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  #1  
Old 07-13-2019, 04:53 AM
Dustyone Dustyone is offline
 
Join Date: Oct 2012
Location: Brisbane,Austalia
Posts: 170
Default MAX Air-Con Cooling, Airflow Systems

MAX A/C Cooling
with AirFlow Systems Light Aircraft Air-Conditioning

I was approached by RV-1O Builder Jason Merritt to assist with the installation of his Air-Con unit.
Jason lives and operates in Central Australia and the brief was to install the most effective A/C unit we could.

I already have an Air Flow Systems A/C in my own aircraft and although it works well, the Aerosport Roof Console has been the largest stumbling block with free air delivery being heavily restricted by the rear bulk head and the vent system . What works extremely well with Ram Air @ over 160 knts ,does not work well with a scroll fan that most A/C units use.
In my own aircraft I added a 4 Axial fan to pressurise the delivery at 2 psi, this has helped a lot however at the cost of more weight and power requirements.

We tried many options to increase airflow delivery, external ducting, side vents and Axial boost fans but what we stumbled across was the old axiom that simpler is nearly always better.

While testing the massive 300 cfm Evap unit that Airflow Systems sells, I found that by reversing the delivery unit and letting the Scroll fan blow straight in the cabin, angled up,it deliverers a MASSIVE amount of air at a good velocity along the roof of the aircraft where it hits the windscreen and then flows down over the body of the Pilot and Co-Pilot.

So, Introducing VH-BKK



With the A/C unit now reversed I needed to design an effective intake air system. I originally tried only two intakes but still found a drop in RPM so a third was added.
The net result is that the cabin air is circulated at a very high rate with each cycle getting cooler.





(This unit is 1 kg lighter than my unit. my total system including Compressor was 23 kg so VH-BKK is 21 1/2 kg)

A lot of work was put into lowering the compressor into the cowl to make the L/H Cowl intake as unrestricted as possible. New Idler extensions and compressor spacers were made. Bill at Airflow Systems said he will be adding the required extensions and spacers to those builders who require them.

Spacing the A/C compressor outwards by 7/16 and using the new longer idler arm meant a new longer belt was required and a relief cut into the lower cowl.


Before Lowering Compressor ...



....and the new Compressor location.


The intake ramp was modified and the removable rubber transitions were added.



continued.......
__________________
Ashley Miller
RV-10 #40597
Dual SDS CPI
http://www.vansairforce.com/communit...d.php?t=140051
Airflow Systems Air-Con
http://www.vansairforce.com/communit...4&postcount=15
VH-XTE 600hrs +
Redcliffe,Brisbane
Australia
Photos : https://goo.gl/photos/zsfBeVofHMe4ze7i7
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  #2  
Old 07-13-2019, 05:16 AM
Dustyone Dustyone is offline
 
Join Date: Oct 2012
Location: Brisbane,Austalia
Posts: 170
Default

The finished aircraft and results were outstanding!

Jason is to be applauded for his vision with this aircraft, a summary of great choices that has resulted in another wonderful RV-10.

Finished interior.....


Finished Cowl.....


Finished intake ramp....

( there is more ongoing work being done in this area to completly isolate the lower cowl. more later )





Flight testing at summer OAT's have proved that there is a marked increase in air delivery and cabin comfort with the pilot and co-pilot getting instant relief once the A/C is turned on.

This day is on the ground with 28 deg C OAT,


This is the Outlet temp and airflow idling on the ground. 7.08 M/sec @ 5.3 Deg C



The air flow at the rear seat station is approx 12 " wide and 4" deep, high against the roof console. Flow is 6.8 M/Sec @ 16.2 deg C



At the front panel, the air flow has slowed and spread out, the flow is approx 18" wide and 8" deep , flowing at 2.26 M/Sec @ 17.8 deg C.
( this is the air the rebounds back to the Pilot and Co-Pilot. )

This is the first light aircraft system where I find myself reaching to turn down the A/C during summer !! The only challenge has been that for standard ops, the rear pax may need a scarf and beanie .



I will be at Osh this year if anyone wants to chat more about this system.

I know that Bill is also designing an improved air delivery system for those builders that still want to retain the standard roof console delivery.
His new ducting would be a large improvement over my first home built system I installed over 5 years ago.
__________________
Ashley Miller
RV-10 #40597
Dual SDS CPI
http://www.vansairforce.com/communit...d.php?t=140051
Airflow Systems Air-Con
http://www.vansairforce.com/communit...4&postcount=15
VH-XTE 600hrs +
Redcliffe,Brisbane
Australia
Photos : https://goo.gl/photos/zsfBeVofHMe4ze7i7
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  #3  
Old 07-13-2019, 05:44 AM
Gash's Avatar
Gash Gash is offline
 
Join Date: Aug 2009
Location: Goodyear, Arizona
Posts: 777
Default

Thanks for the detailed write up. That's a beautiful installation! The temperature was 44 C here in Phoenix yesterday, so I always appreciate seeing how others beat the heat.
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Karl, Goodyear, Arizona (KGYR)
RV-7, Flying
Extra 330LX, Flying
RV-8, Sold
Bearhawk 4-Place, Sold
=VAF= donor 2020

