Hartzell I-1500 Owner'S Manual Download

Page: 7 / 70

99M90

21-40-01

Page: vii

Rev. New

Issued: May 9, 2012

I-Series Combustion Heater
Owners Manual

Record of Revisions

Revision

Letter

Issue

Date

Page

Revised

Description

Inserted

Date By

New

5-09-12

All pages

Original Issue

Summary of Contents for I-1500

Page 1: ...way Montgomery AL 36108 USA Tel 334 386 5400 Fax 334 386 5410 C CO OM MB BU US ST TI IO ON N H HE EA AT TE ER R I I S SE ER RI IE ES S O OW WN NE ER RS S M MA AN NU UA AL L P P N N 9 99 9M M9 90 0 H HE EA AT TE ER R M MO OD DE EL LS S I I 1 15 50 00 0 I I 2 25 50 00 0 I I 3 35 50 00 0 I I 5 50 00 00 0 ...

Page 2: ...ights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Hartzell Engine Technologies LLC I Series Combustion Heater Owners Manual ...

Page 3: ...finitions 1 3 1 4 Model Identification 1 5 1 5 Serial Number Identification 1 5 1 6 Model Number Identification 1 6 1 7 Warranties 1 7 DESCRIPTION AND OPERATION 2 0 General 2 1 2 1 Component Operation 2 2 2 2 Operating Description 2 6 TROUBLESHOOTING 3 0 General 3 1 3 1 Procedure Prior to Repair 3 1 3 2 Troubleshooting 3 2 CLEANING 4 0 General 4 1 4 1 Required Safety Equipment 4 1 4 2 Recommended ...

Page 4: ...General 7 1 7 1 Required Safety Equipment 7 1 7 2 Material Required 7 1 7 3 Special Tool Specification 7 1 GENERAL MAINTENANCE 8 0 General 8 1 8 1 Bi Annual Maintenance 8 2 8 2 Periodic Maintenance 8 2 8 3 Overhaul Maintenance Manual 8 2 8 4 Combustion Air Blower Maintenance 8 3 8 5 Spark Plug Maintenance 8 6 8 6 Vibrator Assembly Maintenance 8 7 8 7 Ventilating Air Blower Maintenance 8 8 8 8 Fuel...

Page 5: ... heater as well as the installation maladies have and will occur It is essential that the heater be properly operated per the airplane flight manual or pilots operating hand book and maintained according to recommended service procedures found herein and in the applicable aircraft service or maintenance manual The heater must be observed closely in inspection and operation to detect any potential ...

Page 6: ...21 40 01 99M90 Page vi Issued May 9 2012 Rev New INTENTIONALLY LEFT BLANK I Series Combustion Heater Owners Manual ...

Page 7: ...1 40 01 Page vii Rev New Issued May 9 2012 I Series Combustion Heater Owners Manual Record of Revisions Revision Letter Issue Date Page Revised Description Inserted Date By New 5 09 12 All pages Original Issue ...

Page 8: ...21 40 01 99M90 Page viii Issued May 9 2012 Rev New I Series Combustion Heater Owners Manual Record of Revisions Revision Letter Issue Date Page Revised Description Inserted Date By ...

Page 9: ...99M90 21 40 01 Page ix Rev New Issued May 9 2012 I Series Combustion Heater Owners Manual Record of Temporary Revisions Temporary Rev Letter Page Number Date Removed Issue Date By By ...

Page 10: ...21 40 01 99M90 Page x Issued May 9 2012 Rev New I Series Combustion Heater Owners Manual Record of Temporary Revisions Temporary Rev Letter Page Number Date Removed Issue Date By By ...

Page 11: ...I Series Combustion Heater Owners Manual 99M90 21 40 01 Page xi Rev New Issued May 9 2012 Pub Number Description Heater Affected Service Publication List ...

Page 12: ...21 40 01 99M90 Page xii Issued May 9 2012 Rev New I Series Combustion Heater Owners Manual Pub Number Description Heater Affected Service Publication List ...

