operation manual - fs.fed.us · operation manual #38000m the iso lair ... vi. cleaning and...

c ==--

HELICOPTER SYSTEMS

OPERATION MANUAL#38000M

FOR THE

FIREFL Y IIMODEL 3800

HELICOPTER FLAME APPLICATION SYSTEM

Revision CDecember 17,2001

of 10

ISOLAIR, INC1620 NW PERIMETER WAYTROUTDALE, OR 97060

FIREFLY IIOPERA nON MANUAL

#38000M

REVISIONS LOG

A

B

01/13/99 Initial Release KLM

KLM03/09/00 I Add sectionVI, B -ground transport

C 12/17/01 Update to 70 gallon aluminum tank and frame. MP

*Changes to the previous revision will be marked with a vertical bar to the right of the affectedtext or graphic.

RevisionCDecember17,2001

of 10


FIREFLY IIOPERATION MANUAL

#38000M

CONTENTS

INTRODUCTION

PREREQUISITES

.................................

............................

INSTALLATION ....................

TESTING TORCH ON HELICOPTER ........................................................

REFILLING TANK ........................................

CLEANING AND MAINTENANCE ..................................................

SYSTEM CONFIGURATION.. ...........................

ELECTRICAL SCHEMATIC ,.........

APPENDIX A - INSPECTION CHECKLIST

APPENDIXB -MALFUNCTION CHECKLIST

.."

..........


of 10

4

4

4

5

7

8

9

10

A-I

B-1


I. INTRODUCTION


#38000M

The ISOLAIR FIREFLY II Model 3800 is light weight, compact HelicopterFlame Application System that consists of a 70 gallon aluminum tank, aluminumframe assembly, and an igniter head and stinger assembly that is supported by theaircraft's cargo hook.

A.

B. Power for the system is obtained from the main buss of the helicopterelectricalsystem. .

II. PREREQUISITES

A. Prior to installation, the aircraftmust have the following approvedmodificationsapplied:

1. Remove the pilot door.

III. INSTALLATION

A. Insure that the suspensioncables are correctly installed tothe ISOLAIR Firefly II torch.Inspect cables and connectorsfor security. Cables should notcross over or under landinggear.

B. Place the ISOLAIR Firefly IItorch on the ground in front ofthe helicopter with the nozzleend to the pilot's side of theaircraft. Ensure that allswitches are off.

C. Ensure that the pear-linkadapter is correctly configuredfor the cargo hook on thehelicopter and that the cables


of 10



#38000M

are between the skids and will not become entangled during takeoff. Attach thepear-link to the cargo hook. At this time conduct a safety check of the cargohook, both manual and electrical releases. After insuring that both switches are inthe off position, secure the electrical cannonplug to the plug on the helicopter.

VIEW' LOOKING AFT VIEW' LOOKING

\

A~

LONGITUDINALLY ORIENTEDCARGO HOOK

LATERALLY ORIENTEDCARGO HOOK

D. Go over testing procedure with the pilot. Discuss pilot-ground crewcommunications and the procedures outlined in the next section of this guide.

IV. TESTING THE ISOLAIR FIREFLY II TORCH WITH THE HELICOPTER

Even if the ISOLAIR torch has been bench tested, it should be tested on the helicopterwhile both are on the ground. At this point it is essential that you have conducted a pre-operational briefing with the pilot and crew. This briefing must include communications,any identified hazards, and emergency procedures. Make sure you have installed thedesired nozzle on the Firefly torch, that there are no cables over the skids, and have a fireextinguisher ready with a trained person.


of 10


A.

B.

C.



#38000M

IGNITION TEST

1. Insure the pump switch is off and flip the ignitor switch on.

2. Turn the propane regulator on.

3. Have pilot activate the torch control switch. Check for propane ignition,set pressure to 7-10 psi.~-- --

4. Have pilot release torch control switch and turn ignitor switch off.

PUMP TEST

1. Check carn lock connection and open hose valve.

2. Insure ignition switch is off and flip pump switch on.

3. Using a non metallic pail for dispensed fuel to fall into, have pilot activatethe ISOLAIR Firefly II torch control switch. Gelled fuel should flowthrough the nozzle tip. At this time all lines should be bled to insure fuelflow.

4. Check that the positive shut off valve does not allow fuel to leak from thenozzle and that it operates freely.

5. Pour gel from the pail back into the tank.

6. Make sure both switches are off

7. The torch is ready for operation.

FINAL CHECK (pRIOR TO TAKEOFF)

1. Bail security pins are locked.

2. Electrode is clean.

3. Firefly II torch and suspension system is positioned in front of the

of 10



#38000M

helicopter with the nozzle end toward the pilot's side of the aircraft.

