Type Acceptance Report TAR 3/21B/28 — R44 Series

The R44 II is a development of the R44 with a 245 shp take-off rating injected version of the six-cylinder Lycoming engine, for improved performance at altitude, and a 100 lb. increase in MTOW, primarily to compensate for a higher empty weight. Minor changes include a revised fuel system including electric fuel pump; incidental changes to engine controls and instruments; slightly increased area of main rotor blades (increased chord on the outer 1/3 of the span, to reduce vibration and blade stresses at altitude); strengthening of some main rotor control system components; the addition of aerodynamic (rounded) tip caps to the main and tail rotor blades, for reduced noise; and a 28-volt electrical system to aid starting. Type Acceptance Report TAR 3/21B/28 — R44 Series Rev.1 : 26 January 2022 4 4. NZCAR §21.43 Data Requirements The type data requirements of NZCAR Part 21B Para §21.43 have been satisfied by supply of the following documents, or were already held by the CAA: (1) State-of-Design Type certificate: FAA Type Certificate Number H11NM FAA Type Certificate Data Sheet H11NM at Revision 10 dated October 6, 2020 – Model R44 approved December 10, 1992 – Model R44 II approved October 3, 2002 (2) Airworthiness design requirements: (i) Airworthiness Design Standards: The certification basis of the R44 Series is FAR Part 27, dated February 1, 1965, including Amendments 27-1 through 27-24. (However RHC advise they elected to comply with the latest amendment of Part 27 for the R44 II engine installation, except as noted in the Compliance Checklist.) The FAA applied one Special condition and three equivalent level of safety findings were made. There have been reviewed and accepted by CAA. The certification basis was updated to Amendment 27-30 (except for a puncture force of 250 lb.) for the crash-resistant fuel system [CRFS] fitted in production to serial numbers detailed on the TCDS, which is also specified as mandatory for those serial numbers when operating in US airspace. CRFS bladder tanks may be retrofitted under the provisions of SB-78B. Note: This is now mandatory for all R44 helicopters in New Zealand under Airworthiness Directive DCA/R44/30. This is an acceptable certification basis in accordance with CAR Part 21B Para §21.41, because FAR 27 is the basic standard for rotorcraft called up under Part 21 Appendix C. There are no non-compliances and no special conditions have been prescribed by the Director under §21.23. (The original R44 type acceptance in NZ was documented under TAR 7/93.) (ii) Special Conditions: No. 27-033-SC Installation of HeliSAS Autopilot and Stabilization Augmentation System (AP/SAS) – As an option the AP/SAS performs non-critical control functions. However, the possible failure conditions, and their effect on the continued safe flight and landing, are more severe than envisioned by the present rules for light helicopters. RHC was required to provide a systems safety assessment (SSA) for the final configuration that will adequately address the safety objectives established by a functional hazard assessment (FHA) and a preliminary system safety assessment (PSSA), including the fault tree analysis (FTA). Other considerations include software design assurance and the installation environment. (iii) Equivalent Level of Safety Findings: Number AT16516LA-R-S-1 – §27.695(a)(1) Power boost and power-operated control system: The rule requires an alternate power-operated control system to be available so the R44 can be flown and landed safely in the event of any single failure. RHC petitioned to use a simple cost-effective hydraulic actuator based on the Bell 206 design, which has a proven reliability history free of any accidents resulting from jamming. The exemption was subsequently replaced by this ELOS, which is based on a control valve design that averts