Lindstrand Series 1 80 User manual

LTL HABMM Issue 2.0

LINDSTRAND TECHNOLOGIES LTD

HOT AIR BALLOON

MAINTENANCE MANUAL

Lindstrand Technologies Ltd

Maesbury Road

Oswestry

Shropshire

SY10 8HA

Tel: +44 (0)1691 671888

Fax: +44 (0)1691 679991

www.lindstrandtech.com

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 Page i

RECORD OF AMENDMENTS

No.

Date

Affected Pages

Incorporated By

Issue 1

Issue 1.1

Issue 2.0

20th April 2016

12th July 2016

10th May 2017

Initial Issue

i, ii, 4

All Pages

Lee Barnfield

Per Lindstrand

Lee Barnfield

Per Lindstrand

This revision is approved

under the authority of

DOA EASA.12J.176

Lee Barnfield

Per Lindstrand

This revision is approved

under the authority of

DOA EASA.12J.176

Amendments

This manual is kept up to date by amendments consisting of loose-leaf pages, required to add new

information or amend existing information. The pages affected by an amendment and the effective date

are shown above. The pages themselves are identified by a change of the issue number at the bottom of

each page. The number after the point in the issue number represents the amendment level of that page,

eg a page marked Issue 2.0 is at Issue 1 modified by Amendment 1. The Checklist of Pages indicates

the issue level of all pages included in this Maintenance Manual.

LTL HABMM Issue 2.0 Page ii

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.

Issue

iii

2.0

A1-1

A1-2

A1-3

A1-4

A1-5

A1-6

A1-7

A1-8

A1-9

A1-10

A1-11

B1-1

B1-2

C1-1

C1-2

C1-3

C1-4

C1-5

C1-6

C1-7

C1-8

2.0

LTL HABMM Issue 2.0 Page iii

MANUAL SUPPLEMENTS

Supplement No.

Title

Tick if Applicable

STATEMENT OF APPROVAL

This manual forms part of the EASA Type Certificate EASA.BA.26, first approved on 20 April 2016.

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. Always make sure before proceeding that you

have the correct manual issue.

The Maintenance Manual does not always make a distinction what work can be carried out by the

operator and what can only be serviced by factory personnel. If in doubt, always consult the

manufacturer on maintenance issues.

It is the responsibility of the balloon owner / operator to ensure that persons engaged in inspection or

maintenance of the balloon are trained, competent and authorised to do any work they undertake.

LTL HABMM Issue 2.0 Page iv

CONTENTS

SECTION 1 - INTRODUCTION

1.1 Purpose of this Manual

1.2 Applicability

1.3 Identification of Systems

1.4 Qualification

SECTION 2 - AIRWORTHINESS LIMITATIONS

2.1 Approval Statement

2.2 Modification

2.3 Mandatory Replacement Time

2.4 Structural Inspection Interval

2.5 Structural Inspection Procedure

2.6 Acceptable Damage

SECTION 3 - TECHNICAL DESCRIPTION

3.1 Envelopes

3.2 Baskets

3.3 Burners

3.4 Fuel Systems

SECTION 4 - PREVENTATIVE MAINTENANCE

4.1 Paperwork

4.2 Envelopes

4.3 Baskets

4.4 Fuel Systems

4.5 Burners

SECTION 5 - REPAIR AND MAINTENANCE

5.1 Envelopes

5.2 Envelope Repairs

5.3 Baskets

5.4 Fuel Systems

5.5 Burners

LTL HABMM Issue 2.0 Page v

CONTENTS Cont....