Page 13: ...d of Revisions ix x New 5 09 12 Service Publication List xi xii New 5 09 12 List of Effective Pages xiii xiv New 5 09 12 List of Illustrations xv xvi New 5 09 12 List of Tables xvii xviii New 5 09 12 Airworthiness Limitations A 1 A 2 New 5 09 12 Introduction 1 1 thru 1 8 New 5 09 12 Description of Operation 2 1 thru 2 6 New 5 09 12 Troubleshooting 3 1 thru 3 6 New 5 09 12 Cleaning 4 1 thru 4 4 New...

Page 14: ...I Series Combustion Heater Owners Manual 21 40 01 99M90 Page xiv Issued May 9 2012 Rev New Content of Pages Date of Latest Revision List of Effective Pages Page Reserved ...

Page 15: ...ure 4 2 Type III Spark Plug Cleaning 2 4 Figure 6 1 Type I Spark Plug Gap Used in I 1500 model only 6 4 Figure 6 2 Type II Spark Plug for I D purpose only 6 4 Figure 6 3 Type III Spark Plug Gap 6 5 Figure 8 1 Typical Combustion Air Blower round 8 5 Figure 8 2 Typical Combustion Air Blower square 8 5 Figure 8 3 Typical Ignition System non pressurized heater 8 11 Figure 8 4 Typical Ventilating Air B...

Page 16: ...21 40 01 99M90 Page xvi Issued May 9 2012 Rev New I Series Combustion Heater Owners Manual INTENTIONALLY LEFT BLANK ...

Page 17: ...I Series Combustion Heater Owners Manual 99M90 21 40 01 Page xvii Rev New Issued May 9 2012 List of Tables PAGE Table 1 1 Basic Model Numbers Inconel 1 3 Table 3 1 Troubleshooting Heater 3 3 ...

Page 18: ...I Series Combustion Heater Owners Manual 21 40 01 99M90 Page xviii Issued May 9 2012 Rev New INTENTIONALLY LEFT BLANK ...

Page 19: ... OR OTHER MANUFACTURERS THAT USE THESE COMPONENTS IN THEIR APPLICATIONS FAILURE TO OBSERVE THESE LIMITATIONS MAY COMPROMISE THE COMPONENT OR THE APPLICATION IT IS USED IN AND MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR SUBSTANTIAL PROPERTY DAMAGE A 1 Airworthiness Limitation Statement 1 0 The Airworthiness Limitations Chapter is FAA accepted and specifies maintenance required under Secs 43 16...

Page 20: ...21 40 01 99M90 Page A 2 Issued May 9 2012 Rev New I Series Combustion Heater Owners Manual INTENTIONALLY LEFT BLANK ...

Page 21: ...ection 1 1 defines preventive maintenance as simple or minor preservation operations and the replacement of small standard parts not involving complex assembly operations Under FAR Part 43 Appendix A Paragraph C Preventive Maintenance there are no specific allowances for preventive maintenance to be performed on combustion heaters All maintenance including preventative maintenance must be performe...

Page 22: ...ombustion heater under TSO C20 A 1 is controlled by the applicable design holder TC STC etc F Service Bulletins Service Information Letters and other important publications may be critical to continued safe operation of the heater and should always be referenced along with this manual Be advised that some service publications do not have a closing action but are re occurring and will require conti...

Page 23: ...gine Technologies LLC 2900 Selma Highway Montgomery AL 36108 Tel 334 386 5400 Fax 334 386 5410 or by our website http www hartzellenginetech com contact 1 3 Definitions This paragraph defines the warnings and notifications used in this manual Warnings place critical attention to use of tools materials procedures or limitations which must be followed without deviation to avoid injury to the technic...

Page 24: ...trical current Infinite resistance RFI Radio Frequency Interference Electrical interference created from commutator brush connection the coil controller or other poor connections SELF PILOTING FLAME The whirling flame design is stable and sustains combustion under the most adverse conditions because it is whirled around itself many times Therefore ignition is continuous and the combustion process ...

Page 25: ... applicable means a variation in the developed part number 34D51 is the developed part number for the heater assembly IS indicates Inconel Spec tube and will come after the part number 1 5 Serial number Identification HET mfg by H A 11 07 0001 Location Built Year Code Month Code Serial Code Example above S N HA11070001 Built in Alabama in 2011 July first unit of the month Hartzell Engine Technolog...

Page 26: ...21 40 01 99M90 Page 1 6 Issued May 9 2012 Rev New I Series Combustion Heater Owners Manual 1 6 Model number Identification Table 1 1 Basic Model Numbers Inconel ...

