Recycle equipment Commercially Available.

Meeting SAE J1990 or J2209 specifications.

Manifold Gauge Set, R-134a, with Commercially Available.

automotive service connections.

Refrigeration Vacuum Pump. Commercially Available.

Scale with 0.1 lb. increments (minimum). Commercially Available.

Scale with 10 gram increments is acceptable
Scale with .01 kilogram increments is acceptable

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Thermometer, 2 each Commercially Available.

2. The following material may be required to perform maintenance described in this manual.

ITEM SOURCE

Refrigerant, HFC-134a Commercially Available.

NOTE: Always use virgin refrigerant. DO NOT use recycled refrigerant.

Lubricant, Refrigeration (HFC-134a) Commercially Available.

Sanden SP-20 (PAG) or PAG-100
Mopar P/N 82300349

NOTE: PAG oil absorbs atmospheric moisture very quickly. Never leave the compressor or oil
container exposed to air for prolonged time. Tightly reseal the oil container and compressor
immediately after exposing the oil to air.

H. Weight and Balance: Compliance with this Service Letter does not effect previous
calculations.

I. Electrical Load Data: Compliance with this Service Letter does not effect previous
calculations.

J. References: Not applicable.

II. CHARGING INSTRUCTIONS

NOTE 1: NEVER INVERT THE REFRIGERANT BOTTLE WHEN SERVICING OR CHARGING

THE SYSTEM. LIQUID REFRIGERANT WILL DAMAGE THE COMPRESSOR.

NOTE 2: ANYTIME THE SYSTEM HAS BEEN OPEN TO AMBIENT CONDITIONS OR YOU
SUSPECT THE SYSTEM HAS BEEN CONTAMINATED WITH AIR OR MOISTURE REPLACE
THE RECEIVER-DRYER BEFORE YOU EVACUATE THE SYSTEM.

NOTE 3: USE ONLY VIRGIN REFRIGERANT IN THIS SYSTEM. DO NOT RETURN

REMOVED REFRIGERANT TO THIS SYSTEM.

NOTE 4: DO NOT ADD OIL WITH THE REFRIGERANT. ONLY ADD OIL TO THE
CRANKCASE OF THE COMPRESSOR. THE SYSTEM MUST BE DISCHARGED TO ADD OIL.

NOTE 5: SEE SECTION III. FOR “TOPPING OFF” PROCEDURES.

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NOTE 6: SYSTEMS THAT ARE NOT COOLING AFTER A TOPPING OFF CHARGE MAY
HAVE DEFECTIVE PARTS. REFER TO CMM Z26-89600 FOR TROUBLE SHOOTING
PROCEDURES.

NOTE 7: WITH R-134a REFRIGERANT THE BUBBLES DO NOT CLEAR IN THE SIGHT
GLASS LIKE R-12. DO NOT ATTEMP TO USE THIS METHOD TO DETERMINE IF THE
SYSTEM IS ADEQUATELY CHARGED.

A. EVACUATION

1. Attach the manifold gauges to the 1) Vacuum pump (yellow hose), 2) discharge (high side) service
port (red hose), 3) the suction (low side) service port (blue hose). Make sure all valves are closed.

2. Pull a deep vacuum for at least 4 hours. Follow the vacuum pump manufacturer recommendations
and procedures for pump operation.

a. When the vacuum pump is running open the 1) valve on the yellow hose (if it has one) to the
vacuum pump, 2) high side (red) valve on the manifold gauges and 3) low side (blue) valve on the
manifold gauges.

b. After 30 minutes of evacuation close the high side (red) valve on the manifold gauges and the low
side (blue) valve on the manifold gauges. Note the vacuum reading. The needle should not move
on either gauge. Wait 5 minutes and check the readings, the vacuum reading should not move
toward zero. DO NOT turn off the pump.

1. If the needle has moved toward zero there is a leak in the system. Stop the procedure and
repair all leaks. After all leaks have been repaired start the evacuation procedure over with
Step 1.

2. If the needle did not move open the valves and continue with the evacuation.

c. Continue to evacuate for at least 3.5 hours after Step 2., b. NOTE: BEFORE you turn off the
vacuum pump close all valves (red and blue on the gauge set and any on the yellow hose)

B. STATIC CHARGE Refer to the aircraft to aircraft maintenance manual for the amount of refrigerant
to be added for that aircraft. If there is not an established amount of refrigerant refer to section C., 6.

1. Attach the manifold gauges to the 1) refrigerant bottle (yellow hose), 2) discharge (high side)
service port (red hose), 3) the suction (low side) service port (blue hose). Make sure all valves are
closed.

2. Bleed the hose (yellow) from the refrigerant bottle to the manifold gauge set to remove all air.
Place the refrigerant bottle on the scale.