SECTION 6 –BALLOON INSPECTION

6.1 100 Hour / Annual Inspection

6.2 Load Bearing Attachments

6.3 Burner

6.4 Fuel Cylinders

6.5 Baskets

6.6 Fabric Strength Test

6.7 Inspection After Overheating

6.8 Inspection After Hard Landing

APPENDICES

A-1 Appendix “A" Annual / 100 Hour Inspection Checklist

B-1 Appendix “B” Envelope Repair and Damage Record

C-1 Appendix "C" All Figures

LTL HABMM Issue 2.0 Page 1

SECTION 1

INTRODUCTION

1.1 PURPOSE OF THIS MANUAL

This Maintenance Manual provides information for the following aspects of a Lindstrand Technologies

Ltd. hot air balloon:

Airworthiness Limitations

Technical Description

Preventative Maintenance

Repair and Maintenance Instructions

Inspection Programs

The manual is intended as a guide and if any detailed information cannot be found in this manual, then

Lindstrand Technologies should be contacted at the address shown on the front page.

The use of un-approved parts or sub-standard materials will invalidate the Certificate of Airworthiness.

Deviation from the repair instructions and material specifications contained in this manual are not

permitted without prior written consent from Lindstrand Technologies Ltd.

1.2 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).

1.3 IDENTIFICATION OF SYSTEMS

A serial number and a description identify all major components of Lindstrand Technologies hot air

balloons. These are located as follows:

Envelope - Engraved on an identification plate which is situated on the top side of

the envelope mouth.

Burner - Engraved onto the stainless steel burner can support bracket.

Basket - Engraved onto a plate attached onto the basket sidewall.

Cylinder - Engraved on a plate, which is fixed to the bottom foot ring of the cylinder.

1.4 QUALIFICATION

The Maintenance Manual is divided into sections. Only section 4, Preventative Maintenance can be

carried out by the owner / operator. All other maintenance and repair, including the annual / 100 hour

inspection, must be accomplished by an appropriately approved and qualified person.

LTL HABMM Issue 2.0 Page 2

SECTION 2

AIRWORTHINESS LIMITATIONS

2,1 APPROVAL STATEMENT

This manual provides information for continued airworthiness as required by EASA directive CS-31HB.82

2.2 MODIFICATION

The balloon must not be flown if it has been modified, without the approval of the National Airworthiness

Authority in the state of registration.

2.3 MANDATORY REPLACEMENT TIME

Fuel hoses are to be replaced after ten years in service.

No other component in Lindstrand Technologies balloons have a mandatory replacement life.

2.4 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.

It is at the discretion of the inspector to carry out a grab test below 250 hours of flight if fabric degradation

is thought to have occurred.

2.5 INSPECTION PROCEDURE

The Inspection Procedure can be found in Section 6 of the Maintenance Manual.

The Inspection Check List is specified in Appendix A of the Maintenance Manual.

2.6 ACCEPTABLE DAMAGE

The balloon must not be flown if there is any of the following:

ENVELOPE: With any damage to the envelope fabric which is above the first horizontal load tape and is

larger than 25 mm in any one direction, or with any damage to load tapes, control lines, or parachute

valve rigging.

ENVELOPE CABLES –STAINLESS STEEL: If more than one strand of wire is broken, or if cables have

been overheated to the point where they have lost their temper and do not spring back to their original

shape when bent, the cable must be replaced before the balloon may be flown.

LTL HABMM Issue 2.0 Page 3

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. If any burner, tank valve or pressure gauge

is not functional, or experiences a fuel leak, it must be repaired or replaced before the balloon may be

flown.

BASKET: When there are more than five strands of a basket wire broken, it must be repaired or replaced

before the balloon may be flown.

BASKET –PLYWOOD FLOOR: If the plywood floor has separated from the lower stainless frame or if

the floor is damaged so that a 250 mm crack is visible on both sides of the floor, the basket must be

repaired or the damaged part replaced before the balloon may be flown.

Any damage must be repaired in accordance with the instructions contained in the Section 5 of this

manual. All repairs must be noted in the balloon log book and approved by a designate of the appropriate

authority.

LTL HABMM Issue 1.2 Page 4

SECTION 3

BALLOON AND SYSTEM DESCRIPTION

A hot air balloon consists of three main components: envelope, basket and burners. In addition, flight

instruments, fuel tanks and other support equipment are needed for safe balloon operation.

