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AirComm Corporation Bell 407 Heating System Instructions for Continued Airworthiness OEM User Manual
AirComm Corporation Bell 407 Heating System Instructions for Continued Airworthiness OEM User Manual
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HEATER SERVICE MANUAL 407H-200M-1 Revision D December 29, 2011 AIR COMM CORPORATION 3330 AIRPORT ROAD BOULDER, CO. 80301 PHONE: 303-440-4075 FAX: 303-440-6355 [email protected] INSTRUCTIONS FOR CONTINUED AIRWORTHINESS BELL HELICOPTER 407 CABIN HEATER SYSTEM
HEATER SERVICE MANUAL 407H-200M-1
Revision D Page i
Record of Revisions
REVISION
NUMBER ISSUE
DATE DATE
INSERTEDBY REVISION
NUMBER ISSUE
DATE DATE
INSERTEDBY
A 05/09/96 N/A NS
B 06/17/96 N/A NS
C 10/31/11 N/A MS
D 12/29/2011 N/A RL
HEATER SERVICE MANUAL 407H-200M-1
Revision D Page ii
LIST OF REVISIONS
Rev Description Date
A Revised page I-1 407H-516 was -510, 407H-514 was -512 05/09/96
B Revised pages 12 & 13 of service instructions to reflect revised Electrical
installation 11/19/92
C Re-formatted entire document to meet 8110.54A and added options for glass
cockpit version of 407 (407GX) 10/28/11
D Clarified parts nomenclatures to match up in various references. Added Chin
Bubble Defroster references. Expanded installation procedures and added
figures accordingly to Chapters 3 and 6. 12/29/11
LIST OF EFFECTIVE PAGES
Title
Page(s) Revision No.
Record of Revisions i D
List of Revisions ii D
List of Effective Pages ii D
Table of Contents iii-iv D
Chapter 0 Introduction 0-1 to 0-3 D
Chapter 1 Airworthiness Limitation Section 1-1 C
Chapter 2 Inspections 2-1 D
Chapter 3 Location and Access 3-1 to 3-15 D
Chapter 4 Placards and Markings 4-1 D
Chapter 5 Servicing 5-1 C
Chapter 6 Standard Practices 6-1 to 6-10 D
Chapter 7 Troubleshooting 7-1 C
HEATER SERVICE MANUAL 407H-200M-1 Revision D Page iii TABLE OF CONTENTS Identification Title Page CHAPTER 0 INTRODUCTION 1. Scope 0-1 2. Purpose 0-1 3. Arrangement 0-1 4. Applicability 0-1 5. Definitions 0-1 6. Abbreviations 0-1 7. Precautions 0-1 8. Units of Measure 0-2 9. Information Essential to the Continued Airworthiness of the Cabin Heater System 0-2 10. Reference Documents 0-2 11. Distribution 0-2 12. Changes to Instructions for Continued Airworthiness (ICA) 0-2 13. System Description and Operation 0-2 CHAPTER 1 AIRWORTHINESS LIMITATION SECTION 1. Airworthiness Limitations 1-1 CHAPTER 2 INSPECTIONS 1. Inspection Requirements 2-1 CHAPTER 3 LOCATION AND ACCESS 1. Location of Cabin Heater Features 3-1 2. Figure 3.1 Heater System Major Components 3-2 3. Figure 3.2 Heater System FWD and AFT Ejectors/Assemblies 3-3 4. Figure 3.3 Forward Flow Control Heater Ejector Outlet 3-4 5. Figure 3.4 Forward Flow Control Heater Ejector Detail 3-5 6. Figure 3.5 Heater Control Valve Assembly 3-6 7. Figure 3.6 Heater Shutoff Valve 3-7 8. Figure 3.7 Engine Bleed Air Components w/Drain Valve 3-8 9. Figure 3.8 Heater System Temp Sensors 3-9 10. Figure 3.9 Heater Overtemp Indicator (GX) 3-10 11. Figure 3.10 Existing Overtemp Annunciator (STD) 3-11 12. Figure 3.11 Heater Power Switch 3-11 13. Figure 3.12 Heater System Electrical Schematic (STD) 3-12 14. Figure 3.13 Heater System Electrical Schematic (GX) 3-13 CHAPTER 4 PLACARDS AND MARKINGS 1. Heater System Placards and Markings 4-1 CHAPTER 5 SERVICING 1. Servicing Requirements 5-1
HEATER SERVICE MANUAL 407H-200M-1 Revision D Page iv TABLE OF CONTENTS (Continued) Identification Title Page CHAPTER 6 STANDARD PRACTICES 1. B-Nut/Fitting Safety Wire Procedure 6-1 2. Removal Replacement Cockpit Heater Ejector Assembly 6-2 3. Removal Replacement Cabin AFT Heater Ejector Assembly 6-4 4. Removal Replacement Heater Shutoff Valve 6-5 5. Removal Replacement Heater Control Valve 6-6 6. Removal Replacement Windshield Defroster Control Valve 6-7 7. Removal Replacement Temp Sensors 6-7 8. Removal Cleaning Replacement Drain Valve 6-8 9. Removal Replacement Bleed Air Plumbing 6-9 CHAPTER 7 TROUBLESHOOTING 1. System Troubleshooting Chart 7-1