Last edited by Gash : 07-13-2019 at 05:47 AM.
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  #4  
Old 07-13-2019, 07:10 AM
rv6ejguy's Avatar
rv6ejguy rv6ejguy is offline
 
Join Date: Mar 2005
Location: Calgary, Canada
Posts: 5,493
Default

Nice work and good detail on how things were done Ashley. Great looking airplane.
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Ross Farnham, Calgary, Alberta
Turbo Subaru EJ22, SDS EFI, Marcotte M-300, IVO, Shorai- RV6A C-GVZX flying from CYBW since 2003- 436.1 hrs. on the Hobbs,
RV10 95% built- Sold 2016
http://www.sdsefi.com/aircraft.html
http://sdsefi.com/cpi2.htm


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  #5  
Old 07-14-2019, 04:28 AM
Dustyone Dustyone is offline
 
Join Date: Oct 2012
Location: Brisbane,Austalia
Posts: 170
Default

Hey Karl,

That is nearly Aussie Temps

Last year I departed Mt Isa in Central Australia it was 43 deg C on the ground .
It was still 30 deg C as we past 6000 ft !

Bill's A/C will always take off approx 15 degrees C from what ever OAT I see.

Love having an A/C aircraft !
__________________
Ashley Miller
RV-10 #40597
Dual SDS CPI
http://www.vansairforce.com/communit...d.php?t=140051
Airflow Systems Air-Con
http://www.vansairforce.com/communit...4&postcount=15
VH-XTE 600hrs +
Redcliffe,Brisbane
Australia
Photos : https://goo.gl/photos/zsfBeVofHMe4ze7i7
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  #6  
Old 07-14-2019, 09:31 AM
ssonixx ssonixx is offline
 
Join Date: Mar 2013
Location: Dallas, TX
Posts: 47
Default Nice work.

Hi Ashley,
Very impressed with your install.

I am contemplating an installation as well and I wanted to understand more about a paragraph in your explanation. Can you expand on your statement about reversing the delivery unit?

“While testing the massive 300 cfm Evap unit that Airflow Systems sells, I found that by reversing the delivery unit and letting the Scroll fan blow straight in the cabin, angled up,it deliverers a MASSIVE amount of air at a good velocity along the roof of the aircraft where it hits the windscreen and then flows down over the body of the Pilot and Co-Pilot.”

If you can explain what the difference is from a normal “stock” installation, I would appreciate it.

Thank you!

Last edited by ssonixx : 07-14-2019 at 06:37 PM.
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  #7  
Old 07-14-2019, 10:24 AM
Gash's Avatar
Gash Gash is offline
 
Join Date: Aug 2009
Location: Goodyear, Arizona
Posts: 777
Default

Quote:
Hi Karl,
Very impressed with your install.
Ashley Miller is the maestro here...I (Karl) am just in the group of admiring bystanders.
__________________
Karl, Goodyear, Arizona (KGYR)
RV-7, Flying
Extra 330LX, Flying
RV-8, Sold
Bearhawk 4-Place, Sold
=VAF= donor 2020
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  #8  
Old 07-14-2019, 06:38 PM
ssonixx ssonixx is offline
 
Join Date: Mar 2013
Location: Dallas, TX
Posts: 47
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Karl, sorry. Pointed my post to Ashley. Thank you.
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  #9  
Old 07-14-2019, 07:05 PM
BobTurner BobTurner is offline
 
Join Date: Dec 2011
Location: Livermore, CA
Posts: 6,084
Default

Im wondering what kind of reinforcement there is on the aft side of the aft baggage wall - considering that Vans says that they are structural.
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  #10  
Old 07-15-2019, 02:48 AM
Dustyone Dustyone is offline
 
Join Date: Oct 2012
Location: Brisbane,Austalia
Posts: 170
Default

Hi Gavin,

With the standard install , the goal is to get the output of the Evaporator and some how force all the air into the roof console.

If you click on my photo file in the signature below, you will see many photos of my first install over 5 years ago.



In the above photo you can see the Evap intake on the left and the output on the right. The hose outlets connect to the roof console bulkhead pass-through.

When I say the Evap is reversed, it is simply turned around so that there are no restrictions from connections to the roof console and the MAX out put of the Evap floods the cabin.
The performance of the evap can be reduced if there is any restriction to the Evap intake. To that end , I tried only two air intakes but found 3 was needed. The results were that the cabin air is cycled much faster and the net cooling effect for the paxs is greatly increased.

The Roof Console is the biggest restriction in the A/C, in my aircraft I have 8 vents and two rear mounted cabin flood vents,it works very well however , where this customer operates it is very HOT most of the time and he wanted more than my install delivered.

The FLIR camera showed me a lot of where all the cold air was blocked,



I hope that helps,
__________________
Ashley Miller
RV-10 #40597
Dual SDS CPI
http://www.vansairforce.com/communit...d.php?t=140051
Airflow Systems Air-Con
http://www.vansairforce.com/communit...4&postcount=15
VH-XTE 600hrs +
Redcliffe,Brisbane
Australia
Photos : https://goo.gl/photos/zsfBeVofHMe4ze7i7
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