any single failure mode of the power portion of the system that prevents continued safe flight. Type Acceptance Report Rev.1 : 26 January 2022 TAR 3/21B/28 — R44 Series 5 Number TD10352LA-R/S-1 – §27.1401(d) Anti-collision Light System: RHC was granted an ELOS to replace the red anti-collision light lens with a combination red and white lens. This design, incorporating a forward-facing red segment and an aft-facing white segment, increases the visual conspicuity of the helicopter without affecting cockpit reflections. Number AT17187LA-R/P-1 – §27.952(c)(1)(i) Breakaway coupling separation load: The FAA Reauthorization Act of 2018 (“Section 317”) requires that all newly-produced helicopters after April 5, 2020 comply with the latest amendment of §27.952 for fuel system crash resistance. §27.952 (c) requires self-sealing breakaway couplings to prevent fuel spillage if components are displaced in a crash. For fuel lines with breakaway couplings the separation load must be no less than 300 pounds. RHC designed a self-sealing breakaway coupling for the R44 and R44 II fuel system with a separation load of approximately 250 pounds. This meets the intent of paragraph §27.952(c)(1)(i) because the RHC design places the coupling in-line in a flexible hose assembly. Measurable, visible hose slack and stretch would need to be taken up before any significant load would be applied to the coupling. The coupling is also shielded from inadvertent access by surrounding structure and components. Therefore, the ground maintenance failures the 300 lb load is intended to protect against would be highly unlikely. (iv) Exemptions: Exemption numbers 5473 for the R44 and 6692 for the R44 II have been superseded by the ELOS detailed above. (This was required for validation of the type certificate by EASA, whose rules do not provide for exemptions.) (v) Airworthiness Limitations: See the MM Chapter 3 Section 3.300 Airworthiness Limitations (3) Aircraft Noise and Engine Emission Standards: (i) Environmental Standard: The Model R44 Series has been certificated for noise under FAR Part 36. (Amendments 36-20 for the R44, 36-24 for the R44 II, and 36-30 for the Cadet.) (ii) Compliance Listing: RHC Report RTR 436 – Noise Test Substantiation See RFM Section 5 Performance. R44 R44 II R44 Cadet Engine: O-540 (225 shp) IO-540 (245 shp) O-540 (210 shp) Gross Weight: 2400 lb. 2500 lb. 2200 lb. Flyover Sound Exposure Level (SEL): 81.9 dB(A) C169-3 muffler 78.9 dB(A) C169-36 muffler 80.9 dB(A) 78.2 dB(A) (4) Certification Compliance Listing: RHC Report RTR 402 – R44 Weight and Balance RHC Report RTR 403 – R44 External Loads Proposal RHC Report RTR 410 – R44 Fuselage Structural Substantiation RHC Report RTR 415 – R44 Cabin Interior Structural Substantiation Type Acceptance Report TAR 3/21B/28 — R44 Series Rev.1 : 26 January 2022 6 RHC Report RTR 423 – R44 Electrical Load Analysis RHC Report RTR 425 – R44 Flight Test Proposal and Data RHC Report RTR 433 – R44 Compliance Checklist RHC Report RTR 440 – R44 Electrical System Load Test RHC Report RTR 472 – Substantiation of IO-540 Engine Installation – Rev.E Project Specific Certification Plan (PSCP) – Project No. AT16422LA-R – R44 Cadet – Revision A dated 12 January 2016 RHC Report 468 – R44 Cadet Substantiation (5) Flight Manual: Robinson R44 Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight Manual – Document RTR 461 CAA Accepted as AIR 2479 Robinson R44 II Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight Manual – Document RTR 462 CAA Accepted as AIR 2821 Robinson R44 Cadet Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight Manual – Document RTR 463 CAA Accepted as AIR 3490 (6) Operating Data for Aircraft and Engine: (i) Maintenance Manual: R44 Maintenance Manual and Instructions for Continued Airworthiness – Document RTR 460 Volume I (ii) Current service Information: R44 Service Bulletins and R44 Service