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(440)-951-47Documen

NC-04-0

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040 J

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Date

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rplanedeice.comPage

1 of 13

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13th 07

13th 07

35

Kelly Aerospace Thermal Systems 1625 Lost Nation Rd. Willoughby, Ohio 44094 (440)-951-4744 www.airplanedeice.com Job No. Document Title Document No. Rev Page

N06-02 Lancair 350/400 Thermawing Deice Installation Manual and ICA NC-04-040 J 2 of 135

REVISIONS

Rev. Description Pages Effected Author Date Approved

A Initial release Len Elder 3/17/05

B Updated installation procedures and added photos detailing procedures

John Kosir 8/31/05

C Kelly Aerospace Thermal Systems-Low Res Pics-Columbia in-house installation

Robert Simmons 4/27/06

D 300 Alternator-Front Mount Robert Simmons 6/13/06

E Alternator, Controller, Rear Engine Alternator Bracket, Engine and Alternator drive pulley’s


F Service Bulletin SB-06-002 Robert Simmons 9/14/06

G SB-06-002 Amendment 1 Robert Simmons 10/11/06

H Inserted GFS Sensor Section 11.1 Hipot Test Section 13 Mega-Ohm Test Section 11.0 Removed All Columbia 300 Installation procedures


I Changed Alternator Belt Tension Robert Simmons 3/19/07

J Added list of figures Stall strip position measurement HCM power wire attachment change Clarified DI-1 electrical pin out instructions Changed washer required on started drive

adapter Added alternator pulley alignment section Clarified GFS shunt install Clarified wing heater installation 350 Clarified stall strip installation 350 Standardized tail heater installation Updated weight and balance for 350 and

400 Added instructions for leading edge

reinforcement

10-13 19-21 66,93

81 86

87

95-96 97-101 102-103

104 112-115

116-121

Charles Persensky

8/13/07



The latest revision of the maintenance manual can be obtained from the Kelly Aerospace website at www.airplanedeice.com.

In the event Internet access is not available, please contact the Customer Service Office

for inquiry or a copy of the latest revision:

Kelly Aerospace

1625 Lost Nation Road

Lost Nation Airport

Willoughby, Ohio 44094

440-951-4744

NOTE: This document should remain with this aircraft, in its entirety, as part of the aircraft permanent records.



AIRWORTHINESS LIMITATIONS

The Airworthiness Limitations section is FAA approved and specifies maintenance required under 43.16 and 91.403 of the Federal Aviation Regulations unless an alternate program has been FAA approved.

Not Applicable



Table of Contents 1.0 INTRODUCTION ...................................................................................................................... 13

1.1 Background .......................................................................................................................... 13 1.2 Scope ................................................................................................................................... 13 1.3 Applicable Documents and Drawings ................................................................................... 14

2.0 SAFETY INSTRUCTIONS ....................................................................................................... 15 2.1 Solvent .................................................................................................................................. 15 2.2 Electrical Power .................................................................................................................... 15

3.0 MATERIALS AND TOOLS ....................................................................................................... 16 3.1 Consumable Material List ..................................................................................................... 16 3.2 Items to be Procured Locally ................................................................................................ 16 3.3 Vendor Contacts ................................................................................................................... 17

4.0 OPEN AIRCRAFT .................................................................................................................... 18 4.1 Applicable manuals ............................................................................................................... 18

4.1.1 Engine Area ................................................................................................................................ 18

4.1.2 Wing Section ............................................................................................................................... 18

4.1.3 Center Section ............................................................................................................................ 18

4.1.4 Interior ......................................................................................................................................... 18

4.1.5 Baggage Compartment ............................................................................................................... 18

5.0 WING PREPARATION AND MOUNTING HOLES ................................................................... 19 5.1 Cover Wings ......................................................................................................................... 19 5.2 Stall Strip Removal ............................................................................................................... 19

5.2.1 Stall Strip Position Measurement ................................................................................................ 19

5.2.2 Stall Strip Removal ...................................................................................................................... 21

5.3 Left Wing Stall Strip and Access Holes ................................................................................. 23 5.4 Right Wing stall strip and Access Holes ............................................................................... 24 5.5 PVC Pipe Guides Hole Saw ................................................................................................. 25 5.6 Drilling of Inboard Wing Rib from Center Section ................................................................. 28 5.7 Drilling Wing Stud Locations ................................................................................................. 29

5.7.1 Outboard Heater- Left and Right ................................................................................................. 29

5.7.2 Left Inboard Heater. .................................................................................................................... 29

5.7.3 Right Inboard Heater ................................................................................................................... 30

5.8 Drilling Holes to Secure Power Wires ................................................................................... 31 5.9 Drilling of RTD Holes ............................................................................................................ 31

5.9.1 Right Outboard RTD ................................................................................................................... 31



5.9.2 Left Outboard RTD ...................................................................................................................... 32

5.9.3 Right Inboard RTD ...................................................................................................................... 32

5.9.4 Left Inboard RTD ......................................................................................................................... 32

5.10 Wing Electrical Hard Point Installation ................................................................................ 32 6.0 POWER WIRING INSTALLATION ........................................................................................... 34

6.1 Left Wing Wiring ................................................................................................................... 34 6.1.1 Negative Stud Connection .......................................................................................................... 36

6.1.2 Positive Wires ............................................................................................................................. 37

6.1.3 Negative Wire from Access Panel to Terminal Block .................................................................. 37

6.1.4 Negative Jumper Wire ................................................................................................................. 38