3. Weigh the refrigerant bottle.

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4. The system OFF. Introduce a static charge into the system. NEVER LIQUID CHARGE THE
SYSTEM.

a. Open the valve on the refrigerant bottle.

b. Open high side valve (red) on the manifold gauge set.

c. Open the low side valve (blue) on the manifold gauge set.

d. Continue to introduce refrigerant until both the high side and low side gauges stabilize and are
reading the same OR the if the system has an established target weight DO NOT exceed the target
weight. When the target weight is achieved charging is complete.

e. Close both the high side and low side valves on the manifold gauge set.

C. RUNNING CHARGE

1. Place the thermometer so you are reading the temperature of the air as it enters the condensing coil
(just before the fan blades).

2. Turn the system ON. Record the temperature of the air entering the condensing coil.

3. Add 25°F (14°C) to the temperature reading for the target condensing temperature.

EXAMPLE 1: (air temp entering coil 93°F) 93 + 25 = 118F

(air temp entering coil 34°C) 34 + 14 = 48C

4. Using the Temperature-Pressure Chart (See TABLE 1) read the corresponding (R-134a) pressure
for temperature calculated in Example 1.

EXAMPLE 2: 118°F =>166 psig.

5. METHOD TO PERFORM RUNNING CHARGE OF A SYSTEM WITH KNOWN TARGET

WEIGHT. If a maximum charge weight (target weight) has been established charge using steps C.,
5., a and C., 5., b.

a. To charge, slowly open the low side (blue) valve on the manifold gauge set until the low side
maximum reading is 40 psig. NOTE: NEVER OPEN THE HIGH SIDE VALVE WHILE THE
SYSTEM IS RUNNING.

b. Continue to charge until you reach the target weight. NOTE: THE TARGET WEIGHT
INCLUDES THE AMOUNT OF REFRIGERANT INTRODUCED DURING STATIC
CHARGE PLUS THE AMOUNT INTRODUCED DURING THE RUNNING CHARGE. When
the target weight is achieved close all valves. The Suction (low side) should be 30 psig ± 7 psig.
Charging is complete.

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6. METHOD TO DETERMINE A TARGET WEIGHT: Calculate a target high side target pressure
using Steps C.,1, C.,2, C.,3, C.,4 (see Example 1 and Example 2).

a. To charge, slowly open the low side (blue) valve on the manifold gauge set until the low side
maximum reading is 40 psig. NOTE: NEVER OPEN THE HIGH SIDE VALVE WHILE
THE SYSTEM IS RUNNING.

b. Continue to charge until you reach the calculated discharge (high side) pressure. When the
target pressure is achieved close all valves. The Suction (low side) should be 30 psig ± 7 psig.
Charging is complete.

c. When charging is complete weigh the bottle and determine weight of the refrigerant charge
introduced into the system. (Starting weight)-(end weight) = (total charge weight) This would
be your target weight for a dry system. NOTE: THE TARGET WEIGHT INCLUDES THE
AMOUNT OR REFRIGERANT INTRODUCED DURING STATIC CHARGE PLUS THE
AMOUNT INTRODUCED DURING THE RUNNING CHARGE.

III. TOPPING OFF

1. Place the thermometer so you are reading the temperature of the air as it enters the condensing coil
(just before the fan blades).

2. Turn the system ON. Record the temperature of the air entering the condensing coil.

3. Add 25°F (14°C) to the temperature reading for the target condensing temperature.

EXAMPLE 1: (air temp entering coil 93°F) 93 + 25 = 118F

(air temp entering coil 34°C) 34 + 14 = 48C

4. Using the Temperature-Pressure Chart (See TABLE 1) read the corresponding (R-134a) pressure
for temperature calculated in Example 1.

EXAMPLE 2: 118°F (48°C) =>166 psig.

5. Continue to charge until you reach the calculated discharge (high side) pressure. When the
target pressure is achieved close all valves. The Suction (low side) should be 30 psig ± 7 psig.
Charging is complete.

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TEMPERATURE - PRESSURE CHART

TEMP PRESSURE (PSIG) TEMP PRESSURE (PSIG)

F° C° R-134a F° C° R-134a

50 10 45.5 100 37.8 124.3

52 47.7 102 128.5
54 50.1 104 132.9
56 52.3 106 137.3
58 55.0 108 142.8
60 15.6 57.5 110 43.3 146.5
62 60.1 112 151.3
64 62.7 114 156.1
66 65.5 116 161.1
68 68.6 118 166.1
70 21.1 71.2 120 48.9 171.3
72 74.2 122 176.6
74 77.2 124 182.0
76 80.3 126 187.5
78 83.5 128 193.1
80 26.7 86.8 130 54.4 198.9
82 90.2 132 204.7
84 93.6 134 210.7
86 97.1 136 216.8
88 100.7 138 223.0
90 32.2 104.4 140 60 229.4
92 108.2 142 235.8
94 112.1 144 242.4
96 116.1 146 249.2
98 120.1 148 256.0
150 65.6 263.0

TABLE 1.

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