4. The Mixmaster will activate the ignition and pump switches, inform thepilot that the switches are on, and exit the area towards the parking tender.

5. Parking tender directs takeoff.

CAUTION

At no time should there be anyone underneath or in close proximity of thehelicopter with the ISOLAIR Firefly II torch attached.

v. REFILLINGTANK

It is essential that the procedures be followed as outlined below.

CAUTION

Mter each landing and prior to each takeoff, ensure that suspension cablesdo not tangle on skid gear.

A.

B.

c.

D.

Revision C

December 17, 2001

Parking tender is responsible for checking and verifying that suspension cablesare not tangled and must be able to communicate any problem to the pilotimmediately.

The helicopter returns with an empty tank. The parking tender directs thehelicopter to its landing position.

Once the helicopter is on the ground, the pilot gives a "thumbs-up" for thedesignated person (Mixmaster) to approach.The Mixmaster turns all switches off, connects the dry-break from the deliveryhose to the dry-break on the ISOLAIR Firefly tank, opens the valve, and directsthe batch-mixer operator to start the pump.

When the tank is full, the Mixmaster instructs the batch-mixer operator to shut offthe pump. Then the Mixmaster closes the valve, disconnects the dry-break, laysthe hose down, turns the switches on, informs the pilot and exits toward the

of 10

ISOLAIR, INC1620 NW PERIMETER WAY

TROUTDALE, OR 97060


#38000M

parking tender.

E. The parking tender instructs the pilot to rise slowly and directs the aircraftforward and over the torch. Once over the torch, the parking tender will have thepilot begin a vertical lift until the cables are tight and the torch is clear of theground.

VI. CLEANING AND MAINTENANCE OF FIREFLY II TORCH AND RELATEDEQUIPMENT.

A. The ISOLAIR Firefly II Torch system, mix truck tank, and batch mixer must haveproper care to be dependable. At the end of each day of use, thorougWyflush allequipment with solvent or jet fuel, and run through all nozzles, hoses, etc. Whennot in use, keep all equipment indoors or cover well.

1. See ISOLAIR FIREFLY INSPECTION CHECKLIST,Appendix A.

B. All equipment must be thoroughly flushed with non flammable solvent or jet fuelprior to ground transport.


of 10



#38000M

IGNITOR HEADASSEMBLY

PIN 38-44

FRAMEPIN 38-3DB

\

SYSTEMCONTROLSWITCH BOXPIN 38-58

RIMARY COMPONENTS

Revision C

Decem ber 17, 2001

of 10


IGNITOR

PUMP

124-903 NCOILN3 COIL 24V DC

3800 SYSTEM SCHEMATIC

Revision C

December 17,2001


#38000M

RED -

BLI<

IGNITOR

GRI\j~

wHT~

of 10

"--'-

BLK

APPENDIX A

FUEL TANKS

FRAME

a. Check tank shell for cracks and punctures.

Handles secure and straight.b.

c. Clean and flushed with diesel or solvent after use.

d. Latch and cover in good working order.

Valve - clean and worKfugpropeny.e.

a. Check all welds.

Cleanb.

c. All bolts and pins in place and tight.

Ignition system - clean and working.d.

e. Pump valve -clean and working.

MOTOR AND ELECTRICAL HOUSING

Cleana.

b. Electrical wiring - free from cracks and connected properly.

Pump motor lubricated.c.

d. All screws and bolts in place and tight.

Pump operating (primed)e.

Page A-I

APPENDIX A

PageA-2

CONNECTORS

a. Clean with clamp tight.

b. Valve clean. CAUTION! Do not open valve unless attached.

c. Grounding cable connections complete.

d. Swivel rotates freely -hose not leaking.

SUSPENSION LEAD LINES AND ELECTRICAL CABLE

a. Clean and free from kinks, nicks and burrs.

b. Suspension line connectors secure and in good condition.

c. All bolts and nuts properly secured -self locking.

d. Electrical connectors clean and tight. Line properly attached to suspension cables.

e. Separator bars not cracked or broken -properly attached between cable swedges.

ACCESSORY CHECKLIST

a. Windsock

b. Fire extinguishers - 2 ea 20 lb. dry chemical & 2 ea 2.5 lb. dry chemical.

c. Propane bottle

d. Goggles

e. Respirator/dust mask

f. First Aid kit

g. 2 ea five gallon non metallic slop buckets

h. Wire brush

1. WD-40

APPENDIX A

J.

k.

Wash basin, soap, and 5 gallons of water or hand cleaner and rags.

Scale and scoop for measuring gelling agent.

1. Cotton overalls.

m. Flight helmet, flight suit, and gloves.

Tool kit.n.

o. Electric pump.

Rubber suction pipe.p.

q. Dry lock connect.