6.1.5 Pull the Data wire ........................................................................................................................ 38

6.2 Right Wing Wiring ................................................................................................................. 39 6.2.1 Securing the Wires and Stud Installation .................................................................................... 39

6.3 RTD’s for Left and Right wing (4 Locations) ......................................................................... 43 7.0 HORIZONTAL STABILIZER ..................................................................................................... 48

7.1 Horizontal Stabilizer Preparation and Mounting Hole Placement ......................................... 48 7.2 Left and Right Horizontal Stabilizer RTD Installation ............................................................ 51 7.3 Horizontal Stabilizer Power Wires ......................................................................................... 54 7.4 RTD Sensor Hole Preparation and Installation ..................................................................... 58 7.5 Fuselage Tail Electrical Hard-points ..................................................................................... 58 7.6 Well Nut Installation .............................................................................................................. 59 7.7 OAT Sensor .......................................................................................................................... 64 7.8 Shunt and Power Terminal Block.......................................................................................... 64 7.9 Alternator to Terminal Block ................................................................................................. 65 7.10 Power Wires between Terminal Block and Tail .................................................................. 66

8.0 CONTROL WIRING HARNESSES .......................................................................................... 70 8.1 Selector Switch Hole and Harness Connection .................................................................... 70 8.2 Controller Harness and Aircraft Interfaces ............................................................................ 71 8.3 Alternator Field Relay Harness ............................................................................................. 76 8.4 OAT and Heater Control Module Data Cable Harnesses ..................................................... 78 8.5 OAT Wiring Data Cable Harness .......................................................................................... 79 8.6 Left Wing HCM Data Cable Harness .................................................................................... 80 8.7 Right Wing HCM Data Cable Harness .................................................................................. 80 8.8 Tail HCM Data Cable Harness ............................................................................................. 81 8.9 Summarized Electrical Harness Pin-outs .............................................................................. 81



8.9.1 DI-1 Connector ............................................................................................................................ 81

8.9.2 J-DI-24 Connector ....................................................................................................................... 82

8.9.3 Wire Harnesses for Wings and Tail ............................................................................................. 83

8.9.4 Wire Harness to OAT .................................................................................................................. 83

9.0 ALTERNATOR INSTALLATION ............................................................................................... 84 9.1 350 and 400 Alternator Bracket Installation .......................................................................... 84 9.2 Alternator Drive Pulley Installation ........................................................................................ 86 9.3 Alternator Pulley Alignment .................................................................................................. 87 9.4 Set Belt tension .................................................................................................................... 88

10.0 DEICE CONTROL MODULE ................................................................................................ 89 11.0 HEATER CONTROL MODULE (HCM) AND BRACKETS .................................................... 90

11.1 Right Wing Heater Control Module ..................................................................................... 90 11.2 Left Wing Heater Control Module ....................................................................................... 91 11.3 Empennage Heater Control Module ................................................................................... 92 11.4 (2) Amp Thermawing System Circuit Breaker ..................................................................... 92 11.5 (7.5) Amp Alternator Field Circuit Breaker .......................................................................... 93

12.0 MEGA-OHM TEST PROCEDURE ........................................................................................ 94 13.0 Ground Fault Sensor (GFS) .................................................................................................. 95 14.0 WING DEICE HEATER AND STALL STRIP INSTALLATION Columbia 350/400 ................ 97

14.1 Wing Deice Heater Part Numbers- 350 .............................................................................. 98 14.2 Wing Deice Heater Part Numbers- 400 .............................................................................. 98 14.3 Wing Deice Heater Installation ........................................................................................... 99 14.4 Stall Strip Part Numbers- 350 ........................................................................................... 102 14.5 Stall Strip Part Numbers- 400 ........................................................................................... 102 14.6 Stall Strip Installation- 350 ................................................................................................ 103

15.0 Horizontal Stabilizer Deice Heater Installation Lancair 350 and 400 .................................. 104 16.0 HIPOT TESTING ................................................................................................................ 105

16.1 Obtain a Suitable HiPot Tester. ........................................................................................ 105 16.2 Connect Hipot Ground ...................................................................................................... 106

17.0 Operation and Testing ........................................................................................................ 108 17.1 Required Equipment ......................................................................................................... 108 17.2 Diagnostic Display ............................................................................................................ 108 17.3 Power Wiring Integrity Check ........................................................................................... 108 17.4 Initial Powerup Check ....................................................................................................... 109 17.5 Operational Test ............................................................................................................... 111



17.6 Weight and Balance ......................................................................................................... 111 17.6.1 Lancair 350 Thermawing Deice System Weight and Balance .................................................. 112

17.6.2 Lancair 400 Thermawing Deice System Weight and Balance .................................................. 114

18.0 LEADING EDGE REINFORCEMENT TAPE INSTALLATION ............................................ 116 18.1 Required tools .................................................................................................................. 116 18.2 Measure ............................................................................................................................ 116 18.3 Mark Length ...................................................................................................................... 117 18.4 Cut to Length .................................................................................................................... 117 18.5 Peel Backing ..................................................................................................................... 118 18.6 Attach one end ................................................................................................................. 118 18.7 Attach Remainder ............................................................................................................. 119 18.8 Attach to Heater Surface .................................................................................................. 119 18.9 Verify Installation .............................................................................................................. 120

19.0 Final Assembly ................................................................................................................... 122 20.0 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA).......................................... 123

