Maintenance Manual - c&d aircraft heaters

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Maintenance Manual for C&D Associates, Inc. Aircraft Combustion Heater Models CD15K, CD25K, CD35K, CD45K CD50K, CD55K and CD70K with P/N’s ending in –1 (dash…
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Maintenance Manual for C&D Associates, Inc. Aircraft Combustion Heater Models CD15K, CD25K, CD35K, CD45K CD50K, CD55K and CD70K with P/N’s ending in –1 (dash one series) (Includes Airworthiness Limitations) MM10001 January 1, 2008 REV. K dated April 16, 2015 FAA Approval has been obtained on technical data in this publication that affects product type design NOTE: No Airworthiness Directives apply at the time of this printing, but “Instructions for Continued Airworthiness” as outlined on page 7 are required. The Airworthiness Limitations Section (Section VI. B.) is MANDATORY. Changes to the Instructions for Continued Airworthiness will be distributed by way of service bulletins and service letters. The Airworthiness Limitations section is FAA approved and specifies maintenance required under section 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. 302 POST ROAD, BUCHANAN, MI, USA PHONE: 269-695-7469 FAX: 269-695-6004 www.aircraftheater.com email: sales@aircraftheater.com Model: P/N S/N Congratulations! You have purchased the world’s highest quality heating system. C&D Associates has been servicing heating systems for over 27 years. Now using the latest modern technology, C&D Associates has received FAA approval to manufacture new TSO-C20 heaters for general aviation aircraft. Installations are available for most twins and some single engine aircraft. Complete heating systems for aircraft with no prior combustion heater, are also available. These units are designed with pilots, passengers, and maintenance personnel in mind. We are confident upon installation and operation of this heater, in accordance with the “Instructions for Continued Airworthiness” contained in this manual; that you will agree on its excellent quality. Please read before performing installation or maintenance of any C&D Associates, Inc. component or system. Warranty New C&D heaters come with 4-yr or 2,000-hrs, whichever comes first, pro-rated warranty. After 1000-hrs of heater operation or 4 years (whichever comes first) the pressure decay test and inspection described in the “Instructions for Continued Airworthiness” becomes mandatory. Any warranty work must be pre-authorized in writing by C&D Associates, Inc. Warranty shipments must be accompanied by proper paperwork reflecting a Warranty Authorization Number obtained directly from C&D Associates, Inc. Return shipments cannot be accepted without this authorization, C&D reserves the right to repair or replace warrantied items. BREAKING ANY TAMPER- PROOF SEAL, OR INTRODUCING TEFLON PRODUCTS (teflon tape, dope ect.) FOR USE AS A FUEL SEALANT VOIDS WARRANTY. C&D is not responsible for aircraft down-time, lost revenues, customs or duties. Factory covers ground freight only in the USA if warranty is authorized. IN NO EVENT SHALL C&D ASSOCIATES, INC. BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGE: however arising, whether in warranty, strict liability, contract, tort, negligence or otherwise, including but not limited to loss of profits, revenue, loss of total or partial use of the products, facilities, services, downtime costs, or claims of purchaser for such or other damages whether on account of products furnished hereunder or delays in delivery thereof, C&D Associates, Inc. liability of any claim shall in no case exceed the purchase price allowable to the product or part thereof which give rise to the claim. Notice of claims against C&D Associates, Inc. must be made in writing within forty-eight (48) hours of discovery affording C&D Associates, Inc. an opportunity to make a prompt investigation of surrounding facts and mitigate any damage which might ensure. Should the responsibility be determined to be C&D Associates, Inc. a waiver by the purchaser of any right later to assert such a claim will be required. Any cause of action against C&D Associates, Inc. arising out of or relating to the contract or the performance hereof shall expire unless bought within one year of the time of accrual thereof. The forgoing limited warranty is exclusive and in lieu of all other warranties expressed or implied, including but not limited to any warranty of merchantability or fitness for particular purpose. Page 1 Dated 1/1/08 Rev K dated 4/16/15 TABLE OF CONTENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TABLE OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION FOR MODEL CD15K, CD25K, CD35K, CD45K, CD50K, CD55K AND CD70K SERIES COMBUSTION HEATERS: I. INTRODUCTION AND GENERAL OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3 II. