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Hartzell I-1500 Owner's Manual

Combustion heater i-series
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Hartzell Engine Technologies LLC
2900 Selma Highway
Montgomery, AL 36108, USA
Tel: 334-386-5400 Fax: 334-386-5410
C C O O M
O O W
99M90
Rev. New
M B B U U S S T T I I O O N N H H E E A A T T E E R R
I I - - S S E E R R I I E E S S
W N N E E R R S S M
P P / / N N 9 9 9 9 M
H H E E A A T T E E R R
M O O D D E E L L S S
M
I I - - 1 1 5 5 0 0 0 0
I I - - 2 2 5 5 0 0 0 0
I I - - 3 3 5 5 0 0 0 0
I I - - 5 5 0 0 0 0 0 0
M A A N N U U A A L L
M 9 9 0 0
21-40-01
Title Page
Issued: May 9, 2012

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  • Page 1 Hartzell Engine Technologies LLC 2900 Selma Highway Montgomery, AL 36108, USA Tel: 334-386-5400 Fax: 334-386-5410 C C O O M M B B U U S S T T I I O O N N H H E E A A T T E E R R...
  • Page 2 All rights 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 21-40-01 99M90...

  • Page 3: Table Of Contents

    I-Series Combustion Heater Owners Manual Table of Contents DESCRIPTION PAGE Title Page Copyright Statement Table of Contents Warning Letter Record of Revisions Record of Temporary Revisions Service Publication List List of Effective Pages xiii List of Illustrations List of Tables xviii AIRWORTHINESS LIMITATIONS A.0 - General...
  • Page 4 I-Series Combustion Heater Owners Manual Table of Contents (cont’d) TESTING 6.0 - General 6.1 - Testing 6.2 - Pressure Decay Test 6.3 - Testing Combustion Air Blower After Brush Change 6.4 - Testing Spark Plug 6.5 - Testing Miscellaneous and Optional Components SPECIAL TOOLS 7.0 - General 7.1 - Required Safety Equipment...

  • Page 5: Issued: May

    Please be certain to give it your undivided attention. Thank you for choosing a Hartzell Engine Technologies LLC Combustion Heater. Maintained properly, it will give you safe and reliable service for many years to come.
  • Page 6 I-Series Combustion Heater Owners Manual INTENTIONALLY LEFT BLANK 21-40-01 99M90 Page: vi Issued: May 9, 2012 Rev. New...

  • Page 7: Description Page

    I-Series Combustion Heater Owners Manual Record of Revisions Issue Page Inserted Revision Date Revised Description Date Letter 5-09-12 All pages Original Issue 99M90 21-40-01 Page: vii Rev. New Issued: May 9, 2012...
  • Page 8 I-Series Combustion Heater Owners Manual Record of Revisions Issue Page Inserted Revision Date Revised Description Date Letter 21-40-01 99M90 Page: viii Issued: May 9, 2012 Rev. New...

  • Page 9: Record Of Temporary Revisions

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

  • Page 11: Service Publication List

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

  • Page 13: List Of Effective Pages

    I-Series Combustion Heater Owners Manual List of Effective Pages Content of Pages Page Date of Latest Revision Title Page - New - 5-09-12 Copyright statement New - 5-09-12 Table of Contents - iii & iv New - 5-09-12 Warning Letter v &...
  • Page 14 I-Series Combustion Heater Owners Manual List of Effective Pages Content of Pages Date of Latest Revision Page Reserved 21-40-01 99M90 Page: xiv Issued: May 9, 2012 Rev. New...

  • Page 15: List Of Illustrations

    Type I - Spark Plug Cleaning Figure 4.2 - Type III - Spark Plug Cleaning Figure 6.1 - Type I - Spark Plug Gap (Used in I-1500 model only.) Figure 6.2 - Type II - Spark Plug (for I.D. purpose only) Figure 6.3 -...
  • Page 16 I-Series Combustion Heater Owners Manual INTENTIONALLY LEFT BLANK 21-40-01 99M90 Page: xvi Issued: May 9, 2012 Rev. New...