20.1 Introduction ....................................................................................................................... 123 20.2 Description ........................................................................................................................ 123 20.3 Control, Operation Information ......................................................................................... 123 20.4 Maintenance Instructions .................................................................................................. 123 20.5 TROUBLESHOOTING ..................................................................................................... 124

20.5.1 Soft Faults ................................................................................................................................. 124 20.5.1.1 Low Aircraft Bus Voltage ..................................................................................................................... 124

20.5.1.2 Low Deice Alternator Output ............................................................................................................... 124

20.5.1.3 Heater Failure ...................................................................................................................................... 124

20.5.2 Hard Faults ................................................................................................................................ 125 20.5.2.1 ftNone .................................................................................................................................................. 125

20.5.2.2 ftDeiceVolt ........................................................................................................................................... 125

20.5.2.3 ftHtrOvrTemp ....................................................................................................................................... 125

20.5.2.4 ftOverCurr ............................................................................................................................................ 125

20.5.2.5 ftHiResist ............................................................................................................................................. 125

20.5.2.6 ftLoResist ............................................................................................................................................ 125

20.5.2.7 ftOverVolt ............................................................................................................................................ 125

20.5.2.8 ftIntrnlErr .............................................................................................................................................. 126

20.5.2.9 ftBadTemp ........................................................................................................................................... 126

20.5.2.10 ftRtdOpen .......................................................................................................................................... 126

20.5.2.11 ftRtdShort........................................................................................................................................... 126

20.5.2.12 ftExcitatn ............................................................................................................................................ 126



20.5.2.13 ftConfigErr ......................................................................................................................................... 126

20.5.2.14 ftWatchdog ........................................................................................................................................ 126

20.5.2.15 ftRamFail ........................................................................................................................................... 126

20.5.2.16 ftFailedHtr .......................................................................................................................................... 126

20.5.2.17 GFS Trip ............................................................................................................................................ 127

20.6 Hr/Annual .......................................................................................................................... 128 20.6.1 Deice Heaters ........................................................................................................................... 128

20.6.2 Control Switch / Annunciator ..................................................................................................... 128

20.6.3 Lamp Test ................................................................................................................................. 128

20.6.4 Deice Control Module ................................................................................................................ 129

20.6.5 Heater Control Modules ............................................................................................................ 130

20.6.6 Wiring ........................................................................................................................................ 130

20.6.7 De-Ice Heaters .......................................................................................................................... 130

20.6.8 Control Switch / Annunciator ..................................................................................................... 131

20.6.9 Deice Control Module ................................................................................................................ 131

20.6.10 Heater Control Module ............................................................................................................ 131

20.6.11 Ground fault sensor ................................................................................................................. 131

20.6.12 RTD’s ....................................................................................................................................... 131

20.6.13 Shunt ....................................................................................................................................... 131

20.6.14 Alternator ................................................................................................................................. 131

20.6.15 Fuses ....................................................................................................................................... 132

20.6.16 Circuit Breaker ......................................................................................................................... 132

20.6.17 Wiring ...................................................................................................................................... 132

20.6.18 Overhaul .................................................................................................................................. 132

21.0 MISCELLANEOUS ............................................................................................................. 133 21.1 Tedlar Washer .................................................................................................................. 133 21.2 Placards ............................................................................................................................ 133 21.3 Removal and or Replacement information........................................................................ 134 21.4 Diagrams .......................................................................................................................... 134 21.5 Special Inspection Requirements ..................................................................................... 135 21.6 Application of Protective Treatments ................................................................................ 135 21.7 Data .................................................................................................................................. 135 21.8 List of Special Tools ......................................................................................................... 135



LIST OF FIGURES Figure 1: Protect Aircraft Wings ............................................................................................................................................................... 19

Figure 2: Place tape on the wing .............................................................................................................................................................. 20

Figure 3: Record relevant distances ......................................................................................................................................................... 20

Figure 4: Scribing around Stall Strips ....................................................................................................................................................... 21

Figure 5: Removal of Stall Strips ............................................................................................................................................................. 22

Figure 6: File Ridges from Stall Strip Area .............................................................................................................................................. 22

Figure 7: Drill Hole in Wing Root Rib Web ............................................................................................................................................... 23

Figure 8: Inboard Right Wing Root Rib .................................................................................................................................................... 24

Figure 9: Access Hole in Right Wing Stub Rib ........................................................................................................................................ 25

Figure 10: Hole Saw setup ...................................................................................................................................................................... 26

Figure 11: Wrap tape around PVC pipe................................................................................................................................................... 26

Figure 12: Insert PVC guide tube into wing access hole ......................................................................................................................... 27

Figure 13: Hole tool attached to drill extension rod ................................................................................................................................. 27

Figure 14: Drill hole into the rib ................................................................................................................................................................ 28

Figure 15: Center rib hole placement ....................................................................................................................................................... 28

Figure 16: Use a grinding stone to gently smooth edge and remove mesh ............................................................................................. 30

Figure 17: Holes used to secure wire harness with wire wraps hanging out ........................................................................................... 31

Figure 18: Apply mixed two part epoxy to both mating surfaces ............................................................................................................. 33

Figure 19: Assembled hard point attachment .......................................................................................................................................... 33

Figure 20: Wing interior ........................................................................................................................................................................... 35

Figure 21: Outboard negative wire ........................................................................................................................................................... 36

Figure 22: Inboard negative wire .............................................................................................................................................................. 36

Figure 23: Positive wire routing ............................................................................................................................................................... 37