Chain saw, dolmar, chaps and saw tools.r.

s. Orange paint, flourescent flagging.

Grounding rod and cables.t.

u. Credit card secured for batch mixer.

v. Emmery cloth and extra tip parts.

Funnel, coffee can.w.

x. Non-Ferrous, metal pipe wrench.

NOZZLE ASSEMBLY

a. Disassemble, clean and lubricate

Replace worn parts.b.

DRYBREAKVALVE

a. Disassemble, clean and lubricate

Page A-3

APPENDIX A-~

Page A-4

b. Replace worn parts.

TANK

a. Clean and rinse thoroughly.

b. Check for cracks and punctures.

c. Contact tank manufacturer for repair or replacement.- -

--

MOTOR / ELECTRICAL SYSTEM

a. Replace brushes.

b. Lubricate bearings.

PUMP

a. Disconnect - check for gel accumulation.

b. Clean as required.

I.

II.

ill.

IV.

v.

VI.

A.B.C.

APPENDIX BMALFUNCTION CHECKLIST

CURRENT BREAKER OR HELICOPTER CONTINUES TO POP OPEN:

Check electrical system on torch motor.Check pump for drag or obstruction.Check gel-gas consistency.

NO SPARK FROM IGNITOR:

A.B.C.D.KF.G.

Check breaker on helicopterCheck wire connector on ignitor electrode.Check coil wire for security.Check electrical connection between helic~pt~r and to!C~.Clean-carDoilfrom electrodes.Replace ignitor electrode on torch and set gap at 3/8".Replace propane bottle.

ABSENCE OF-FUEL:

A.B.C.D.E.F.

Checkone-wayvalveon tank forobstruction. .

Check hose connection valve to be sure it is open.Check hose for obstruction.

Check pump for obstruction.Check gel-gas for consistency.Clean nozzle.

TORCH DRIPS WHEN SHUT OFF:

A.B.

Check spring tension on valve to ensure closure. Replace spring if weak.Change nozzles for debris or clogging.

TORCH NOZZLE FLARES UP OR GEL-GAS PARTICLES TOO SMALL:

A.B.

Gel-gas mixture too thin - add more chemical or let gel set fora longer time.Air speed too fast.

TORCH WORKS DURING GROUND TEST BUT NOT IN THE AIR:

A.B.

Check electrical connections between torch and helicopter.Air speed too fast - slow air speed until the gel-gas ignites, then increase todesired speed.

Page B-1

ISOLAIR, INC1620 NW Perimeter WayTroutdale, OR 97060 USA

I.

FIREFLY II TORCH

BATCH MIXING

II.

A.

B.

The batch mixer must be clean. Insure that batch mixer is grounded and bondedto the bulk fueler. Fill batch mixer with desired amount of fuel.

Begin agitation of the fuel and add the appropriate amount of jelling agent. Oncethe jelling agent has been added, continue agitation for approximately 5 minutes.Shut off the mixer and the fuel will reach the correct consistency in approximately15-20 minutes, depending on temperature.

BENCH TESTING THE ISOLAIR FIREFLY II TORCH

B.

A. The ISOLAIR Firefly torch will be kept clean and have had maintenance checksto avoid operational delays. Once tlTetorch has been cleaned and-reaSsembled,itcan be tested for serviceability on the ground. A 20-lb dry chemical fireextinguisher must be readily available to a trained person during torch testingprocedure. The torch will not be loaded with jelled fuel for bench testing.

The following steps are to be performed during a batch test:

1.

(~)Connect two 12-voltbatteries in a series to

produce 24 volts. Seefigure 1.

2. (!) G~ ~(!) GAttach the battery adaptercord to the cannon plugconnector of the 9 pin plugof the Firefly II torch, afterensuring that both pumpand ignition switches are inthe off position.

12VOLTBATTERY

12VOLTBATTERY

Figure 1

3. With the ignition switch on and the pump switch off, checkto see that theigniter is producing a spark.

4. With the pump switch on and the igniter switch off, check to see that themotor and pump operate normally.

5. Turn both switches off and disconnect the plug from the battery adaptercord.

6. Check all nuts, bolts and connectors for tightness and serviceability.

0u.s. DepartmentofTransportationResearch andSpecial ProgramsAdministration

400 Seventh St., S.W.Washington, D.C. 20590

MAY11 200t

DOT-E 12633(FIRST REVISION)

PIRATION DATE: February 28, 2003

(FOR RENEWAL, SEE 49 CFR § 107.109)

1. GRANT~EE : Isolcrir Hericopter SystemsTroutdale, OR

2. PURPOSE AND LIMITATION:

a. This exemption authorizes the transportation in commerceof gasoline in a non-DOT sp~cification, non-bulk packaging(drum) mounted in a heli-torch frame. This exemptionprovides no relief from the Hazardous Mat~rials Regulations(HMR) other than as specificallystatedherein.

b. The safety analyses performed in development of thisexemption only considered the hazards and risks associatedwith transportation in commerce. .