3.1 ENVELOPE

The envelope is made of a coated nylon or polyester. The material is cut into panels which are sewn

together in vertical rows called gores. The gores are reinforced with horizontal and vertical structural load

tapes which are continuous to the top centre of the balloon where they are sewn into a load ring.

Stainless steel or Kevlar® cables transfer basket loads to load tapes which in turn support the load. The

base of the envelope and scoop are comprised of a fire resistant Nomex® material.

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.

Lindstrand Technologies produce the following envelopes:

Balloon Type

Volume

FAI Class

cu.m.

cu.ft.

Series 1 70

1,982

70,000

AX7

Series 1 80

2,266

80,000

AX8

Series 1 90

2,550

90,000

AX8

Series 1 105

2,970

105,000

AX8

Series 1 120

3,400

120,000

AX9

Series 1 150

4,250

150,000

AX10

Series 1 180

5,100

180,000

AX10

Series 1 210

5,950

210,000

AX10

Series 1 240

6,800

240,000

AX11

Series 1 260

7,360

260,000

AX11

Series 1 300

8,500

300,000

AX11

Series 1 310

8,780

310,000

AX11

LTL HABMM Issue 2.0 Page 5

Balloon Type

Volume

FAI Class

cu.m.

cu.ft.

Racer 56

1,590

56,000

AX6

Racer 65

1,840

65,000

AX7

The Series 1 and Racer range are smooth 24 gore envelopes. There are several models in the Series 1

range from 70,000 cubic ft (1,982 cu.m) to 310,000 cubic ft (5,100 cu.m). See Figure 1a, 1b and 1c

(Appendix C) for a typical Series 1 envelope.

3.2 BASKET

Wicker is the preferred material for the passenger compartment basket of a hot air balloon because it is

sturdy, flexible and relatively lightweight. The flexibility of wicker helps with balloon landings and

cushions some of the impact force at landing. The basket contains the fuel tanks, instruments, pilot, and

passengers.

Flexible nylon poles, in conjunction with stainless steel cables, located on the upper portion of the

structure transfer the basket load to the envelope attachment points and support the burner assembly.

Basket skids affixed to the floor add rigidity and provide a point of abrasive resistance to the floor.

Sidewalls surround and protect the passengers, equipment and fuel tanks. Single-T baskets have

padded basket dividers or partitions to form passenger compartments. For more details on basket

occupancy see Flight Manual Section 2.1.8.

3.3 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.

The fuel is supplied to the burner assembly through the fuel hoses that connect the fuel tanks to the

burner assembly. The fuel system also provides fuel to the pilot light. The LPG fuel is diverted from the

main supply line at the burner via a pilot shut-off valve. The fuel goes through a vapour converter and

regulator and is distributed through a pilot head. A piezo-electric system ignites the vapour.

The burner coil is manufactured from stainless steel tubing. The fluid rises to the top of the coil and then

descends into the jet ring. The jet ring is equipped with a combination of removable jets and machined

holes.

The main liquid tank valve controls the flow of LPG fuel to the burner, while the main squeeze trigger

valve controls fuel flow at the burner. With the liquid tank valve open, opening the burner blast valve

permits LPG to enter the heat exchange coil where it is vaporised. After exiting the heat exchange coil

through the jet ring in the lower portion of the coil, the propane is ignited by the pilot light.

LTL HABMM Issue 2.0 Page 6

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. The use of liquid fire is particularly useful when flying over livestock.

For description see Figure 2, Appendix C.

3.4 FUEL CYLINDERS

Fuel cylinders are equipped with a main liquid valve, a float gauge, pressure relief valve and ullage valve.

The main liquid valve regulates the flow of the liquid propane to the burner. The float gauge provides a

reading of the remaining capacity of the tank in a percentage. The pressure relief valve allows for the

release of propane from the tank should the tank exceed the maximum design pressure. The pressure

relief valve normally releases at 375 pounds per square inch (psi).

LTL HABMM Issue 2.0 Page 7

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.

4.1 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.