Figure 24: Negative wire routing ............................................................................................................................................................... 37

Figure 25: Connect the heaters adjacent to the landing light.................................................................................................................... 38

Figure 26: Countersink mounting hole ...................................................................................................................................................... 39

Figure 27: Position terminal studs in mounting holes ............................................................................................................................... 40

Figure 28: Thread retaining nut onto terminal stud ................................................................................................................................... 40

Figure 29: Inject epoxy around the terminal stud ...................................................................................................................................... 41

Figure 30: Trim the terminal stud .............................................................................................................................................................. 42

Figure 31: Sand rough areas of epoxy ..................................................................................................................................................... 42

Figure 32: Piloted countersink micro-stop tool .......................................................................................................................................... 43

Figure 33: File leading edge for RTD placement ...................................................................................................................................... 44

Figure 34: Insert RTD into nylon over braid .............................................................................................................................................. 45

Figure 35: Pull RTD through leading edge hole ........................................................................................................................................ 45

Figure 36: RTD in mounting recess .......................................................................................................................................................... 46

Figure 37: After curing smooth the epoxy ................................................................................................................................................. 46

Figure 38: Transfer distance from web gap seal to center of electrical hardpoint ..................................................................................... 48

Figure 39: Transfer distance from gap seal .............................................................................................................................................. 49

Figure 40: Mark centerline of electrical hardpoint ..................................................................................................................................... 49

Figure 41: Measure to center of mounting holes ...................................................................................................................................... 50



Figure 42: Drill mounting hole in horizontal stabilizer ............................................................................................................................... 51

Figure 43: Mark centerline of access holes in rib ..................................................................................................................................... 52

Figure 44: Drill the slot holes .................................................................................................................................................................... 52

Figure 45: File the slot sides ..................................................................................................................................................................... 53

Figure 46: Drill an access hole ................................................................................................................................................................. 53

Figure 47: Use a temporary bridge to hold the stud in place while applying epoxy .................................................................................. 55

Figure 48: Routing the power wire ............................................................................................................................................................ 55

Figure 49: Materials needed for two-part expanding foam ....................................................................................................................... 56

Figure 50: Inject foam into horizontal stabilizer ........................................................................................................................................ 56

Figure 51: Use a hacksaw to trim the stud ............................................................................................................................................... 57

Figure 52: Fuselage electrical hard-point insulators (exterior) .................................................................................................................. 58

Figure 53: Epoxied insulators ................................................................................................................................................................... 59

Figure 54: File the leading edge to a depth of .090” ................................................................................................................................. 60

Figure 55: Verify the depth of the well nut area ........................................................................................................................................ 60

Figure 56: Use a straight edge to visually inspect the impression ............................................................................................................ 61

Figure 57: When completed the well nut hole should look like this ........................................................................................................... 61

Figure 58: Well nuts and mounting screw in position ............................................................................................................................... 62

Figure 59: Apply masking tape around the well nut area .......................................................................................................................... 62

Figure 60: Apply epoxy to the well nut taper area .................................................................................................................................... 63

Figure 61: Smooth epoxy with tape .......................................................................................................................................................... 63

Figure 62: Shunt ....................................................................................................................................................................................... 64

Figure 63: Power wire through firewall ..................................................................................................................................................... 65

Figure 64: Buss bar between shunt and power distribution terminal ........................................................................................................ 65

Figure 65: View toward rear bulkhead with power wires .......................................................................................................................... 67

Figure 66: Route power wires through the fuselage ................................................................................................................................. 67

Figure 67: Secure wires with wire ties and tie blocks ............................................................................................................................... 68

Figure 68: Secure wires with wire ties ...................................................................................................................................................... 68

Figure 69: Secure wire bundle to the fuselage ......................................................................................................................................... 69

Figure 70- Use an instrument panel cutout tool to make the annunciator holes ....................................................................................... 70

Figure 71- Placard placement .................................................................................................................................................................. 71

Figure 72: Connect the wire harness to the selector switch ..................................................................................................................... 71

Figure 73: Replace the panel making sure not to damage the selector switch ......................................................................................... 72

Figure 74: Route harness down the left side of the fuselage .................................................................................................................... 72

Figure 75: Splice into the “Lamp Test” wire .............................................................................................................................................. 73

Figure 76: Circuit breaker panel ............................................................................................................................................................... 74

Figure 77: Oxygen circuit breaker detail ................................................................................................................................................... 74

Figure 78: Shunt placement and wiring .................................................................................................................................................... 75

Figure 79: Mount alternator field relay ...................................................................................................................................................... 76

Figure 80: Location for 7.5 amp ALT 3 field circuit breaker ...................................................................................................................... 76

Figure 81: Bend the buss bar to make room for the new circuit breaker .................................................................................................. 77

Figure 82: Terminal strip ........................................................................................................................................................................... 78

Figure 83: Connect the wire harness to the OAT ..................................................................................................................................... 79



Figure 84: Attach control harness to HCM left wing ................................................................................................................................. 80

Figure 85: Rear view of DI-1 ..................................................................................................................................................................... 81

Figure 86: Alternator bracket to be mounted on the rear of the engine .................................................................................................... 84

Figure 87: Alternator bracket with alternator attached .............................................................................................................................. 85

Figure 88: Tensioner rod and bracket ...................................................................................................................................................... 85

Figure 89: Drive Pulley ............................................................................................................................................................................. 86

Figure 90: Insert tensioner rods ................................................................................................................................................................ 87