Page 27: ... returned through an authorized HET distributor in a manner prescribed by that specific distributor The affected heater must be received by the factory fully assembled and not altered in any way for disposition by HET warranty department Warranty shall be denied for any heater received altered modified or disassembled The HET Limited warranty policy in affect for your heater was delivered with the...

Page 28: ...21 40 01 99M90 Page 1 8 Issued May 9 2012 Rev New I Series Combustion Heater Owners Manual INTENTIONALLY LEFT BLANK ...

Page 29: ...nd necessary radio noise suppressors Optional equipment includes a duct switch fuel pump fuel regulator and shutoff valve combustion air blower inlet adapter and a fanning strip electrical connectors All components except the combustion air blower duct switch fuel regulator and shutoff valve and fuel pump are combined into one assembly to facilitate installation and service operations The optional...

Page 30: ...ich converts 12 volts or 24 volts to high voltage oscillating current to provide a continuous spark across the spark gap A shielded high voltage lead connects the ignition assembly to the spark plug Combustion air enters the combustion chamber tangent to its surface and imparts a whirling or spinning action to the air This produces a whirling flame that is stable and sustains combustion under the ...

Page 31: ... a fuel control system and on to the heater fuel nozzle Pump supply is adequate for use with all kerosene burning heaters in the HET line and can be mounted in a horizontal position or vertically mounted provided the motor end of pump is at the top Installation note regardless of mounting position an appropriate drain connection should be selected in the adapter section between motor and pump so a...

Page 32: ...re control switches or the master switch is de energized The fuel nozzle is located near the fuel shutoff point thus providing a no drool feature Combustion Air Pressure Switch This switch is mounted on the combustion air inlet tube of the heater to sense combustion air differential pressure across the heater The differential pressure is the difference between pressure of combustion air coming int...

Page 33: ...e the circuit interrupted by a switch not the line from blower to ground See Figure 2 5 Combustion Air Blower See Figure 2 6 2 7 This centrifugal type blower is normally mounted separately from the heater to permit more flexibility for installation It supplies combustion air to the combustion chamber of the heater typically from outside air See Figure 2 7 Performance of the combustion air blower i...

Page 34: ... is a normally closed momentary OFF switch that de energizes or breaks the lock in power to the safety relay to stop the heater fuel supply and ignition Operating Procedure 1 Place the MASTER SWITCH in the ON or HEAT position The ventilating air and combustion air blowers should operate and the red HEATER FAILURE LIGHT should be on 2 Energize then release the HEATER START SWITCH The red HEATER FAI...

Page 35: ...rocedure Prior to Repair WARNING FOR APPROVED MECHANICS SERVICING OR REPAIRING THE HEATER GREAT CARE AND CAUTION MUST BE TAKEN TO AVOID HAZARDOUS SITUATIONS WHEN MOUNTED AND USED ON OR OFF AN AIRCRAFT OR ROTORCRAFT THE HEATER WILL PRESENT A PHYSICAL HAZARD FROM THE USE OF AVIATION FUEL AND POTENTIAL UNCONTAINED FIRE IN THE SURROUNDING AREA IN ADDITION HEATER IGNITION SYSTEMS SUPPLY HIGH VOLTAGE EL...

Page 36: ...ow proper combustion to occur or will stop it all together Exhaust restriction may not be apparent as a restriction may form due to the positioning of the exhaust pipe or scarf in the wind stream The aircraft or rotorcraft service or maintenance manual will indicate proper placement of the heater exhaust system and overboard requirements 3 2 Troubleshooting WARNING 1 THERE ARE NO OWNER OPERATOR MA...

Page 37: ... but not Remove and repair or replace fuel pump building up sufficient pressure Restriction in fuel nozzle orifice Remove the nozzle and clean or replace it See 99M91 Overhaul Maintenance manual Testing chapter Fuel heater solenoid not working Remove and check solenoid Replace if faulty Fuel lines clogged or broken Inspect all lines and connections It may be necessary to disconnect lines at variou...