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 A. Listing of P/N’s per model series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 III. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IV. CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 V. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 VI. (ICA) INSTRUCTIONS FOR CONTINUED AIRWORTHINESS LIMITATIONS SECTION A. Preflight/Operational check and shutdown procedures 7 B. Airworhiness Limitations (MANDATORY) 7 C. Flight Manual Supplement (FMS) Sample 9 NOTE: The FMS supplied with your new heater must be inserted in the aircraft flight manual VII. HEATER MAINTENANCE AND SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A. Removal and Installation 12 B. 100hr/Annual Inspection and operational check 12 C. 250hr/2yr service and inspection 12 D. 1000hr/250hr 4 year service and inspection 12 E. 2000hr service and overhaul 13 F. Heater Pressure Decay(PDT) and combustion air pressure switch test 13 G. Heater disabling 15 VIII. HEATER OVERHAUL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 IX. HEATER ASSEMBLY INSPECTION AND TESTING . . . . . . . . . . . . . . . . . . . . . 16 X. TESTING AFTER INSTALLATION OR OVERHAUL. . . . . . . . . . . . . . . . . . . . . . 23 A. General 23 B. Bench Testing 23 C. Operational Test 23 D. Heat Output – Determining Temperatures – Adjustments 24 XI. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 A. “Heater Quick Check” XII. FIGURES FOR REFERENCE TYPICAL COMBUSTION HEATER CUT-AWAY Figure 21 . . . . . . . . . 31 TYPICAL TEST SET-UP PRESSURE DECAY TEST Figure 22 . . . . . . . . . 32 COMBUSTION AIR SWITCH INSTALLATION Figure 23 . . . . . . . . . 33 TYP. EXHAUST TUBE SEAL SHOWN INSTALLED Figure 24 . . . . . . . . . 34 SPARK PLUG REFERENCES Figure 25 . . . . . . . . . 35 TYPICAL TEST SETUP Figure 26 . . . . . . . . . 36 TYPICAL WIRING SCHEMATICS Figure 27 . . . . . . . . . 37 XIII. PARTS VIEW OF HEATER ASSEMBLY– TYPICAL Figure 28 . . . . . . . . . 38 XIV. ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 XV. PARTS VIEW OF EXPLODED HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . 41 Page 2 Dated 1/1/08 Rev K dated 4/16/15 TABLE OF REVISION REVISION LETTER REVISION DATE INSERTION DATE SECTION DESCRIPTION A 3/25/09 3/25/09 Warranty VII. 4. IX. A. 11. IX. H. 1, 3. IX. H. 1, 3. Added Teflon notes & purging delivery line notes. XIV. Changed amber light to green on rotary heat control. B 9/15/09 9/15/09 Pg 3, 4 Removed model # ref. VII.E.1 IX.A1 Added recommend tube replacement note. XIV. Changed blue light to amber to indicate failure. C 7/27/10 7/27/10 Pg 1 Airworthiness Limitations sect. corrected from IV.B to VI.B. D 3/8/11 3/22/11 XV Removed plug and changed elbow p/n, added 21794 nozzle holder option. E1 7/14/11 7/14/11 Pg 17 Add motor overhaul information. E2 10/3/11 10/3/11 Pg 1, 3, 7 Added models CD50K & CD70K E3 10/3/11 10/3/11 Pg 12 Pg 13 Add note about pdt test. Changed pdt test time from 250hr/2 yr to 250hr/4 yr. F 2/3/12 2/3/12 Pg 37 Added 4-10 pressurized wiring schematic. G 7/24/12 7/24/12 Pg 11 II. iv. O/H temp from 350 deg to 300-450 deg. Pg 15 VIII.A. Corrected overhaul yr from 5 to 4. H 9/10/13 9/10/13 Pg 25 XI. B.1. Corrected “0 to 20” psi for Jet fuel to “0 to 200” I 8/1/14 8/1/14 Cover Page Added models CD50K & CD70K J 3/26/15 3/26/15 Pg 12, 23, 29, 30, 35 Added torque notes K 4/16/15 4/16/15 Pg 23 Added “not” to allow lead wire to twist….. Page 3 Dated 1/1/08 Rev K dated 4/16/15 I. INTRODUCTION: Aircraft combustion heaters manufactured by C&D Associates, Inc. are designed primarily to provide heat to the passengers and crew during ground and/or flight. Additional uses are de-icing and engine preheating. Heat output generally is from 15,000 to 55,000 BTU. Heaters are FAA TSO-C20 approved and are designed to use the aircraft fuel (aviation gas or jet) in both pressurized and non-pressurized aircraft. Designated models are CD15K, CD25K, CD35K, CD45K, CD50K, CD55K & CD70K, with a p/n ending in “-1”. II. SCOPE: This manual provides maintenance information for aircraft combustion heaters manufactured