Figure 91: Installed alternator being tensioned ......................................................................................................................................... 88

Figure 92: Use a calibrated torque wrench and alternator torque tool to determine the belt tension ........................................................ 88

Figure 93: Drill mounting holes for the de-ice controller ........................................................................................................................... 89

Figure 94: Mount wing heater module bracket ......................................................................................................................................... 90

Figure 95: HCM mounted in wing ............................................................................................................................................................. 91

Figure 96: Tail heater module bracket mount ........................................................................................................................................... 92

Figure 97: Bend buss bar to isolate the circuit breaker ............................................................................................................................ 93

Figure 98: GFS shunt installed in the correct location .............................................................................................................................. 95

Figure 99: Shunt wiring detail ................................................................................................................................................................... 96

Figure 100: Locate the stud .................................................................................................................................................................... 100

Figure 101: Make an impression in the heater ....................................................................................................................................... 100

Figure 102: Puncture heater with a sharp instrument ............................................................................................................................. 100

Figure 103: Insert connector screw ........................................................................................................................................................ 101

Figure 104: Installed connection screw .................................................................................................................................................. 101

Figure 105: HiPot tester.......................................................................................................................................................................... 105

Figure 106: HCM’s ready for HiPot test .................................................................................................................................................. 106

Figure 107: Properly grounded HiPot negative lead ............................................................................................................................... 106

Figure 108: Wires disconnected before HiPot test ................................................................................................................................. 107

Figure 109: Required materials for leading edge reinforcement installation ........................................................................................... 116

Figure 110: Measure area to be covered ............................................................................................................................................... 116

Figure 111: Mark length of heater .......................................................................................................................................................... 117

Figure 112: Use a cutting board to prevent damage to wing .................................................................................................................. 117

Figure 113: Remove release paper ........................................................................................................................................................ 118

Figure 114: Attach one corner then stretch across to ensure fit ............................................................................................................. 118

Figure 115: Apply heat to adhesive tape ................................................................................................................................................ 119

Figure 116: Apply heat while firmly pressing down to attach leading edge tape ..................................................................................... 119

Figure 117: Forward view of installation ................................................................................................................................................. 120

Figure 118: Side view of finished installation .......................................................................................................................................... 120

Figure 119: Detail of copper bus after leading edge tape installation ..................................................................................................... 121

Figure 120: Hard fault ............................................................................................................................................................................. 129

Figure 121: Soft fault .............................................................................................................................................................................. 129

Figure 122: Tedlar® washer installed prior to heater .............................................................................................................................. 133

Figure 123: Field control relay placard ................................................................................................................................................... 134



1.0 INTRODUCTION

1.1 Background

The Kelly Aerospace Thermawing Deice System is designed to remove ice from the leading edge of the wings and horizontal stabilizers of the aircraft. The system is intended as an aid during inadvertent flight in icing conditions. The system is not intended to allow flight into known icing conditions.

The Kelly Aerospace Thermawing Deice System Kit is comprised of the Thermawing electrically heated deice heaters, a dedicated alternator including drive pulley and belt, Deicer Control Module, Heater Control Modules, Control Switch with integral annunciator, 2 amp circuit breaker, current limiter, and miscellaneous mounts, covers, hardware and wire.

The pilot controls the system via the Thermawing De-Ice Control Switch. After setting the Control Switch to the ‘ON’ position, the controller will conduct a self-test and then illuminate the ‘AIRFRAME’ annunciator in green. The system operates automatically by sensing the outside air temperature and other system inputs. When the system enters operational mode the ‘ON’ annunciator will illuminate in green.

1.2 Scope

These instructions guide the proper installation and maintenance of the Kelly Aerospace Thermawing Deice System for Columbia 350 and 400 aircraft. The Thermawing Deice System kit contains all of the necessary components to accomplish the installation. Instructions for continued airworthiness are included in the maintenance and troubleshooting sections of this document.



1.3 Applicable Documents and Drawings Lancair Columbia 350 and 400 Airplane Maintenance Manual (AMM) Lancair Columbia 350 and 400 Airplane Electrical Manual (AEM) Federal Aviation Administration (FAA) AC 43.13-1 & 2 Recommended Practices and

Procedures latest revision. Applicable Manufacturers Material Safety Data Sheets (MSDS) Teledyne Continental Engine Maintenance Manual (EMM) Kelly Aerospace Kit Component List NC-04-036- (Columbia 350) Kelly Aerospace Kit Component List NC-04-038- (Columbia 400) Kelly Aerospace NC-05-003- Thermawing Deice Heater Installation Guide Kelly Aerospace Drawing AL-0003- Columbia 350/400 Rear Alternator Mounting Kelly Aerospace Drawing DI-00034- Columbia 350/400 Deice Electrical Schematic Kelly Aerospace Drawing DI-00035- Columbia 350 Deice System Kelly Aerospace Drawing DI-00037- Columbia 400 Deice System Kelly Aerospace Drawing DI-00054- RTD Assembly Kelly Aerospace Drawing DI-00066- Wire Harness – Deice controller to Alternator Field Kelly Aerospace Drawing DI-00067- Wire Harness Kit - Switch to Controller Kelly Aerospace Drawing DI-00068- Wire Harness – Eaton Switch to Wire Harness Kelly Aerospace Drawing DI-00069- Wire Harness Kit – Wing and Tail Kelly Aerospace Drawing DI-00070- Wire Harness Kit – OAT Probe Kelly Aerospace Drawing DI-00082- (6 Pages) Wing/Fuselage Hole Locations Kelly Aerospace Drawing DI-00089- Terminal Stud Assembly - Wings Kelly Aerospace Drawing DI-00090- Terminal Stud Assembly – Horizontal Stabilizer Kelly Aerospace Drawing DI-00095- Horizontal Stabilizer Hole Locations Kelly Aerospace Drawing DI-00099- Tail Insulator Installation Kit Kelly Aerospace Drawing DI-00100- Terminal Stud Assembly Kelly Aerospace Drawing DI-00101- Stall Strip and electrical connection and mounting Columbia Drawing LC57605000- Stall Strip Location