Letters (iii) Illustrated Parts Catalogue: R44 Illustrated Parts Catalog – Document RTR 460 Volume II (7) Agreement from manufacturer to supply updates of data in (5), and (6): CAA 2171 form for R44 II from RHC V.P. Engineering dated 20 February 2003. Publications are now available on the RHC website at www.robinsonheli.com (8) Other Information: EASA Operational Suitability Data (OSD) Flight Crew Data R44 – Doc. RTR 465 FAA Master Minimum Equipment List – Robinson R22, R22 Alpha, R22 Beta, R22 Mariner (H10WE) – R44, R44 II (H11NM) RHC Report RTR 423 – R44 Electrical Load Analysis Type Acceptance Report Rev.1 : 26 January 2022 TAR 3/21B/28 — R44 Series 7 (9) CAA Comments on Original R44 Validation: There was one comment as a result of the CAA inspection of the R44. There were no 'designated' emergency exits on the aircraft under §27.807, which presumably means that all four doors carry out that function. However none of the door operating controls or instruction placards were red, as required by §27.1557(d). The main concern was with the rear door locking knob. This was an anonymous black knob with no instructions. If the door was locked a rear passenger unfamiliar with the aircraft might be unable to open the door and evacuate the aircraft. (They may be able to use the front door but if they were expected to do so it would also be expected that the door would be designated an emergency exit.) RHC advised a placard stating "Push to Lock" was added at the rear door locking knob in October 1993. This was revised in June 2011 to read "Push to Lock, Do Not Lock in Flight". Type Acceptance Report TAR 3/21B/28 — R44 Series Rev.1 : 26 January 2022 8 5. New Zealand Operational Rule Compliance Compliance with the retrospective airworthiness requirements of CAR Part 26 is a prerequisite for the grant of a type acceptance certificate. Civil Aviation Rules Part 26 Subpart B – Additional Airworthiness Requirements Appendix B – All Aircraft PARA: REQUIREMENT: MEANS OF COMPLIANCE: B.1 Marking of Doors and Emergency Exits To be determined on an individual aircraft basis B.2 Crew Protection Requirements – CAM 8 Appendix. B #.35 Not Applicable – Agricultural aircraft only Appendix E - Helicopters PARA: REQUIREMENT: MEANS OF COMPLIANCE: E.1 Doors and Exits FAR §27.783 and FAR §27.807(b)(2) – Simple direct- action levers comply with this requirement E.2.1 Emergency Exit Marking FAR §27.807(b)(3) and FAR §27.1557(d) Compliance with the following additional New Zealand operating requirements has been reviewed and were found to be covered by either the original certification requirements or the basic build standard of the aircraft, except as noted: Civil Aviation Rules Part 91 Subpart F – Instrument and Equipment Requirements PARA: REQUIREMENT: MEANS OF COMPLIANCE: 91.505 Shoulder Harness if Aerobatic; >10 pax; Flight Training FAR §27.785(b) – Four-point safety harness is an option 91.507 Pax Information Signs – Smoking, safety belts fastened N/A – Certificated seating capacity less than ten pax. seats 91.509 Min. VFR (1) ASI (2) Machmeter (3) Altimeter (4) Magnetic Compass (5) Fuel Contents (6) Engine RPM (7) Oil Pressure FAR §27.1303(a) – Fitted as Standard – See POH Section 7 N/A – No Mach limitations FAR §27.1303(b) – Fitted as Standard – See POH Section 7 FAR §27.1303(c) – Fitted as Standard – See POH Section 7 FAR §27.1305(d) – Fitted as Standard – See POH Section 7 FAR §27.1305(k) – Fitted as Standard – See POH Section 7 FAR §27.1305(h) – Fitted as Standard – See POH Section 7 (8) Coolant Temp (9) Oil Temperature (10) Manifold Pressure (11) Cylinder Head Temp (12) Flap Position (13) U/c Position (14) Ammeter/Voltmeter N/A – Air-cooled engine FAR §27.1305(j) – Fitted as Standard – See POH Section 7 FAR §27.1305(e) – Fitted as Standard – See POH Section 7 FAR §27.1305(b) – Fitted as Standard – See POH Section 7 N/A – Helicopter N/A – Fixed