  • Page 17: List Of Tables

    I-Series Combustion Heater Owners Manual List of Tables PAGE Basic Model Numbers (Inconel ® ) Table 1.1 - Table 3.1 - Troubleshooting - Heater 99M90 21-40-01 Page: xvii Rev. New Issued: May 9, 2012...
  • Page 18 I-Series Combustion Heater Owners Manual INTENTIONALLY LEFT BLANK 21-40-01 99M90 Page: xviii Issued: May 9, 2012 Rev. New...

  • Page 19: Airworthiness Limitations

    I-Series Combustion Heater Owners Manual AIRWORTHINESS LIMITATIONS General Information CAUTION: THE AIRWORTHINESS LIMITATIONS HEREIN ARE THOSE MANDATED BY HARTZELL ENGINE TECHNOLOGIES LLC. THESE LIMITATIONS MINIMUM REQUIRED MEET CONTINUED AIRWORTHINESS BUT MAY BE SUPERCEDED BY MORE STRINGENT REQUIREMENTS AS PUBLISHED BY THE FAA, AIRCRAFT, ROTORCRAFT OR OTHER MANUFACTURERS THAT USE THESE COMPONENTS IN THEIR APPLICATIONS.
  • Page 20 I-Series Combustion Heater Owners Manual INTENTIONALLY LEFT BLANK 21-40-01 99M90 Page: A-2 Issued: May 9, 2012 Rev. New...
  • Page 21 DAMAGE. REFER TO THE HET WEBSITE FOR THE MOST RECENT REVISION LEVEL. This owners manual has been approved by Hartzell Engine Technologies LLC to provide the proper methods and procedures that A/P Mechanics, FAA approved repairmen, and/or other approved facilities should use for incidental maintenance of Hartzell Engine Technologies LLC I-Series heaters as may be indicated by the owner.

  • Page 22: About The Manual

    Inconel ® combustion tubes which do not apply to the current B-Series heater AD. * Model I-1500 is smaller in diameter. B. The manual describes maintenance on heater or components as they may be installed on the aircraft/rotorcraft. Maintenance tasks must be accomplished by competent qualified personnel using appropriate equipment.

  • Page 23: How To Use The Manual

    Utilize the aircraft manufacturers AFM, POH, and other service manuals and related publications before returning the aircraft to service. All inquires concerning this or other HET manuals should be directed to Hartzell Engine 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”.
  • Page 24 I-Series Combustion Heater Owners Manual CONTINUITY: The continuous path for the flow of current in an electrical circuit. DESIGN HOLDER: This may be defined as the company or entity responsible for design and certification of an aviation product. Type Certificate (TC), Supplemental Type Certificates (STC), and Form 337 Field Approvals (or foreign equivalents) are typical examples.

  • Page 25: Model Identification

    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 Technologies (HET) Heater units. 99M90 21-40-01 Page:1-5 Rev. New Issued: May 9, 2012...

  • Page 26: Model Number Identification

    I-Series Combustion Heater Owners Manual Model number Identification Table 1.1- Basic Model Numbers (Inconel ® ) 21-40-01 99M90 Page:1-6 Issued: May 9, 2012 Rev. New...

  • Page 27: Warranties

    Owners Manual Warranties Hartzell Engine Technologies LLC (HET) offers a Limited warranty with each new, overhauled, or rebuilt heater assembly or component (parts) it sells through it’s distribution system. NO expressed or implied warranty exists when repairing, overhauling, or rebuilding any assembly or component using this manual except as it may already apply to any new HET replacement part purchased.
  • Page 28 I-Series Combustion Heater Owners Manual INTENTIONALLY LEFT BLANK 21-40-01 99M90 Page:1-8 Issued: May 9, 2012 Rev. New...