Page 38: ...urned out motor Remove combustion air motor for overhaul or replacement of motor Heater fires but Insufficient fuel supply Ice or Inspect fuel supply to heater including shutoff burns unsteadily water in system fuel lines valve solenoid valve fuel filter fuel pump and fuel lines Make necessary repairs Spark plug partially fouled Replace spark plug CAUTION Do not create spark gap by holding lead to...

Page 39: ...on or aircraft service manual Inoperative or chattering com Check adjust or replace switch bustion air pressure switch Inoperative overheat switch Check or replace switch Inoperative cycling switch Adjust or replace the switch Low voltage Attach external power See aircraft service manual Heater fails to Fuel solenoid valve in heater Remove and replace solenoid assembly shut off stuck open See 99M9...

Page 40: ...21 40 01 99M90 Page 3 6 Issued May 9 2012 Rev New I Series Combustion Heater Owners Manual Intentionally Left Blank ...

Page 41: ...RESULT IN DEATH SERIOUS BODILY INJURY AND OR SUBSTANTIAL PROPERTY DAMAGE WARNING 2 PROLONGED EXPOSURE TO VOLATILE CLEANING AGENTS IS HAZARDOUS TO YOUR HEALTH USE DEGREASERS AND SOLVENTS IN WELL VENTILATED AREAS USE APPROPRIATE EYE PROTECTION GLOVES AND COTTON APRONS REVIEW ALL SAFETY INFORMATION FOR THE CHEMICAL BEING USED PRIOR TO USING IT CAUTION AGGRESSIVE USE OF CHEMICAL DEGREASERS CLEANING SO...

Page 42: ...aintenance manual P N 99M91 for more detailed cleaning and repair information Components separated during disassembly may be cleaned in several ways Aluminum components Use of degreaser or solvents should be used by spray or wiping however dipping or immersion may be used if attended Aluminum may degrade if left in degreasers or solvents for extended periods of time Consult the directions for the ...

Page 43: ...aise the long extension of the plug far enough out of the cleaner nozzle opening to provide an effective job Plug the ceramic insert cavity at the terminal end of the plug with a piece of paper or cloth to keep out any of the cleaning sand Wipe this cavity out thoroughly with a cloth If after cleaning spark plug porcelain is then white and the electrodes are not eroded re gap the spark plug as des...

Page 44: ...s are used on on the remaining HET I Series combustion heaters Type Ill Spark Plug If the spark plug appears to be in good condition the upper housing and the outer surface of the ground electrode sleeve may be wiped clean with a shop towel moistened with isopropyl alcohol the internal porcelain may be blown clean using shop air directed through the vent holes or through the open end No abrasive c...

Page 45: ...accumulations of soot on the skin of the aircraft Soot accumulates are caused by the heater burning at a fuel rich condition 5 2 Operational Check Typical Heater An operational check should be performed prior to commencing any inspection interval or prior to any unscheduled maintenance to help determine the heater condition 1 Place the MASTER SWITCH in the ON or HEAT position The ventilating air b...

Page 46: ...ance manual or the applicable aircraft rotorcraft service manuals for appropriate details 1 Inspect ventilating and combustion air inlets and exhaust outlet for restrictions and security at the aircraft skin line Check any external scoop and make sure they are not distorted and are securely attached to the aircraft 2 Inspect the drain line to make sure it is free of obstructions Run a wire of the ...

Page 47: ... of the 100 hour inspection 1 If installed disconnect the external fuel shutoff valve apply fuel pressure and check that the valve shuts off fuel completely Internal fuel shutoff check for fuel pressure drop with solenoid shutoff and accompanying fuel drip from heater drain Power on to flow fuel These components are replacement items only 2 If installed disconnect the fuel regulator and shutoff va...

Page 48: ...the inlet from outside air and the outlet into the aircraft cabin if the heater has been inactive After active use check the heater air inlets and cabin air outlets which may become clogged or damaged due to ground debris or icing 3 Ignition System Prior to or after active heater use inspect and clean the spark plug lead end and spring 4 Exhaust System Examine the exhaust tube and shroud if applic...

Page 49: ... activity or maintenance not covered in this manual consult the HET P N 99M91 Overhaul and Maintenance manual All testing activities must be accomplished by properly licensed mechanics or repairmen experienced in aircraft rotorcraft heating systems 6 1 Testing A Equipment 1 Standard tools Standard mechanic s handtools Torque wrench pound inch newton centimeter Torque wrench pound foot newton meter...

