Be-400 flight crew reported returning to departure airport after experiencing a pneumatic system mal...

Attributes
ACN	1442033
Time
Date	201704
Local Time Of Day	0001-0600
Place
Locale Reference	ZZZ.Airport
State Reference	US
Environment
Light	Daylight
Aircraft 1
Make Model Name	Beechjet 400
Operating Under FAR Part	Part 135
Flight Phase	Takeoff
Route In Use	Direct
Flight Plan	IFR
Component
Aircraft Component	Pneumatic System
Person 1
Function	Pilot Not Flying Captain
Qualification	Flight Crew Air Transport Pilot (ATP)
Experience	Flight Crew Last 90 Days 25 Flight Crew Total 19500 Flight Crew Type 32
Person 2
Function	First Officer Pilot Flying
Qualification	Flight Crew Multiengine Flight Crew Flight Instructor Flight Crew Air Transport Pilot (ATP)
Experience	Flight Crew Last 90 Days 7 Flight Crew Total 2477 Flight Crew Type 7
Events
Anomaly	Aircraft Equipment Problem Critical Flight Deck / Cabin / Aircraft Event Smoke / Fire / Fumes / Odor

Narrative:

During the takeoff roll the master caution and air cond fail annunciator illuminated between the PIC's calls of '80 knots' and 'V1.' (note: the master caution and annunciator lights illuminated immediately prior to the call of 'V1.') because there was no engine fire; engine failure; or loss of directional control; the takeoff was continued in accordance with the takeoff briefing.immediately after rotation; and on the initial climb out; a loud 'pop' was heard. This was instantly followed by a loud 'rushing' sound of air and the feeling of 'popping' in the ears. The cabin/cockpit proceeded to fill with smoke and very hot air. The PIC and sic immediately exchanged controls; with the PIC assuming control of the aircraft. The sic [requested priority handling]; informing tower that an immediate return for landing was required. The sic confirmed with the tower that fire trucks would be needed; and they were rolled. Out of an abundance of caution; and because the winds were light; a return landing on [opposite direction runway] was performed. The landing was normal.the aircraft exited [the] runway. All souls on board (6 total) exited the aircraft safely and without incident. The passengers were returned to the FBO by the assistant airport director in an airport vehicle. The flight crew remained with the aircraft and had it towed back to the FBO by line personnel.

Original NASA ASRS Text

Title: BE-400 flight crew reported returning to departure airport after experiencing a pneumatic system malfunction shortly after takeoff that filled the aircraft with smoke and hot air.

Narrative: During the takeoff roll the Master Caution and AIR COND FAIL Annunciator illuminated between the PIC's calls of '80 knots' and 'V1.' (Note: the master caution and annunciator lights illuminated immediately prior to the call of 'V1.') Because there was no engine fire; engine failure; or loss of directional control; the takeoff was continued in accordance with the takeoff briefing.Immediately after rotation; and on the initial climb out; a loud 'pop' was heard. This was instantly followed by a loud 'rushing' sound of air and the feeling of 'popping' in the ears. The cabin/cockpit proceeded to fill with smoke and very hot air. The PIC and SIC immediately exchanged controls; with the PIC assuming control of the aircraft. The SIC [requested priority handling]; informing Tower that an immediate return for landing was required. The SIC confirmed with the Tower that fire trucks would be needed; and they were rolled. Out of an abundance of caution; and because the winds were light; a return landing on [opposite direction runway] was performed. The landing was normal.The aircraft exited [the] runway. All souls on board (6 total) exited the aircraft safely and without incident. The passengers were returned to the FBO by the Assistant Airport Director in an airport vehicle. The flight crew remained with the aircraft and had it towed back to the FBO by line personnel.

Data retrieved from NASA's ASRS site and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.

Be-400 flight crew reported returning to departure airport after experiencing a pneumatic system malfunction shortly after takeoff that filled the aircraft with smoke and hot air.