All preventative maintenance work carried out by the balloon owner or operator, in accordance with the

instructions contained within this section of the Maintenance Manual must be documented with an entry in

the balloon log book, which includes the following information:

a. A description of the work performed

b. The date of completion of the work performed

c. The name of the person who made the repair or approved it

d. The total number of hours on the balloon when the work was performed

4.2 ENVELOPES

4.2.1 Cleaning and Storage

Envelopes may be cleaned by gently applying a mild, non-detergent soap diluted with water onto

the fabric using a sponge or cloth.

The envelope (including load tapes, Nomex and ropes) must be dried out completely before

being packed and stored. The recommended method of drying out the balloon is to cold air

inflate.

CAUTION:

Storing a balloon wet may cause permanent damage to the fabric and / or coating.

LTL HABMM Issue 2.0 Page 8

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.

Repairs to load tapes anywhere on the envelope must be undertaken by a qualified repairman or

facility.

4.2.3 Nomex Scoop and Nomex

Fabric damage to the Nomex panel 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. Repairs to load tapes anywhere on the

envelope must be undertaken by a qualified facility / person.

4.2.4 Red and White (Candy Stripe) Parachute or Solid Red FDS Deflation Line

There is excess deflation line stored in the large loop at the tied-off end in the envelope which

may be let out assuring the existing knot is duplicated. It is not permitted to shorten either line.

4.3BASKETS

4.3.1 Cleaning, Storage and Re-Varnishing

Baskets should be stored in a cool, dry area.

Mud which has dried onto the basket can be removed using a garden hose. Padding can be

cleaned using a suitable suede or leather cleaner as appropriate. The cushion floor foam can be

cleaned using detergent and water.

Baskets may be re-varnished to renew the protective layer. Avoid varnishing over the rope

handles or suede / leather covering.

NOTE:

Avoid high pressure spray washers as they may damage the natural wicker and possibly

strip the natural protective outer layer off. To avoid trapping moisture, do not replace the

cushion floor and fuel tanks until the basket is completely dry.

4.3.2 Basket Upholstery

Damage to the suede or leather trim can be repaired by carefully unlacing the cord holding the

trim on to the basket and gluing or stitching a patch of replacement leather to the underside of the

damaged section. The size of the replacement patch should include a 15 mm (5/8") overlap

around the edges of the damaged section. After repair, replace the leather on the basket by

lacing it into place.

LTL HABMM Issue 2.0 Page 9

4.3.3 Suspension System

Non-certified persons may replace the carabiners with parts provided by Lindstrand Technologies

as original equipment replacement parts. 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.

4.4 FUEL SYSTEMS

4.4.1 Fuel Cylinders

Flight cylinders require little specific attention throughout their service life. It is however advised

that the following instructions are followed.

4.4.2 Handling Cylinders

Although the cylinders are strong, care should be taken when moving them. Ensure that when

the cylinders are placed on rough, uneven ground, that the cylinder is resting on the foot ring and

not on the dome of the cylinder itself. Be cautious of small stones on the ground when placing

the cylinder down, this is often the most common cause of small dents in the base of the cylinder.

CAUTION:

Avoid dropping cylinders on hard surfaces as this may dent or distort the foot ring.

4.4.3 Transportation of Cylinders

Cylinders should be transported standing upright. Transporting cylinders on their sides should be

avoided and could cause damage to their internal components. Cylinders should always be

securely fastened during transportation.

4.4.4 Cleaning of Cylinders Externally

Cylinders may be washed using detergent and water. Remove tank covers prior to washing.

4.4.5 Protection of Connectors

Dust caps should be fitted over the male half of connectors to prevent the accumulation of dirt in

the connectors. It is a good practice to depress the connector nipple on the female half of the

connector before the cylinder is stored, in order to prevent liquid from becoming trapped between

the valve and the connector seal.

It is a good practice to regularly lubricate the whole connector (both male and female halves) with

silicone grease, in either the solid or spray form.

LTL HABMM Issue 2.0 Page 10

4.5BURNERS

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. Burners are especially vulnerable during transportation to and from launch and landing

sites, especially when this involves crossing roadside curbs or rough terrain. Whenever possible,

store the burner inside the basket using straps or carabiniers to secure it to the internal rope

handles that will prevent the unit moving and damaging itself or other items in the basket.