Page 50: ...nd or heater or airframe wiring 2 If the heater is tested on an aircraft rotorcraft to observe heater performance make sure that the area in and around the aircraft rotorcraft is secure and the testing area is well ventilated Make sure that all staff and personnel are warned that testing is progress 3 If the heater is being tested on the bench and combustion will occur be sure that the heater is r...

Page 51: ...PLUG OR VIBRATOR AND MAY SHORTEN THE USEFUL LIFE OF THESE ITEMS DO NOT TOUCH THE SPARK PLUG WHILE ENERGIZED IT HAS DANGEROUSLY HIGH VOLTAGE AND MAY CAUSE INJURY OR EVEN DEATH MAKE SURE TO PLUG THE SPARK PLUG HOLE IN THE HEATER TO PREVENT ANY POSSIBILITY OF RESIDUAL FUEL BLOWING OUT AND IGNITING Three types of spark plugs are used on HET Combustion Heaters I Series heater models use Type III Spark ...

Page 52: ...g Used in I 1500 model only 6 4 Testing Spark Plug cont d CAUTION NEVER INSTALL TYPE I OR TYPE II SPARK PLUGS INTO AN I SERIES MODEL I 2500 I 3500 OR I 5000 COMBUSTION HEATER TYPE I IS USED IN I 1500 ONLY DAMAGE MAY OCCUR TO THE HEATER IGNITION UNIT OR THE HEATER MAY NOT FUNCTION OPERATION OF A HEATER WITH A DAMAGED IGNITION UNIT MAY RESULT IN EQUIPMENT DAMAGE OR PHYSICAL INJURY ...

Page 53: ...g The gap between the center electrode disk and ground electrode should be between 0 105 0 015 inch See Figure 6 3 Prior to installation spark plugs can be checked visually for sparking across the gap prior to installing the plug as follows Disconnect the wire from the No 3 terminal on the heater wiring side of the terminal strip to de energize the fuel solenoid valve Connect the high voltage lead...

Page 54: ...pproximately 7500 rpm at rated voltage Current draw for 12 volt motors is approximately five amps and for 24 volt motors is approximately 2 9 amps This can be tested using a mechanical or optical tachometer 3 If current draw is excessive or if speed is too low replace the brushes Recheck both current draw and rpm after brushes are properly run in Refer to Para 6 3 for run in 4 If after replacing b...

Page 55: ...MPROPER TOOL CAN RESULT IN DAMAGE TO THE HEATER AIRCRAFT OR OTHER EQUIPMENT WHICH MAY ALSO LEAD TO PHYSICAL INJURY OR DEATH 7 1 Required Safety Equipment Safety gloves Safety glasses or Protective goggles Protective apron Eye wash station 7 2 Material Required Building materials are not required 7 3 Special Tools Specifications The Special tools listed herein must be purchased Common items are rec...

Page 56: ... LLC Phone 334 386 5400 2900 Selma Highway Fax 334 386 5410 Montgomery AL 36108 USA Website http www hartzellenginetech com NOTE The HET P N PDT 285B and P N PDT 286B contain the Test Box Instruction Manual 94E48 fuel pressure gauge various lines and fittings as well as a selection of expansion bulbs They are intended for use in shops specializing in aircraft combustion heater inspection overhaul ...

Page 57: ...he aircraft Instructions for removal of some components are included provided the installation permits accessibility With the exception of the pressure decay test no special tools are required for normal periodic maintenance of HET aircraft combustion heaters Maintenance indicated under the Periodic Inspection will require use of this manual and or P N 99M91 Overhaul Maintenance manual accomplishe...

Page 58: ...e to ground debris or icing Prior to running heater ventilation and combustion air blowers inspect and clean the inlet and outlet air system Run the blowers to push out any debris from the heater and inspect and clean again 3 Ignition System Prior to active heater use and again after the active heater use inspect and clean the spark plug lead end and spring 4 Exhaust System Examine the exhaust tub...

Page 59: ... the brush shows replacement is not required On Motor Part No s 27D39 and 34D30 it is necessary to remove motor case to replace brushes 2 Inspect the brush for wear If brushes are worn to a length of 3 16 or less they must be replaced If this limit has not been reached the brushes may be reinstalled in the orientation noted in step 1 3 Looking through the brush guide inspect the commutator which s...