HEATER SERVICE MANUAL 407H-200M-1 Revision D Page 0-1 Chapter 0 INTRODUCTION 1. SCOPE The scope of this manual encompasses the scheduled and unscheduled maintenance procedures for the continued airworthiness of the Air Comm Corporation cabin heater system installed in the Bell 407 series helicopter. 2. PURPOSE The purpose of this manual is to provide the aircraft mechanic in the field with the necessary information to maintain the cabin heater system. 3. ARRANGEMENT This manual is arranged by chapters which are broken down into paragraphs and sub- paragraphs. All of the chapters and paragraphs are listed in the front of this manual in the Table of Contents, and are further identified by their individual page number. 4. APPLICABILITY This manual is applicable to Bell Helicopter 407 models that are equipped with the Air Comm Corporation kit number 407H-200, -201, -202 and -203 cabin heater systems. 5. DEFINITIONS The following terms are provided to give a ready reference to the meaning of some of the words contained within this manual. These definitions may differ from those given by a standard dictionary. Outside Ambient Air Temperature (OAT): The temperature of the air surrounding a person or object outside the helicopter. Inside Ambient Air Temperature (IAT): The temperature of the air as measured at the inlets of the heater system. 6. ABBREVIATIONS cm: Centimeters Lbs: Pounds LH: Left hand RH: Right hand 7. PRECAUTIONS The following precautions are found throughout this manual, and will vary depending on the seriousness of the Hazard or Condition: WARNING: May be a maintenance procedure, practice, condition, etc., which could result in personal injury or loss of life. CAUTION: May be a maintenance procedure, practice, condition, etc., which could result in damage or destruction of equipment. NOTE: May be a maintenance procedure, practice, condition, etc., or a statement which needs to be highlighted.
HEATER SERVICE MANUAL 407H-200M-1 Revision D Page 0-2 8. UNITS OF MEASUREMENT All measurements contained within this manual are given in the United States standard measurement. 9. INFORMATION ESSENTIAL TO THE CONTINUED AIRWORTHINESS OF THE CABIN HEATER SYSTEM. This manual provides information which is required for operation and maintenance of the Air Comm air cabin heater system installed in the Bell model 407 series helicopter. After completion of the cabin heater installation this document must be placed with the appropriate existing aircraft documents. 10. REFERENCE DOCUMENTS The approval basis of the system covered by this ICA is Supplemental Type Certificate SR00221DE. 11. DISTRIBUTION This document is to be placed with the aircraft maintenance records at the time of system installation. Changes will be made to this document in response to “Safety of Flight”, and or “Non-safety of Flight” issues. Any changes will result in a revision to this document. Revisions shall be noted in the Record of Revisions (page i), and on the List of Revisions (page ii) of this manual. In addition to the revision of the manual, those changes categorized as “Safety of Flight” shall have a Service Bulletin issued to the operator providing the necessary information to comply with, and or to correct, the “Safety of Flight” issue. Replacement, and or revised copies of this manual may be acquired by contacting: Air Comm Corporation Service Department 3330 Airport Road Boulder, CO.80301 Phone No. 303-440-4075 Fax No. 303-440-6355 [email protected] 12. CHANGES TO INSTRUCTIONS FOR CONTINUED AIRWORTHINESS Changes made to a line or paragraph of this document will be indicated by a vertical bar in the right hand margin, while a complete page change will be indicated by a vertical bar next to the page number. (Example: Any change will appear with a vertical bar next to that change). 13. SYSTEM DESCRIPTION AND OPERATION The cabin heating system is a bleed air type system which consists of bleed air components (plumbing), an electrically actuated shutoff valve, a heater control valve, and four heater ejector assemblies. When the switch is in the “HEATER” position and the heater control valve is opened, bleed air flows from the engine compressor through the bleed lines to the heater ejectors/assemblies, where it is mixed with cabin air and exhausted to both the front and rear passengers. The forward heater ejectors are located under the front seats and the aft