NOTE: Aircraft with electric air conditioning installed refer to drawing DI-00034 Sheet 3 for 14

VDC or Sheet 7 for 28 VDC for wiring detail



2.0 SAFETY INSTRUCTIONS

2.1 Solvent

Adhesive and solvent vapors are toxic and flammable. Use only with proper ventilation. Avoid prolonged breathing of vapors. Excessive exposure may cause dizziness or nausea. Seek fresh air immediately.

Follow precautions listed on the manufacturers Material Safety Data Sheets (MSDS) sheets for health and safety considerations. The manufacturers Material Safety Data Sheets supersede this document regarding environmental information as well as handling, application, removal, and disposal procedures.

2.2 Electrical Power

This installation involves the addition of equipment to the aircraft electrical system. A separate alternator is installed to provide all requisite electrical power for the Thermawing Deice System. The Thermawing Deice System electrical equipment should be isolated from the aircraft electrical system.

NOTE: Do not connect other electrical loads to the Thermawing Electrical System. The Thermawing Electrical

System operates on varying voltages that could cause damage or fire to improperly attached devices.

Electrical power should be disconnected from the aircraft to reduce the risk of electrical shock or spark induced fire.



3.0 MATERIALS AND TOOLS

3.1 Consumable Material List

Description Part Number Vendor

Roller, 4" Hard surface 7533A12 www.mcmaster.com

Epoxy Gel 5 min Devcon 14265 66215A23 www.mcmaster.com

Nozzles, 12" 74695A12 www.mcmaster.com

Heat Gun 12-00527 www.aircraftspruce.com

#6 Wire Black MS22759/16-6 www.aircraftspruce.com

#6 Wire White MS22759/16-9 www.aircraftspruce.com

Two Part Expanding Foam X30 Richfill 101-2784 01-08900 (1qt) www.aircraftspruce.com

Stainless Professional Knife 12-00339 www.aircraftspruce.com

Replacement blades 12-00340 www.aircraftspruce.com

Micro stop countersink 12-00940 www.aircraftspruce.com

Countersink cutter # 10 12-00944 www.aircraftspruce.com

Syringes 50cc 7510A665 www.mcmaster.com

1 1/4" PVC Pipe 10 feet Local hardware store

Rod 7/16" 13 feet Local hardware store

Weed trimmer line assorted colors Local hardware store

3.2 Items to be Procured Locally Sand paper Masking tape Paper covering Clean rags Torque Wrench Mechanics Hand Tools Alcohol PVC Pipe 1 ¼“ Hole Saw 1 ¼” Diamond Blade (kit) Hole Saw 1” Diamond Blade (kit) Hole Saw 3/4” Diamond Blade (kit) Hole Saw 9/16” Diamond Blade (kit) Silicon Sealer ½” Hole Saw



3.3 Vendor Contacts McMaster-Carr

Atlanta (404) 346-7000 Chicago (630) 833-0300 Cleveland (330) 995-5500 Los Angeles (562) 692-5911 New York/ Philadelphia (609) 689-3000 Aircraft Spruce (877) 477-7823 East (770) 487-2310 West (951) 372-9555



4.0 OPEN AIRCRAFT

4.1 Applicable manuals

Prior to installation read the applicable manuals for the following operations.

4.1.1 Engine Area

Remove upper and lower cowl sections

4.1.2 Wing Section

Remove navigation light assemblies L & R Remove Landing Light Lenses and Lamps Remove Stall Warning Indicator and label wires Remove Under-wing vent panels DO NOT REMOVE FUEL BAY PANELS

4.1.3 Center Section

Remove lower emergency access panel

4.1.4 Interior

Remove Pilot and Co-pilot seats and cover plates in floor Remove Passenger seats Remove glare shield Remove both MFD's Unscrew Left Engine Instrument Cluster Remove Pilots, Co-pilots kick panels, and doorsill protectors Remove Pilots, Co-pilots, and Passenger Side Panels

4.1.5 Baggage Compartment

Remove all carpeting and side panels in forward and aft baggage area Remove forward floor access panel Remove aft section battery panel and disconnect batteries Remove aft section aft panel and remove ELT



5.0 WING PREPARATION AND MOUNTING HOLES

5.1 Cover Wings Prepare the aircraft wings for drilling and marking steps by covering with suitable paper or an equivalent protector. The application of a suitable protector will decrease the likelihood of wing damage during system installation. See Figure 1.

Figure 1: Protect Aircraft Wings

5.2 Stall Strip Removal

NOTE THIS STEP IS CRITICAL: During this step be patient and take

as much time is needed to accomplish this process correctly

5.2.1 Stall Strip Position Measurement

Prior to removing the stall strips, ensure that you have the exact location of the stall strips marked in any way necessary. It is extremely important that the new stall strip is set at exactly the same angle as the old stall strip. The method we prefer is explained below. On the trailing edge of the wing find a suitable datum to make spanwise measurements from the edge of the aileron is suggested. Place a strip of tape directly behind the stall strip along the trailing edge of the wing and another piece of equal length about mid-way on the wing parallel to the first piece of tape. The tape used should be of the type that does not mar the paint in any way. See Figure 2.