  • Page 29: Description And Operation

    I-Series Combustion Heater Owners Manual Chapter 2 DESCRIPTION OF OPERATION DESCRIPTION 2.0 General A. The cabin heater is designed to provide fresh, conditioned (heated) air from outside the aircraft to warm the crew and passenger areas during any phase of flight. In addition, the heater is designed to maintain a desired cabin temperature within the limitations of the given heater.

  • Page 30: Component Operation

    I-Series Combustion Heater Owners Manual DESCRIPTION Component Operation Spark Spray Ignition The controlled atomized spray from a specially designed spray nozzle, coupled with high voltage spark plug ignition, ensures instant firing and continuous burning under all flight conditions. Spark spray ignition combined with the exclusive HET whirling flame combustion has been proved by millions of hours of heater operation in all types of aircraft throughout the world.
  • Page 31 I-Series Combustion Heater Owners Manual DESCRIPTION Component Operation (cont’d) The Electric Fuel Pump Aviation Gasoline Applications (See Figure 2.3) For aviation gasoline applications, the electric fuel pump provides fuel pressure for ground operation and during flight. (The heater may be operated from the engine fuel pump, provided the fuel pressure output is controlled within the operating pressure range of the heater).
  • Page 32 I-Series Combustion Heater Owners Manual DESCRIPTION Component Operation (cont’d) There are several additional components required to allow the heater to function effectively. These components are used on most models but not all (will vary with heater application). The description below provides a better understanding of how typical heaters of various types function.
  • Page 33 I-Series Combustion Heater Owners Manual DESCRIPTION Component Operation (cont’d) Air Blower This blower is attached to the inlet end of the heater assembly and provides a source of ventilating air through the heater. Ram air from the ventilating air intake scoop is normally used during flight.

  • Page 34: Operating Description

    I-Series Combustion Heater Owners Manual OPERATION Operating - Description Operating Controls The typical basic schematic diagram (Figure 2.8) shows in addition to the heater circuit, an aircraft/rotorcraft supplied control circuit. For the purpose of this manual, this circuit will be used to describe heater operation. However, the customer control circuit can and will vary in different installations and may have additions or changes added by the aircraft/rotorcraft design holder.

  • Page 35: General

    I-Series Combustion Heater Owners Manual Chapter 3 TROUBLESHOOTING General The purpose of this chapter is to provide a troubleshooting reference for the owner/operator to help diagnose conditions that may be found in the heater operation before placing the aircraft/rotorcraft into service repair. The owners responsibility in this chapter is to observe and record the fault. The cabin combustion heater is virtually a self contained design, however there are many variations in the aircraft/rotorcraft design from manufacturer to manufacturer and model to model.
  • Page 36 I-Series Combustion Heater Owners Manual Procedure Prior to Repair: (cont’d) Check the aircraft/rotorcraft fuel supply and supply lines. Heater fuel pump and heater installations vary greatly from airframe to airframe. The distance and geometry of the supply lines can affect the ability to supply fuel to the heater. Twists and turns as well as corrosion, in the supply lines over time may cause restrictions.
  • Page 37 I-Series Combustion Heater Owners Manual Troubleshooting (cont’d) TABLE 3.1 Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Heater fails to light. Master switch or circuit breaker Turn ON master switch or close circuit breaker. OFF. (See aircraft AFM or POH for operation.) Low voltage supply. Apply external power supply.
  • Page 38 I-Series Combustion Heater Owners Manual Troubleshooting (cont’d) TABLE 3.1 Troubleshooting (cont’d) TROUBLE PROBABLE CAUSE REMEDY Ventilating air "MASTER" switch "OFF". Broken Energize the "MASTER" switch. Check & repair blower fails to run. or loose wiring to motor. wiring. (See aircraft AFM or POH for operation.) Circuit breaker open.
  • Page 39 I-Series Combustion Heater Owners Manual Troubleshooting (cont’d) TABLE 3.1 Troubleshooting (cont’d) TROUBLE PROBABLE CAUSE REMEDY Heater starts then Lack of fuel at heater. Check fuel supply through all components from goes out. the tank to the heater. Make the necessary corrections.
  • Page 40 I-Series Combustion Heater Owners Manual Intentionally Left Blank 21-40-01 99M90 Page: 3-6 Issued: May 9, 2012 Rev. New...

