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LINDSTRAND Series 1 80 Maintenance Manual

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LINDSTRAND TECHNOLOGIES LTD
HOT AIR BALLOON
MAINTENANCE MANUAL
Lindstrand Technologies Ltd
Maesbury Road
Oswestry
Shropshire
SY10 8HA
UK
Tel:
+44 (0)1691 671888
Fax:
+44 (0)1691 679991
www.lindstrandtech.com
All rights reserved. No part of this Manual may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopy, recording, or any information storage and retrieval system, without permission in writing from
Lindstrand Technologies Ltd, Maesbury Road, Oswestry, Shropshire, SY10 8HA, England.
LTL HABMM
Issue 2.0

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Summary of Contents for LINDSTRAND Series 1 80

  • Page 1 All rights reserved. No part of this Manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage and retrieval system, without permission in writing from Lindstrand Technologies Ltd, Maesbury Road, Oswestry, Shropshire, SY10 8HA, England. LTL HABMM...
  • Page 2 RECORD OF AMENDMENTS Date Affected Pages Incorporated By Issue 1 April 2016 Initial Issue Lee Barnfield Per Lindstrand Issue 1.1 July 2016 i, ii, 4 Lee Barnfield Per Lindstrand This revision is approved under the authority of DOA EASA.12J.176 Issue 2.0...
  • Page 3 CHANGE OF OWNERSHIP If the ownership of this balloon changes, it is important for the new owners to contact Lindstrand Technologies Ltd to ensure that they receive Maintenance Manual Amendments and Supplements, as appropriate. CHECKLIST OF PAGES Page No. Issue Page No.
  • Page 4 Future revisions will require approval, signified by an approval number. USE OF THIS MANUAL This manual sets out the maintenance procedure and schedule for all Lindstrand Technologies hot air balloons. As each balloon may have specific features for dedicated systems, every balloon has a dedicated manual showing the serial number on the cover.

  • Page 5: Table Of Contents

    CONTENTS SECTION 1 - INTRODUCTION Purpose of this Manual Applicability Identification of Systems Qualification SECTION 2 - AIRWORTHINESS LIMITATIONS Approval Statement Modification Mandatory Replacement Time Structural Inspection Interval Structural Inspection Procedure Acceptable Damage SECTION 3 - TECHNICAL DESCRIPTION Envelopes Baskets Burners Fuel Systems SECTION 4 - PREVENTATIVE MAINTENANCE...
  • Page 6 CONTENTS Cont..SECTION 6 – BALLOON INSPECTION 100 Hour / Annual Inspection Load Bearing Attachments Burner Fuel Cylinders Baskets Fabric Strength Test Inspection After Overheating Inspection After Hard Landing APPENDICES Appendix “A" Annual / 100 Hour Inspection Checklist Appendix “B” Envelope Repair and Damage Record Appendix "C"...

  • Page 7: Section 1 - Introduction

    Lindstrand Technologies Ltd. APPLICABILITY The information contained within this manual applies to all hot air balloons manufactured by Lindstrand Technologies Ltd under EASA Approval (see Section 3, Technical Description, for a comprehensive list of models covered).

  • Page 8: Section 2 - Airworthiness Limitations

    No other component in Lindstrand Technologies balloons have a mandatory replacement life. INSPECTION INTERVAL The inspection interval for Lindstrand Technologies hot air balloons is one year or 100 hours of flight time; whichever is sooner. If the balloon envelope has more than 250 hours of operational use or an overheat event is thought to have occurred, then a fabric strength test should be carried out.
  • Page 9 ENVELOPE CABLES – NON METALLIC: If any cable has been damaged in a way to expose the Kevlar core (yellow braid) or reduce the flexibility of the exterior polyester cover, the cable must be replaced before the balloon may be flown. FUEL SYSTEM: When any damage exists to fuel hoses, fuel tanks, tank or burner fittings, burner coils, burner frame, or when any fuel leak occurs in any fuel fitting.
  • Page 10 A parachute is located at the top of the envelope and allows for the controlled release of hot air. Partial opening of the parachute valve can be used to cool the balloon. Some Lindstrand Technologies balloons are also equipped with turning vents which allow for the pilot to turn the balloon on its vertical axis while in flight.
  • Page 11 Flight Manual Section 2.1.8. BURNER The Lindstrand Vortech burner is effectively the engine of the hot air balloon. The burner system consists of burners (two), and fuel lines that carry LPG from the fuel tanks to the burners. The burners convert ambient air into hot air, which in turn provides the lift required for flight.
  • Page 12 In addition to the main coil and jet ring, it is possible through the use of the liquid fire valve to ignite un- vaporised propane. This produces a softer flame, that has a lower audible level, but a burn efficiency less than the main coil.