by C&D Associates, inc. 302 Post Rd. Buchanan, MI 49107 USA. The purpose of this manual is to guide its reader to a thorough understanding and working knowledge of the C&D Associates, Inc. “–1” series combustion heater and subsequent components. While general concepts in operation mentioned herein apply to all aircraft combustion heater makes, the design and operation of a “-1” combustion heating unit is completely unique to itself. In order to achieve continued efficiency and longer Time Before Overhaul (TBO) the envelope of operation as outlined in this manual must be met. A C&D AIRCRAFT COMBUSTION HEATER HAS BEEN INSTALLED. PLEASE FOLLOW THE AIRCRAFT OPERATING MANUAL FOR COMBUSTION HEATER OPERATING SEQUENCE AN D ASSOCIATES, INC. "INSTRUCTIONS FOR CONTINUED AIRWORTHINESS" EDITION, DATED 4-4-02 REVISION NONE OR LATER FAA APPROVED RE . FOR ELIGIBILITY SEE WWW.AIRCRAFTHEATER.COM COMBUSTION AIR INLET FUEL ADAPTER & FILTER ASSEMBLY FUEL SOLENOID OVERHEAT SWITCH 21528 SCEET HOSE & CLAMPS IGNITION LEAD HOSE & CLAMPS IGNITION UNIT & MOUNT POWER & COMB. FUEL PUMP HEATER HOBBS (OPT) &/OR SHUTOFF THERMOSTATGROUND (OPT) VENT BLOWER (OPT) WARNING OVERHEAT ADAPTER COMBUSTION TUBE & JACKET REGULATOR DRAIN EXHAUST SHROUD EXHAUST PIPE CYCLING SWITCH MIXER, HEAD GASKET FUEL BOX COMUSTION BLOWER ASSEMBLY NOZZLE, ORING, NOZZLE HOLDER 5 BLADE OR SQUIRREL CAGE FAN AIR BLOWER 56 34 56 34 2 1 2 1 NUMBER PLATE TERMINAL BLOCK WIRING HARNESS C&D ASSOCIATES, INC. FUEL BOX TOP ROTORY SWITCH DATAPLATE COMBUSTION AIR SWITCH THERMOSTAT FAN ENDPLATE SPARK PLUG FUEL PUMP BLOWER MOUNTING CLAMPS FIGURE 1 -Heater configurations may differ- -For reference only- BTU’S LENGTH DIAMETER VDC/AMP WEIGHT FUEL PRESS AV/JET MAX. FUEL GAL/HR 15-25,000 9-17” 5.50 12VDC/3-18 AMPS 24 VDC/3-14 AMPS 10-25 lbs 7/100 .25 GPH 25-35,000 17-20” 6.00 12VDC/14- 20AMPS 24VDC/7- 12AMPS 20-30 lbs 7/100 .5 GPH 35-45,000 20-23” 6.00 20-30 lbs 7/100 .65 GPH 45-55,000 21-24” 6.00 20-30 lbs 7/100 .75 GPH 55-65,000 21-24” 6.00 20-30 lbs 7/100 .85 GPH Page 4 Dated 1/1/08 Rev K dated 4/16/15 LISTING OF P/N’S PER SERIES * INDICATES KEROSENE BURNING CD11000 SERIES CD11000-1 CD11001-1 CD11002-1 CD11003-1 CD11004-1 CD11005-1 CD11006-1 CD11007-1 CD11014-1 CD11049-1 CD11050-1 CD11214-1 CD11215-1 CD12000 SERIES CD12003-1 CD12004-1* CD12006-1 CD12007-1 CD12008-1 CD12009-1 CD12010-1 CD12011-1 CD12012-1 CD12013-1 CD12015-1 CD12016-1 CD12017-1 CD12018-1 CD12022-1* CD12031-1 CD12032-1 CD12036-1 CD12039-1 CD12043-1 CD12044-1 CD12059-1 CD12060-1 CD12061-1 CD12064-1 CD12065-1 CD12066-1 CD12067-1 CD12089-1 CD12090-1 CD12091-1 CD12099-1 CD12189-1 CD14000 SERIES CD14010-1 CD14019-1 CD14020-1 CD14025-1 CD14026-1 CD14027-1 CD14028-1 CD14041-1 CD14045-1 CD14046-1* CD14048-1 CD14050-1 CD14055-1 CD14060-1 CD14066-1 CD14070-1 CD14071-1 CD14072-1 CD14073-1 CD14075-1 CD14077-1 CD14078-1 CD14090-1 CD14125-1 CD14126-1 CD14127-1 CD14152-1 CD14186-1 CD14187-1 CD14188-1 CD14190-1 CD14192-1 Page 5 Dated 1/1/08 Rev K dated 4/16/15 III. DESCRIPTION Each heater system normally consists of a heater assembly, a ventilation air blower, a combustion air blower, nozzle holder, solenoid valve assembly, spark plug, high-voltage ignition system, combustion air pressure switch, overheat switch, cycling switch generally combined in a complete assembly. Optional equipment includes thermostat, fuel pump, fuel regulator and remote shut off valve, heater circuit breaker, controls, and operation indicator lights. The optional equipment items are provided as separate components since they may be mounted at different locations in the aircraft and customer preferences. Aviation Gasoline Applications use an electric fuel pump provides fuel at 7.0 to 9 PSI for operation. 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 and does not adversely affect engine operation. Jet Fuel Application use an electric fuel pump assembly through a fuel control system that provides fuel pressure at 105 + /- 5 PSI. IV. CONSTRUCTION: The majority of the heater is manufactured using corrosion resistant stainless steel. The combustion tube is a welded, gas tight container consisting of the combustion chamber and radiator assembly with Durakoat applied to high wear areas for longer life. The combustion tube is encased in a stainless steel shroud or 'jacket' assembly. Space between the tube and shroud provides an area for heat transfer. The ventilation fan, combustion air inlet, fuel feed assembly and combustion head assembly are