  • Page 41: Cleaning

    I-Series Combustion Heater Owners Manual Chapter 4 CLEANING General This chapter indicates the proper cleaning methods and materials for cleaning the heater for maintenance or repair. Except for cosmetic cleaning of the heater exhaust pipe on the exterior of the aircraft/rotorcraft, all cleaning activities must be performed by an appropriately licensed or approved mechanic.

  • Page 42: Exterior Cleaning

    I-Series Combustion Heater Owners Manual NOTE: Prior to cleaning the heater whether mounted on the aircraft or as removed, observe and note condition. Look for any signs of hot air or exhaust leaks, electrical arcing from wiring or ignition, and cracks or tears in the heater jacket or other heater parts.

  • Page 43: Spark Plug Cleaning

    Owners Manual Spark Plug Cleaning Type I Spark Plug (for I-1500 model only) Cleaning is accomplished on a conventional aircraft type spark plug cleaner, except that it may be necessary to use several adapters in order to raise the long extension of the plug far enough out of the cleaner nozzle opening to provide an effective job.
  • Page 44 Type I spark plugs are used only in the I-1500 model heater. Type III spark plugs are used on on the remaining HET I-Series combustion heaters.

  • Page 45: Check

    I-Series Combustion Heater Owners Manual Chapter 5 CHECK General This chapter calls out the various checks and inspections needed to assure reliable and safe operation of the combustion heater while in service. It is the owners responsibility to observe and understand the task and the time it occurs. These required checks are listed in hours time in service (TIS) or calendar time whichever is applicable.
  • Page 46 I-Series Combustion Heater Owners Manual Periodic Inspection Checks (cont’d) Note: It is recommended that a timing meter be used on the heater assembly to establish heater hours of operation. If a timing meter is not used, count one (1) heater hour for each two (2) flight hours for normal aircraft operation.
  • Page 47 I-Series Combustion Heater Owners Manual Periodic Inspection Checks (cont’d) 500 Hours time in service and each 500 hours thereafter ( or 60 months, the first to occur ). Inspection shall be conducted on all I-Series heaters (including new, rebuilt, upgraded, or overhauled).

  • Page 48: Bi-Annual Maintenance Checks

    I-Series Combustion Heater Owners Manual Bi-Annual Maintenance Checks The heating system should be inspected at regular intervals, the frequency of which should be determined by the type of service and the conditions under which the aircraft or rotorcraft is operated. It is recommended that in addition to the periodic inspection requirements, inspection/maintenance should be made at least twice a year, preferably to coincide with the onset of cold weather and warm weather.

  • Page 49: Testing

    I-Series Combustion Heater Owners Manual Chapter 6 TESTING General WARNING: THERE ARE NO OWNER/OPERATOR MAINTENANCE ACTIVITIES PERMITTED ON HET COMBUSTION HEATERS. THE FOLLOWING TESTING PROCEDURES MUST BE ACCOMPLISHED BY A QUALIFIED LICENSED MECHANIC OR REPAIRMAN FAMILIAR WITH AIRCRAFT HEATING SYSTEMS. FAILURE TO OBSERVE THIS WARNING MAY COMPROMISE THE COMPONENT OR THE APPLICATION IT IS USED IN.

  • Page 50: Pressure Decay Test

    I-Series Combustion Heater Owners Manual Testing (cont’d) B. Precautions WARNING: WHETHER THE HEATER IS INSTALLED OR REMOVED, MAKE SURE THAT THE AREA IN AND AROUND THE AIRCRAFT, ROTORCRAFT, OR SHOP IS SECURE AND THE TESTING AREA IS WELL VENTILATED. MAKE SURE THAT ALL STAFF AND PERSONNEL ARE WARNED THAT TESTING IS PROGRESS.