  • Page 13: Envelopes

    SECTION 4 PREVENTATIVE MAINTENANCE WARNING! Installation of any non-approved parts or materials, the modification of any aircraft part, or the utilisation of a non-approved repair method, could result in a hazardous condition which could result in death or injury. PAPERWORK DOCUMENTATION Only preventative maintenance as permitted by this section may be carried out by the balloon owner without sign-off by an appropriately qualified airworthiness inspector.

  • Page 14: Baskets

    4.2.2 Owner / operator Envelope Repairs Any fabric damage to the lower two panels may be repaired by the owner / operator, provided there is no damage to the vertical or horizontal load tapes or any control mechanism. The repair must be made using approved fabric, thread and technique as outlined in Section 5.

  • Page 15: Fuel Systems

    Substitution of carabiners, except as specified in the type design, is prohibited. For further information, please contact Lindstrand Technologies Ltd. Nylon poles must be replaced with Lindstrand Technologies supplied poles only. No other material may be substituted.

  • Page 16: Burners

    BURNERS 4.5.1 Storage and Handling of Burners Although designed to withstand well in excess of typical inflation, flying and landing loads, the burners, as the sole power source for the balloon, are a critical, precision made component and should be treated with care. Burner life and reliability will be shortened significantly through harsh handling.

  • Page 17: Section 5 - Repair And Maintenance

    5.1.1 Envelope Construction Materials This section describes the materials to be used. In case of doubt, please consult Lindstrand Technologies Ltd. It is important to ensure that any repairs performed on the envelope are achieved by using the material listed below.
  • Page 18 Nomex Mutilple Colours Aramid polymer related to nylon, but has 1.5 metre aromatic backbone making it more rigid Roll width and more durable. It has excellent thermal, chemical, and radiation resistance for a polymer material. 20 mm wide Load Tape (light weight) White or Black Polyester or Nylon Load Tape (medium weight) White or Black...

  • Page 19: Envelope Repairs

    Sewing Machines Sewing machines should be of a twin needle variety and for advice and detailed specification on the type of sewing machine and stitching required to repair a Lindstrand Technologies hot air balloon envelope, please contact Lindstrand Technologies. LTL HABMM Issue 2.0...
  • Page 20 5.2.2 Fabric Repairs There are various types of fabric repairs for hot air balloon envelopes, the exact type of repair is often depended on the size of damage or the position of the damage on the envelope. Appendix B provides a quick reference guide for location of damage on the balloon. It is advisable if damage is noted that it is clearly marked on the chart in Appendix B and that the balloon is packed in such a way that damage can be easily found when repairing.
  • Page 21 The damaged panel can be used as a template for the replacement panel, or alternatively pre-cut replacement panels are available from Lindstrand Technologies. The new panel should be stitched in using a French fell seam. Any tapes should be sewn back on and a careful inspection of the repaired area.
  • Page 22 Contact Lindstrand Technologies for further advice with regards to envelope suspension cables. 5.2.11 Parachute Centralising Lines Before removing any damaged cords, measure the length of the relevant cord, or if it is broken, measure the length of the cord adjacent to it.