located at one end while the heater and air outlet and exhaust are generally located at the other. On the inlet end of the combustion tube is the 'head assembly'. Attached on the head assembly is the fuel feed and nozzle assembly that houses the spray nozzle. Externally mounted is the ignition assembly, fuel solenoid, & wire mounting terminal board. Also a combination of mechanical and solid state switches, used to regulate heat and airflow, and provide safety control for shut down of unit in the event of malfunction. Page 6 Dated 1/1/08 Rev K dated 4/16/15 V. OPERATION: In order for the heater to operate, it must have (1) an external power source, (2) ignition, (3) combustion and ventilation air and (4) a fuel source. Heat in the combustion chamber or tube is achieved by burning a fuel to air mixture of proper proportions. Any deviation of this ratio will cause reduced heat output, poor operation, and shortened TBO. For the following, assume that these are provided as required. Atomized spray from a specially designed spray nozzle, a balanced combustion air and exhaust, coupled with high-voltage spark plug ignition, insures instant firing and continuous burning under all flight conditions. Spark plug ignition combined with the whirling-flame combustion has been proved by millions of hours of heater operation in all types of aircraft throughout the world. Heat is provided by burning a fuel-air mixture in the combustion chamber of the heater. Jet or aviation fuel is injected into the combustion chamber through the spray nozzle. The resulting cone-shaped fuel spray mixes with combustion air and is ignited by a spark from the spark plug. Electric current for ignition is supplied by an ignition unit which 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 most adverse conditions because it is whirled around itself many times. A B C D D CONVEX END DOME EXHAUST COMBUSTION CHAMBER/FLAME TUBE BAFFLES HEAT EXCHANGER CROSSOVER MIXER ASSEMBLY HEAD ASSEMBLY FUEL INJECTOR REVOLVING SPARK FUEL SUPPLY INCOMING COMBUSTION AIR IGNITOR JACKET E E HEATED AIR VENT/FRESH AIR FIGURE 2 A. Combustion Air Supply. This is provided by way of a external ram air scoop and or a blower assembly independent of the vent/fresh air supply. Combustion air enters the head assembly, and then is metered into the mixer chamber. B. Ignition is supplied via high-voltage oscillating current, this coupled with the igniter design, create a revolving continuous spark located in the head assembly. This igniter is positioned in the path of an internal fuel injector designed to atomize the fuel at a pre-determined pressure. C. This ignited fuel/air mix is then dragged from mixer assembly as additional combustion air channels through the head assembly into the combustion chamber portion of the liner. The majority of combustion is created at this point in the combustion chamber or flame tube area. D. The flame travels full length of the combustion chamber hitting the end dome, it then doubles back along the inside wall and on into the outer layer of the heat exchanger. The spent gasses again travel the length of the tube around a series of baffles then exiting out the exhaust. E. Air for the ventilation system is picked up via an external ram air scoop and/or a blower assembly typically mounted on the inlet end of the jacket. Air is forced through the heated external passages of the combustion chamber. Ventilating air thus comes in contact with the heated cylindrical surfaces subsequently pushing heated air into the cabin. Page 7 Dated 1/1/08 Rev K dated 4/16/15 VI. ICA (INSTRUCTIONS FOR CONTINUED AIRWORTHINESS) Second Edition: Rev D dated 10-3-11 When C&D Associates, Inc. heater is installed in an aircraft, the following action is required. A description of its operational principals, controls, servicing, maintenance, troubleshooting and testing can be found in the attached MM10001 maintenance manual on page 1 “Table of Contents.” APPLICATION Applies to C&D Associates Model #CD15K, CD25K, CD35K, CD45K, CD50K, CD55K and CD70K with part number ending in “–1”. Combustion heaters marked as meeting the standards of FAA TSO- C20, installed in aircraft certified in any category. A. PREFLIGHT/OPERATIONAL CHECK AND SHUTDOWN PROCEDURE Note: Pilots operating under FAR91 may perform the checks required 1. Ensure that combustion and ventilation air inlets are free of any obstructions or constrictions
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