  • Page 51: Testing Combustion Air Blower After Brush Change

    Three types of spark plugs are used on HET Combustion Heaters. I-Series heater models use Type III Spark Plug exclusively except for the I-1500 which uses a Type I spark plug. The data shown for the Type II Spark Plug below is for identification purposes on I-Series heaters which have been upgraded.
  • Page 52 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: Testing Miscellaneous And Optional Components

    I-Series Combustion Heater Owners Manual Testing Spark Plug (cont’d) NOTE: If the Type III spark plug fails to clean up properly and/or if electrodes are badly eroded, it should be replaced. NO RE-GAPPING OF TYPE III SPARK PLUG IS POSSIBLE DO NOT BEND THE CENTER ELECTRODE OR THE DISK ON TOP OF THE CENTER ELECTRODE.
  • Page 54 I-Series Combustion Heater Owners Manual Testing Miscellaneous and Optional Components (cont’d) A. Test ventilating air and combustion air motors for correct rpm and current draw: Connect motor to correct voltage power supply (12 or 24 volts DC). Rotation should be counter clockwise when viewed from the shaft end.

  • Page 55: Special Tools

    I-Series Combustion Heater Owners Manual Chapter 7 SPECIAL TOOLS General This chapter indicates the Special tools necessary to perform maintenance or repair. These tools are designed use by licensed mechanics or in shops specializing in aircraft combustion heaters. The tools in this chapter are those other than standard mechanics hand tools. CAUTION: THE SPECIAL TOOLS LISTED HEREIN ARE GENERALLY PURCHASED UNLESS AN EQUIVALENT IS INDICATED.
  • Page 56 Pressure Decay Test Kit 26E24-1 (Kit of required parts for decay test not using below tester.) - or - Pressure Decay Tester P/N PDT 285B -or- P/N PDT 286B The above special tools, may be purchased from: Hartzell Engine Technologies LLC Phone: (334) 386-5400 2900 Selma Highway...

  • Page 57: General Maintenance

    I-Series Combustion Heater Owners Manual Chapter 8 GENERAL MAINTENANCE General WARNING: THERE ARE NO OWNER/OPERATOR MAINTENANCE ACTIVITIES PERMITTED ON HET COMBUSTION HEATERS. THE FOLLOWING MAINTENANCE PROCEDURES MUST BE ACCOMPLISHED BY A QUALIFIED LICENSED MECHANIC OR REPAIRMAN FAMILIAR WITH AIRCRAFT HEATING SYSTEMS. FAILURE TO OBSERVE THIS CAUTION MAY COMPROMISE THE COMPONENT OR THE APPLICATION IT IS USED IN.

  • Page 58: Bi-Annual Maintenance

    I-Series Combustion Heater Owners Manual Bi-annual Maintenance The heating system should be inspected at regular intervals, the frequency of which should be determined by the type of service and the conditions under which the aircraft or rotorcraft is operated. It is recommended that in addition to the periodic inspection requirements, inspection/maintenance should be made at least twice a year, preferably to coincide with the onset of cold weather and warm weather.