Page 60: ... in the attaching clamp so the air tubing can be connected and slide the tubing into position at the point where it was disconnected during removal Do not tighten until after tightening the motor in the attaching strap 4 Tighten the blower motor mounting strap securely making certain the air tubing is in proper alignment 5 Secure the air tubing by tightening the clamp or installing the sheet metal...

Page 61: ...5 Rev New Issued May 9 2012 I Series Combustion Heater Owners Manual 8 4 Combustion Air Blower Maintenance cont d Fig 8 1 Typical Combustion Air Blower Assemblies round Fig 8 2 Typical Combustion Air Blower Assemblies square ...

Page 62: ...RK PLUG WHILE ENERGIZED IT HAS DANGEROUSLY HIGH VOLTAGE AND MAY CAUSE INJURY OR EVEN DEATH MAKE SURE TO PLUG THE SPARK PLUG HOLE IN THE HEATER TO PREVENT ANY POSSIBILITY OF RESIDUAL FUEL BLOWING OUT AND IGNITING CAUTION NEVER INSTALL A TYPE II SPARK PLUG INTO AN I SERIES HEATER SEVERE DAMAGE TO THE HEATER AND HEATER IGNITION UNIT WILL OCCUR AND PHYSICAL INJURY MAY RESULT A Removal Type I Type III ...

Page 63: ... with a deep socket Tighten to a torque of 28 ft lbs 5 Install the grommet in the heater jacket opening Carefully insert the spring connector on the high voltage lead into the spark plug shell press down gently and start the nut on the threads Tighten the nut to 20 ft lbs 8 6 Vibrator Assembly Maintenance see Figure 8 3 if applicable to ignition unit 1 Remove the necessary access panels to reach t...

Page 64: ...wheel on the end of motor shaft and rotate it until the set screw is aligned with the flat side of the motor shaft Tighten the set screw just tight enough to hold it at this time 2 Attach the capacitor and leads assembly to the motor bracket with the screw and lock washer Make sure a good electrical ground connection is made at this point 3 Insert this assembly into the blower housing and position...

Page 65: ...s guide or holder internal noting the orientation of the brush for later reinstallation Remove foreign material from the brush guide and commutator with a stream of filtered oil free compressed air Check for brush wear Inspect the commutator for grooved brush pitting or burning The commutator surface should be smooth and medium brown in color Replace the motor if the commutator or other parts show...

Page 66: ...and lockwasher Remove the thru bolt 3 Remove the housing assembly 4 Carefully remove brushes and holder assembly 5 Remove armature very carefully taking care not to damage the commutator or stator 6 Before replacing the bearings it is advisable to Inspect the components of the motor for condition check the stator wires insulation and check the armature with a growler for performance If armature fa...

Page 67: ...99M90 21 40 01 Page 8 11 Rev New Issued May 9 2012 I Series Combustion Heater Owners Manual 8 7 Ventilating Air Blower Maintenance cont d Fig 8 5 Typical Ventilating Air Blower Ass y pressurized heater ...

Page 68: ...st prior to further operation 8 10 Miscellaneous Components Maintenance Inspection and Servicing NOTE All discrepant parts must be replaced with approved new HET parts and components Destroy and discard removed parts Refer to the applicable portion of the P N 99M91 Overhaul Maintenance manual IPC for specific part numbers for the heater being worked on 1 Discard all rubber parts such as grommets g...

Page 69: ...aft 4 The HET P N 99M91 Overhaul Maintenance manual steps in disassembly must be followed to remove fuel pump components B Inspection and test Typical 1 Inspect all parts visually for damage 2 Inspect the fuel pump electrical resistance by connecting an ohmmeter between the connector terminal and ground on the pump housing Resistance should be between 19 0 and 30 0 ohms for 24 volt models and 4 8 ...

Page 70: ...ge 8 14 Issued May 9 2012 Rev New 8 11 Fuel Pump Maintenance cont d I Series Combustion Heater Owners Manual Fig 8 6 Typical Fuel Pump Components low pressure pump Fig 8 7 Typical Fuel Pump Components high pressure pump ...

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