  • Page 23: Baskets

    5.3.5 Basket Floor All Lindstrand Technologies baskets have a plywood floor. If the floor has cracked through both sides of the floor, then it either must be patched or replaced totally. To patch the floor, remove any protective varnish from the damaged area by sanding prior to bonding the patch in place.
  • Page 24 If more than twelve horizontal strands in a 600 mm by 600 mm area are broken, they must be repaired. If a hole in the wicker exists larger than 100 mm at the widest dimension, it must be repaired. For advice on damage and repair of basket wicker work contact Lindstrand Technologies. LTL HABMM Issue 2.0...

  • Page 25: Fuel Systems

    FUEL SYSTEMS For detailed cylinder maintenance guidance please see relevant cylinder manufacturer’s Maintenance Manual. For Lindstrand Balloons USA fuel cylinders maintenance guidance see Lindstrand Balloons USA Manual for Continued Airworthiness, Section 5.3. BURNERS The Vortech burner has been designed for ease of operation and for ease of maintenance. Most components are complete units so that burners can be returned to service in a short period of time, while the problem component can be maintained in a work shop environment.

  • Page 26: Section 6 - Balloon Inspection

    There is no difference in the parts inspected during an annual or a 100 hour inspection. Completion of an annual or 100 hour inspection must be completed by an appropriately rated person. 6.1.1 Applicability The Maintenance Schedule applies to all Lindstrand Technologies balloons certificated in any category. 6.1.2 Qualification Inspection must be carried out by a properly certified and rated inspector under National Authority of the country of registration.
  • Page 27 6.1.4 Envelope It is recommended that inspection of the envelope be achieved by a gore-by-gore fabric inspection. Inspect the following: The temperature link (temp flag) will be installed in the balloon crown area. Temperature labels must not be removed by operators. Check the temperature label for overheating.

  • Page 28: Load Bearing Attachments

    LOAD BEARING ATTACHMENTS 6.2.1 Envelope Cables All envelope cables on Lindstrand Technologies balloons are manufactured from stainless steel. Replacement with galvanised mild steel is not acceptable. For stainless steel envelope cables, check that there are no broken wires or severe kinks. Slight discolouration due to burning is permissible provided that the flexibility is not reduced.

  • Page 29: Burner

    Check the age of fuel hoses, fuel hoses must be replaced after ten years of service. WARNING! Only approved Lindstrand Technologies fuel hoses may be used! Installation of any other hoses or manifolds is dangerous and is specifically not approved. If unapproved hoses are found connected to the aircraft fuel system, they must be replaced with approved parts.