  • Page 59: Combustion Air Blower Maintenance

    I-Series Combustion Heater Owners Manual Combustion Air Blower Maintenance: (Refer to Figure 8.1 & 8.2) A. Removal: Remove access panels if necessary to reach the combustion air blower assembly. Disconnect the electrical cable connection at the most convenient location. Disconnect the air tube between the blower and combustion air adapter on the heater. If the combustion air blower inlet adapter is used, disconnect it from the inlet tubing.
  • Page 60 I-Series Combustion Heater Owners Manual Combustion Air Blower Maintenance: (cont’d) C. Installation: (Refer to Figure 8.1 & 8.2) Prior to installing the combustion air blower, inspect all parts of the assembly for loose screws, loose nuts, and poor ground connection on the blower housing. Make sure the blower wheel is tight on the shaft and properly located in the housing.
  • Page 61 I-Series Combustion Heater Owners Manual Combustion Air Blower Maintenance: (cont’d) Fig. 8.1 Typical Combustion Air Blower Assemblies (round) Fig. 8.2 Typical Combustion Air Blower Assemblies (square). 99M90 21-40-01 Page: 8-5 Rev. New Issued: May 9, 2012...

  • Page 62: Spark Plug Maintenance

    Three types of spark plugs are used on HET combustion heaters. The I-Series Aircraft Combustion Heaters uses a Type III in all models except the I-1500 which uses a Type I. The Type I and Type III are described and pictured in Chapter 6, Figures 6.1 and 6.3, of this manual. All of the testing procedures for the spark plug are Chapter 6 as well.

  • Page 63: Vibrator Assembly Maintenance

    I-Series Combustion Heater Owners Manual Spark Plug Maintenance: (cont’d) C. Inspection and Servicing (Type III Spark Plug) Inspect the Type III spark plug , if it fails to clean up properly and/or if electrodes are badly eroded, it should be replaced. No re-gapping of the Type III is possible. Do not bend the center electrode or the disk on the at the center electrode.

  • Page 64: Ventilating Air Blower Maintenance

    I-Series Combustion Heater Owners Manual Ventilating Air Blower Maintenance A. Removal: (See Figure 8.4) If the heater is equipped with an adapter and screen assembly, remove it from the blower housing by removing the three screws and lockwashers. Loosen the four screws and rotate the blower and motor housing to disengage the notched end from the four screws in the end of the heater jacket.
  • Page 65 I-Series Combustion Heater Owners Manual Ventilating Air Blower Maintenance: (cont’d) NOTE: Due to the variation in motor availability, the motor installed in your particular installation may not have available brushes or replaceable brushes. In this case, the motor must be replaced. D.
  • Page 66 I-Series Combustion Heater Owners Manual Ventilating Air Blower Maintenance: (cont’d) NOTE: Due to the variation in motor application, the motor installed in your particular installation may not have available or replaceable bearings. In this case, the motor must be replaced. Check the IPC Chapter of the P/N 99M91 Overhaul &...
  • Page 67 I-Series Combustion Heater Owners Manual Ventilating Air Blower Maintenance: (cont’d) Fig. 8.5 Typical Ventilating Air Blower Ass’y (pressurized heater). 99M90 21-40-01 Page: 8-11 Rev. New Issued: May 9, 2012...

  • Page 68: Fuel Nozzle Maintenance

    I-Series Combustion Heater Owners Manual Fuel Nozzle Maintenance: No periodic maintenance is required on the fuel nozzle. If it is suspect that the fuel nozzle is clogged or not spraying the proper pattern as may be found in Chapter 3, Troubleshooting, it may be removed and cleaned or replaced in lieu of overhauling the heater.

  • Page 69: Fuel Pump Maintenance

    I-Series Combustion Heater Owners Manual 8.11 Fuel Pump Maintenance: (See applicable aircraft service manual) The heater fuel pump or pumps are largely dependent on the design of the particular installation on a specific aircraft or rotorcraft. Some installations require low pressure or high pressure pumps and others require two pumps placed in series to obtain the pressure and flow required for supplying fuel from a tank to the heater.
  • Page 70 I-Series Combustion Heater Owners Manual 8.11 Fuel Pump Maintenance: (cont’d) Fig. 8.6 Typical Fuel Pump Components (low pressure pump) Fig. 8.7 Typical Fuel Pump Components (high pressure pump) 21-40-01 99M90 Page: 8-14 Issued: May 9, 2012 Rev. New...

This manual is also suitable for:

I-5000I-2500I-3500

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