Figure 2: Place tape on the wing

Using a flexible tape measure put the lip on the back edge of the wing and hang the other end over the stall strip. Use a marker to record the position of the tape measure on the masking tape and record the position of the apex of the stall strip. See Figure 3.

Figure 3: Record relevant distances



Repeat this process for both the inboard and outboard ends of each stall strip to ensure proper replacement. If possible do not remove the tape from the wing and use the same tape measure to identify the location for the stall strip to be re-installed at. If the tape has to be removed measure from the datum point (such as the aileron edge) and record the distance to the markings on the tape from the chord wise measurement. The inboard edge of the new stall strip has to be located exactly as the Columbia drawings state (LC57605000 for 400 and LA57605000 for 350). The drawing includes a tolerance of +/- one-inch lateral movement, but the heater CANNOT allow for those tolerances. The heater placement MUST be as close to the wing station as possible. Any deviance in any direction will result in an inadequate installation.

5.2.2 Stall Strip Removal

Locate the stall strip to the correct wing station. File down the leading edges of the original stall strip to create a flat surface. On the filed surface, drill a pilot hole 3/4” from the outside edges of the stall strip. The pilot hole should penetrate the aircraft wing. The pilot hole will provide proper alignment for the well nut. We highly recommend using Columbia’s stall strip placement templates (Located on CAM’s public ftp). Remove the stall strips by scribing around the edge of the strips to start the separation of the strip from the wing. Please refer to Figure 4.

NOTE: Be careful not to penetrate the gel-coat. Damage to the

underlying conductive mesh should be avoided.

Figure 4: Scribing around Stall Strips



Using a putty knife or sharp scraper, separate the stall strips from the wing leading edge. See Figure 5.

Figure 5: Removal of Stall Strips

Sand and file the epoxy left from the stall strips. The wing surface should be smooth with no sharp edges. See Figure 6.

Figure 6: File Ridges from Stall Strip Area



Laterally locate the exact position of the where the new stall strip will be. Drill a pilot hole 3/4” from the outside edges of the stall strip. The pilot hole will provide proper alignment for the well nut.

5.3 Left Wing Stall Strip and Access Holes NOTE: Verify that the proper drawing sheet is being followed. The drawing consists of several pages and is used for the 350 and 400 aircraft.

When drilling holes exercise care not to delaminate the fiberglass structure. Use sharp drills and diamond impregnated hole saws and do not force the tools. The holes must have clean edges with minimal chipping of the gel coat.

Drill 2 holes in leading edge for stall strips per drawing DI-00082 page 2 for the 350 and DI-00082 page 5 for the 400.

As shown in Figure 7, drill a hole through the wing root rib web to provide access for the wires to run into the fuselage. Hole size and locations are detailed on the left hand side of Drawing DI-00082 Page 1.

Figure 7: Drill Hole in Wing Root Rib Web



5.4 Right Wing stall strip and Access Holes

When drilling holes exercise care not to de-laminate the fiberglass structure. Use sharp drills and diamond impregnated hole saws and do not force the tools. The holes must have clean edges with minimal chipping of the gel coat.

Drill the required mounting hole locations in the right wing per the instructions on Kelly Aerospace drawing DI-00082 page 6 for the Columbia 400, DI-00082 page 3 for the Columbia and 350.

NOTE: Verify that the proper drawing sheet is being followed. The drawing consists of several pages and is used

for the 350 and 400 aircraft.

An access hole is drilled in the stub rib at the wing cuff. Refer to drawing sheet of DI-00082 (Page 1) for hole diameter. Use a field-fabricated guide to place the hole saw at the proper location. The guide is made of 1 ¼ PVC pipe (local procurement) to guide the hole saw. Wrap at least ¼“ of material around outside of pipe to provide a spacer to keep the hole saw from getting too close to wing structure.

Figure 8: Inboard Right Wing Root Rib



5.5 PVC Pipe Guides Hole Saw

The PVC pipe (local acquisition) is inserted into the right wing access opening near the wing root. The taped end of the PVC pipe is pushed into contact with the stub rib web as close to the leading edge as practicable. Insert the 1 ¼” hole saw until it contacts the rib web. Drill the access hole through the web taking care not to damage the lines running along the wing spar. See Figure 9.

Figure 9: Access Hole in Right Wing Stub Rib



Figure 10: Hole Saw setup

An 11-foot bit extension (local fabrication) is used to connect the hole saw to the drill motor. See Figures 10 through 14.

Figure 11: Wrap tape around PVC pipe



Figure 12: Insert PVC guide tube into wing access hole

Figure 13: Hole tool attached to drill extension rod



Figure 14: Drill hole into the rib

5.6 Drilling of Inboard Wing Rib from Center Section

With a piece of 1 ¼” x 18” PVC pipe, wrap tape wrapped around the edge of the pipe to create a ¼” edge distance from the structure. From the lower forward access area, drill a 1” hole into the left and right side rib locations forward of the existing fuel lines at the leading edge. Drill as close to the bottom of the rib as possible. Insert the 1” x 3‘ clear plastic tube. Run the tube into the wing so it extends all the way in up to the inboard wing access hole and insure it rests below the fuel lines. After power wires and heater studs are in place push clear tube outboard to the power stud. Keep 1” outside of the inboard rib. Epoxy the inboard end around the diameter of the tube to the rib. Epoxy the outboard end of the tube to the leading edge along the bottom of the wing below the fuel lines.