undercarriage FAR §27.1351(d) – – Fitted as Standard – See POH Section 7 91.511 Night (1)Turn and Slip (2) Position Lights Turn co-ordinator optional fit FAR §27.1385 (3) Anti-collision Lights (4) Instrument Lighting FAR §27.1401 FAR §27.1381 91.513 VFR Communication Equipment Operational Requirement – Compliance as applicable 91.517 IFR Instruments and Equipment Not Applicable – The R44 is only approved for VFR flight 91.519 IFR Communication and Navigation Equipment Not Applicable – The R44 is only approved for VFR flight 91.523 Emrgcy Eqpmt. (a) More Than 10 pax – First Aid Kits per Table 7 – Fire Extinguishers per Table 8 (b) More than 20 pax – Axe readily acceptable to crew (c) More than 61 pax – Portable Megaphones per Table 9 Not Applicable – Less than 10 passengers Not Applicable – Less than 10 passengers Not Applicable – Less than 20 passengers Not Applicable – Less than 61 passengers 91.529 ELT – TSO C91a after 1/4/97 (or replacement) To be determined on an individual aircraft basis 91.531 Oxygen Indicators – Volume/Pressure/Delivery Oxygen System not fitted as standard 91.533 Oxygen for un-pressurised aircraft Density Altitude Limit – 14,000 ft. However maximum altitude above ground level is 9000 ft. to allow landing within five minutes in case of fire. 91.541 SSR Transponder and Altitude Reporting Equipment Operational Requirement – Compliance as applicable 91.543 Altitude Alerting Device – Turbojet or Turbofan Not Applicable – Not turbo jet or turbofan powered 91.545 Assigned Altitude Indicator Not Applicable – The R44 is only approved for VFR flight A.15 ELT Installation Requirements To be determined on an individual aircraft basis Type Acceptance Report Rev.1 : 26 January 2022 TAR 3/21B/28 — R44 Series 9 Civil Aviation Rules Part 135 Subpart F – Instrument and Equipment Requirements PARA: REQUIREMENT: MEANS OF COMPLIANCE: 135.355 Seating/Restraints – Shoulder harness – flight-crew seats FAR §27.785(b) 135.357 Additional Instruments (Powerplant and Propeller) FAR §27.1305 135.359 Night Flight Landing light, Passenger compartment Operational Requirement – Compliance as applicable 135.361 IFR Operations Speed, Altitude, spare bulbs/fuses Not Applicable – The R44 is only approved for VFR flight 135.363 Emergency Equipment (Part 91.523 (a) and (b)) Operational Requirement – Compliance as applicable 135.367 Cockpit Voice Recorder Not Applicable – Less than 10 passenger seats 135.369 Flight Data Recorder Not Applicable – Less than 10 passenger seats 135.371 Additional Attitude Indicator Not Applicable – Not turbo jet or turbofan powered NOTES: 1. A Design Rule reference in the Means of Compliance column indicates the Design Rule was directly equivalent to the CAR requirement, and compliance is achieved for the basic aircraft type design by certification against the original Design Rule. 2. The CAR Compliance Tables above were correct at the time of issue of the Type Acceptance Report. The Rules may have changed since that date and should be checked individually. 3. Some means of compliance above are specific to a particular model/configuration. Compliance with Part 91/119 operating requirements should be checked in each case, particularly oxygen system capacity and emergency equipment. Attachments The following documents form attachments to this report: Copy of FAA Type Certificate Data Sheet Number H11NM Sign off …………………………………….. ……………………………............... David Gill Checked – Rens Molenaar Team Leader Aircraft Inspection Certification Engineer Appendix 1 List of Type Accepted Variants: Model: Applicant: CAA Work Request: Date Granted: R44 AC 21-1.2/NZCAR Part 21 Appendix A(c) R44 II Robinson Helicopter Company 3/21B/28 13 March 2003 R44 Cadet Robinson Helicopter Company 22/21B/10 26 January 2022 Type Acceptance Report TAR 3/21B/28 — R44 Series Rev.1 : 26 January 2022 10 Appendix 2 Three-view drawing Robinson R44 Cadet.