3. REGULATORY SYSTEM AFFECTED:180.

49 CFRParts 106, 107 and 171-

.4. REGULATIONS FROMWHICHEXEMPTED: 49 CFR § 173.202(c) inthat a non-specification aluminum drum is not authorized,except as specified herein.

5. BASIS: This exemption is based on the application ofIsolair Helicopter Systems dated February 5, 2001, submittedin accordance with§ 107.105 and the public proceedingthereon, and an additionalletter dated March 9, 2001.

Continuation of DOT-E 12633 (1st rev.) Page 2

MAY1 1 200t

6. HAZARDOUS MATERIALS (49 CFR § 172..101):

.7. SAFETY CONTROL MEASURES:

a. PACKAGING -

(1) Packagingprescribedis a non-DOT specifi~~tionaluminum drum of not more than 70 ga116ns capacity.Each drum, horizontally positioned, has two top hatchesand a bottom opening with a ball valve and fittings fora pump. The externally mounted pump must be anexplosion proof electric fuel transfer pump.

(2) Each drum and attachedpUmp must be securely.mounted in a heli-torch frame, as shown on the drawingson file with the Office of Hazardous MaterialExemptionsand Approvals(OHMEA). .

b. OPERATIONAL CONTROLS -

(1) The ball valve between the drum and pump must beclosed during transportation.

(2) The fuel transfer pump must be disconnected fromits power source during transportation.

(3) No more than two heli-torchframesmay betransported on one vehicle.

(4) Prior to transportationby motor vehicle,eachdrum must be emptied to the maximum extent possibleunder the operating circumstances, to a volume of less

. than 10 gallons.

Proper Shipping Name/ Hazard Identi- PackingHazardous Materials Description Class/ fication Group

Division Number

I

Gasoline I 3I

001203I

III


MAY 1 1 2001

c. TESTING: -

(1) Upon completion of manufacture, each drum must bepneumatically leakproof tested at a test pressure of 3psig for 5 minutes. Additionally, each drum must behydrostatically tested at a test pressure of 5 psig fora minimum of 10 minutes. Any leakage or deformity ofthe drum constitutes a failure of either test.

(2) Prior to each filling, each drum must be visuallyinspected to determine that the drum has not beenpunctured or damaged since the prior filling.

8. SPECIAL PROVISIONS:----

a. A current copy of this exemption must be maintained ateach facility where the package is offered or reoffered fortransportati6n."

b. MARKING - The drum mounted in the heli-torch frame must

be plainly and durably marked ~DOT-E 12633H as required by§ 172.301(c).

9. MODES OF TRANSPORTATION AUTHORIZED: Motor vehicle.

10. MODAL REOUIREMENTS: A current copy of this exemption mustbe carried aboard each motor vehicle used to transportpackages covered by this exemption.

11. COMPLIANCE: Failure by a person to comply with any of thefollowing may result in suspension or revocation of thisexemption and penalties prescribed by the Federal hazardousmaterials transportation law, 49 U.S.C. 5101 et seq:

0 All terms and conditions prescribed in this exemptionand the Hazardous Materials Regulations, 49 CFR Parts171-180.

0 Registration required by § 107.601 et seq., whenapplicable.


Each "Hazmat employee", as defined in § 171.8, who performsa function subject to this exemption must receive trainingon the requirements and conditions of this exemption inaddition to the training required by §§ 172.700 through172.704.

No person may use or apply this exemption, including displayof its number, when this exemption has expired or isotherwise no longer in effect.

12. REPORTING REOUIREMENTS: The carrier is required to reportany incident involving loss of packaging contents orpackaging failure to the Associate Administrator forHazardous Materials Safety (AAHMS) as soon as practicable.(Sections 171.15 and 171.16 apply to any activity undertakenunder the authority of this ex~mption.) In addition, theholder (s) of this exemption must inform the AAHMS, in .

writing, of any incident involving the package and shipmentsmade under the terms of this exemption. .

Issued in Washington, D.C.:

,~ HAY 11 20m

(DATE)

Safety

Address all inquiries to: Associate Administrator for HazardousMaterials Safety, Research and Special Programs Administration,U.S. Department of Transportation, 400 Seventh Street, SW,Washington, D.C. 20590.Attention: DHM-31.

The original of this exemption is on file at the above office.Photo reproductions and legible reductions of this exemption arepermitted. Any alteration of this exemption is prohibited.

PO: PO/AM

operation manual - fs.fed.us · operation manual #38000m the iso lair ... vi. cleaning and...

Documents