  • Page 30: Fabric Strength Test

    100 hour / Annual inspection must be reported to Lindstrand Technologies to determine the appropriate action. The balloon must not be flown until it is capable of passing the 100 hour / Annual inspection.
  • Page 31 APPENDIX A ANNUAL / 100 HOUR AIRWORTHINESS INSPECTION CHECKLIST FOR LTL HOT AIR BALLOONS REG NO.: MODEL: ENVELOPE SERIAL NO.: TOTAL ENVELOPE TIME: OWNER: DATE STARTED: WORK ORDER NO.: BASKET PART NO.: SERIAL NO.: TOTAL TIME (if different from envelope): BURNER PART NO.: SERIAL NO.:...
  • Page 32 PART NO.: PART NO.: SERIAL NO.: SERIAL NO.: TOTAL TIME (if different from envelope): TOTAL TIME (if different from envelope): PASS/FAIL DOCUMENTS AND REQUIRED EQUIPMENT Log Book Record (Temperature) label reading in log book Components match aircraft log book All repairs/alterations correctly entered Airworthiness Directives (A/D’s) complied with Flight Manual Present and correct for this model...
  • Page 33 Turning Vent areas: panel behind the outer flap, in each colour. 14 kg, 25 mm grab test over 75 mm span (1 test, warp and weft in each vent in each colour) Recording (Temp.) Label Latest installed. Reading: If previous indicated temp is 127°C or above, install a new dated label, record temp indicated in aircraft log book.
  • Page 34 Lower termination point secure and intact -pulley attachment on double gear Lower pulley / pulleys undamaged, functional, attachment secure FDS Activation Line (Solid Length correct (must allow envelope to streamer Red) without opening valve) No melt or abrasion damage Lower pulley(s) undamaged, functional and secure Turning Vent Rigging (Black No abrasion or melt damage Line)
  • Page 35 Parachute Centering Lines Each line must be checked for correct length, no abrasions, all knots secure Shroud Lines and Upper Shroud lines in good condition, knots secure Pulley Upper pulley in good condition, free running Pulley lubricated with silicone spray Velcro Tabs Clean and free of debris Holding force good...
  • Page 36 Check condition of pulley (if installed in larger balloons) Combination Centering Pull- Check general condition , no abrasion, heat Down Lines damage or excessive dirt Check knot at parachute edge Check attachment to quicklink at red (or red/white) line pulley (secure, no abrasion) BURNER Outer Frame General condition...
  • Page 37 Piezo ignitor actuator set screw secure Check for strong spark to pilot light cup Inspect damage to ceramic tube Bezel ring around ignitor tight Main and Liquid Fire Valves Check for smooth operation and no leaks Pressure Gauge Functions correctly Needle zeros Bezel ring tight Fuel Lines...
  • Page 38 Pilot light / piezo ignitor tested, with each tank (minimum 3 activations) BASKET ID Plate Present, numbers match log book Cushion Floor Removed for basket inspection In good condition Outside Runners In good condition and bolts tight Nylon runner protectors intact and secure Cables Across Bottom Leather / rawhide protective covering in good condition...
  • Page 39 No more than 12 broken horizontal strands in a 600 mm by 600 mm area No excessive breakage of wicker at belt or step holes Flexi Poles Intact Cylinder Straps All present and in good condition Clasps fully functional Rope Handles Check for excessive wear Manifolds (Rego) or Tema Replace fuel hoses after ten years in service...
  • Page 40 O-Rings on Rego style valve Checked for damage Test Rego / Tema fittings for self seal Test QSO valve with burner connected to assure function Protective caps present and in good condition Pressure relief valve clean and covered 15% valve operation checked Tightness of (4) fuel quantity gauge screws checked Tank body free of dents or gouges...
  • Page 41 INSPECTION DAMAGE LOG DAMAGE AREA OR RECOMMENDATION SIGNED COMPONENT LTL HABMM Issue 2.0 Page A1-11...
  • Page 42 APPENDIX B DAMAGE / REPAIR INSPECTION CHART FOR SERIES 1, 24 or 28 GORE ENVELOPE RANGE Panel Init/Date PARA Model No.: Serial No.: Registration No.: LTL HABMM Issue 2.0 Page B1-1...
  • Page 43 APPENDIX B LOWEST NYLON PANEL DESIGNATION LTL HABMM Issue 2.0 Page B1-2...
  • Page 44 APPENDIX C FIGURES AND DIAGRAMS Figure 1a - Series 1, 24 Gore Envelope LTL HABMM Issue 2.0 Page C1-1...
  • Page 45 Figure 1b - Series 1 28 Gore Range 28 GORE SERIES 1 HORIZONTAL CUT LTL HABMM Issue 2.0 Page C1-2...
  • Page 46 Figure 1c - Series Racer 24 Gore Range 24 GORE SERIES RACER HORIZONTAL CUT LTL HABMM Issue 2.0 Page C1-3...
  • Page 47 Figure 2 - Overview of Vortech Double Burner LTL HABMM Issue 2.0 Page C1-4...
  • Page 48 Figure 3 - Load Tape Repairs LTL HABMM Issue 2.0 Page C1-5...
  • Page 49 Figure 4 - Overlying Tape Repairs LTL HABMM Issue 2.0 Page C1-6...
  • Page 50 Figure 5 - Envelope Cable Loop Repairs LTL HABMM Issue 2.0 Page C1-7...
  • Page 51 Figure 6 - Bowline Knot LTL HABMM Issue 2.0 Page C1-8...

This manual is also suitable for:

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