Padded transportation bags are available as an option for some burner sizes.

CAUTION:

Traveling with the burner erected on the nylon rods is not advised. It will subject it to

repeated jarring and can damage the burner, the burner frame, associated connectors to

the burner, and the upper basket frame. If this is unavoidable, a thorough inspection of the

burners, all connectors, toggle valve handles, burner-to-frame interface, frame-to-rod

interface, and rod-to-basket interface is advised prior to the next flight.

When it is necessary to position the burner on the ground is advisable to place it with the tops of

the coils downwards onto a non abrasive surface. Allowing sand, dirt and other foreign matter to

enter the fuel line connections increases the risk of burner failure and therefore should be

avoided at all times. Keep hoses ends clear of the ground and wherever possible use dust caps

to cover the connections when disconnected from the fuel tanks or manifolds.

4.5.2 General Cleaning

Heat discolouration of the coils can be removed using products such as Blue Away and Semi-

Chrome designed for cleaning of motorcycle exhaust systems.

LTL HABMM Issue 2.0 Page 11

SECTION 5

REPAIR AND MAINTENANCE

5.1 ENVELOPES

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.

CAUTION:

It is critical that all repairs maintain the integrity of the original design of the aircraft.

Consequently, the same materials (fabric, thread, load tape) and sewing techniques used

during manufacture must be used for repair and maintenance of the aircraft.

Envelope Construction

Materials

Colour

Type

Dimensions

Rip Stop Nylon

Multiple Colours

High tenacity woven ripstop nylon with a

soft polyurethane fluorocarbon

elastomeric coating.

1.5 metre

Roll width

Longlife Nylon

Multiple Colours

Taffeta weave heavy nylon base cloth

with a silicone elastomeric coating

1.5 metre

Roll width

Diamond Weave

Multiple Colours

High tenacity nylon fabric woven in a

diamond pattern with a polyurethane

coating.

1.5 metre

Roll width

Lightweight Fabric

Multiple Colours

Lightweight ripstop nylon base cloth with

a silicon co polymer coating.

1.5 metre

Roll width

Ultra-Light Weight Rip Stop

Nylon

Multiple Colours

Lightweight ripstop nylon base cloth with

a silicone coating.

1.5 metre

Roll width

LTL HABMM Issue 2.0 Page 12

Nomex

Mutilple Colours

Aramid polymer related to nylon, but has

aromatic backbone making it more rigid

and more durable. It has excellent

thermal, chemical, and radiation

resistance for a polymer material.

1.5 metre

Roll width

Load Tape (light weight)

White or Black

Polyester or Nylon

20 mm wide

Load Tape (medium weight)

White or Black

Polyester or Nylon

20 mm wide

Load Tape (heavy weight)

White or Black

Polyester or Nylon

20 mm wide

Load Tape (Aramid Fibre)

White or Black

Aramid Fibre

15 mm wide

Top Rim Load Tape

White or Black

Polyester or Nylon

25 mm wide

Bottom Rim Load Tape

White or Black

Polyester or Nylon

50 mm wide

Sewing Main Thread

White or Grey

Metric 30 three strand continuous filament

polyester of bonded construction.

Treated to provided extra resistance to

ultra violet exposure.

900d,

450d x2,

300d x3

Denier

Sewing Bobbin Thread

White or Grey

Metric 30 three strand continuous filament

polyester of twisted construction. Treated

to provide extra resistance to ultra violet

exposure.

900d,

450d x2,

300d x3

Denier

Nomex Sewing Thread

White or Grey

Filament thread that has one or more

plies that are twisted to make a thread.

Made by wrapping Nomex thread with

cotton.

Parachute Centralising

Lines

White

Braided Kevlar

2.0 mm

Parachute Pull Down Lines

White

Braided Polyester

2.7 mm

LTL HABMM Issue 2.0 Page 13

Parachute and FDS Venting

Line

White and Red

(Candy)