HEATER SERVICE MANUAL 407H-200M-1 Revision D Page 0-3 heater ejectors are located on the sides of the rear aft-facing seats in the cabin. The warm air in the cockpit is ducted forward through ejector outlets which are located in the forward seat box structure. The warm air for the cabin is exhausted through the heater ejectors located on each side of the aft-facing cabin seats. Outlet flow can be individually adjusted by rotation of flow control ejector outlets in the front, or by rotating the flow control knob on the aft heater ejectors. The heater control valve assembly is mounted under the pilot’s seat and the heater control handle is located on the front of the seat box. It controls heater bleed air to the forward and aft heater ejectors. A shutoff valve in the engine compartment, mounted just FWD of the firewall, is electrically actuated by the heater power switch mounted in the overhead console. The shutoff valve closes if a heater over-temperature condition is sensed. Temperature sensors are installed throughout the aircraft as part of the heater system. If a sensor detects and over temperature condition, the heater overtemp annunciator (STD) or indicator (GX) will illuminate. This will also automatically close the shutoff valve. The heater power switch must be cycled to the OFF position in order to reset the shutoff valve and the heater overtemp annunciator/indicator. The system includes a windshield defroster system. The defroster system contains a defroster control valve, located in the center console and defroster ejectors, located in each defroster eyebrow. The ejectors pump warm air across the windshield. The original defroster blowers supplied with the aircraft are not required but may remain installed at the discretion of the operator. The defroster and heater may be used simultaneously. An optional chin bubble defroster is available. It includes two additional defroster ejectors located adjacent to each chin bubble. Warm air is controlled by the windshield defroster control valve. A drain valve (engine bleed air components) is incorporated as a part of the heater system. This valve is used to drain cleaning solution overboard when washing the internal parts of the engine. The drain valve is located inside the RH engine access door and incorporates a spring loaded ball valve that is normally open when the engine is off. The drain valve is closed when the heater lines are pressurized during normal engine operation.
HEATER SERVICE MANUAL 407H-200M-1 Revision C Page 1-1 Chapter 1 AIRWORTHINESS LIMITATION SECTION The Airworthiness Limitations section is FAA approved and specifies maintenance required under paragraph 43.16 and 91.403 of the Federal Aviation Regulations unless an alternate program has been FAA approved. 1. Airworthiness Limitations No airworthiness limitations associated with this design change
HEATER SERVICE MANUAL 407H-200M-1 Revision D Page 2-1 Chapter 2 INSPECTIONS 1. Inspection Requirements Item Annually Prior to Heating Season Special Inspection Information Ref. Figure Heater Control Valve Assembly & Windshield Defroster Control Valves X Check valve for ease of mechanical operation and security. 3.1, 3.6, 3.7 Engine Bleed Air Components (Plumbing) X Check for security and evidence of air leaks around fittings. Check insulation, hose and tube assemblies for damage or deterioration. 3.1 Heater Ejectors/ Assemblies X Visually inspect heater ejector nozzles for evidence of blockage, corrosion, deterioration or deformation through the heater air outlet. No blockage of the heater ejector nozzles is allowable. Check ejector flow control valve for freedom of operation. 3.1 - 3.5 Placards & Markings X Check for security and legibility. 4.1 Drain Valve (Engine Bleed Air Components) X 1. Remove valve and disassemble. 2. Clean as required. 3. Check for O-ring damage. 4. Reassemble valve and reinstall. NOTE Slight leakage is acceptable 5. With engines operating ensure valve assembly is closed. 3.9 Heater Overtemp Annunciator / Indicator X Verify operation of the heater overtemp warning light. Temp Sensor specifications: a. Normally open b. Closes at 160°F. This results in illumination of the overtemp light and closure of the firewall shutoff valve. c. When temp sensor cools to 140±5°F, it will reopen and overtemp annunciator / indicator will extinguish. 3.11, 3.12 Shutoff Valve X Check shutoff valve for security and operation. Conduct functional check during ground operation. NOTE Air pressure must exist at the inlet side of the valve to ensure correct valve operation Functional Check 1. Ensure heater switch is in the OFF position. 2. With aircraft engines running ensure there is no airflow to the heater ejectors. 3. Place the heater switch to the HEATER position. 4. Check for warm air at each of the air ejectors. 5. Return switch to the OFF position. 3.8, 3.14, 3.15