Figure 15: Center rib hole placement



5.7 Drilling Wing Stud Locations

Refer to Drawing DI-00082 for detailed placement of power and negative stud locations. All measurements are taken from the cuff edge position station 145. All measurements should be marked and double checked before drilling.

Note: Studs are drilled on the underside of the wing

A 0.562” diameter hole is drilled thru the skin of the wing. The hole for the electrical hard point is countersunk 1/8” deep to provide a recess for the Retaining Nut, DI-00065, and to remove the ground mesh from within 1/8” of the wing surface. The terminal will need to sit flush with the wing surface.

NOTE: A second layer of mesh may be embed below the surface layer and could come into

contact with the stud. A mega-ohm meter can be used to locate a possible second layer. If

mesh is found to be in contact with the stud, the stud must be removed and isolated from the

mesh.

5.7.1 Outboard Heater- Left and Right

Measure outboard from cuff 51.125” and aft 1.75” aft of leading edge and place a mark for power stud. Measure outboard 1.38” and 4.0” aft of leading edge for negative stud location. These measurements should be checked by measuring between stud location marks and find the dimension 49.75” This is the dimension centered between copper strip and copper strip of the outboard heater.

5.7.2 Left Inboard Heater.

The left inboard heater is in two parts separated by the landing light. Measure inboard from the cuff, station 145, 90.88” (7/8) and aft 1.75” for the 400 89.63” and 1.75” aft for the 350 and make a mark. Measure inboard .87 (7/8) from cuff and aft 1.75” and make a mark for the 350 and 400. Measure inboard 36.63 (5/8”) and aft 1.75” for the 400 and inboard 36.5” and aft 1.75” for the 350 and make a mark. Measure inboard from cuff 17.310 (5/16) and 1.75” aft for the 400 and inboard 17.37” and 1.75” aft for the 350 and make a mark. These plots are for the power and negative stud locations. Verify your mark positions by measuring from stud center to stud center for the long heater 53.13” for the 350 and 54.250” for the 400. For the short heater the distance between studs should measure 16.5” for 350 and 16.44” for the 400.



5.7.3 Right Inboard Heater

The right inboard heater is a one-piece heater. Measure from the cuff inboard 90.75” for the 400 or 89.63” for the 350 and aft of the leading edge 1.75” and make a mark. Measure inboard .87” (7/8”) and aft 1.75” and make a mark, same for 350 and 400. Verify your mark positions by measuring from stud center to stud center for the long heater 88.75” for the 350 and 89.88 (7/8)” for the 400.

CAUTION: ENSURE THAT ALL STEEL

GROUNDING MESH IS REMOVED

Once all dimensions are verified, drill a pilot hole to locate holes. With pilot hole drilled re-drill the holes to the proper dimensions. Once holes are drilled, use the special tool to finish hole drilling. Tool is made to cut the mesh from the skin and leave a .562” diameter hole countersunk to permit the stud nut to be recessed into the wing. It is very important that while drilling the tool is held perpendicular to the bottom of the wing surface to keep the stud 90° to the bottom of the wing. Use a fore and aft rocking motion to facilitate keeping the stud at the 90° positions.

Figure 16: Use a grinding stone to gently smooth edge and remove mesh



5.8 Drilling Holes to Secure Power Wires

A series of five holes are drilled in the underside of the right wing and 3 in the left wing near the leading edge between the electrical hard point near the fuselage and the electrical hard point inboard of the wing cuff. The holes are 0.250” diameter and spaced 11” from the electrical hard points and then evenly spaced between. A second series of two holes are drilled in underside of the wings near the leading edge between the electrical hard point near the wing tip and the electrical hard point outboard of the wing cuff. The holes are 0.250” diameter and spaced 11” from the electrical hard points. The holes are drilled so we can have a place to secure wire that will be installed later. Figure 17 displays tie wraps hanging from drilled holes.

Figure 17: Holes used to secure wire harness with wire wraps hanging out

5.9 Drilling of RTD Holes

Drilling of the RTD holes is similar to power stud and negative studs. All measurements are from the wing cuff station 145. See DI-00082

5.9.1 Right Outboard RTD

Measure outboard from the cuff 13.0” and mark location on the apex of the leading edge. Drill a .250” hole for the 350. Measure outboard 6.0” from the cuff for the 400.



5.9.2 Left Outboard RTD

Measure outboard from the cuff 13.0” and mark the location on the apex of the leading edge for the 350. Measure outboard 6.0” from the cuff for the 400. Drill a .250” hole for the 350 and 400.

5.9.3 Right Inboard RTD

Measure inboard from the cuff 5.0” and mark the location on the apex of the leading edge. Drill a .250” hole for the 350 and 400.

5.9.4 Left Inboard RTD

Measure inboard from the cuff 5.0” and mark the location on the apex of the leading edge. Drill a .250” hole for the 350 and 400. A notch on the leading edge should be filed in so the RTD can sit flush with the wing.

5.10 Wing Electrical Hard Point Installation

These are general instructions for the installation of the terminals in the wings. Refer to the subsequent wiring section of this manual for detailed instructions for proper routing of the power wires. The 6 gauge power wires are attached to the terminal stud prior to the wires being pulled thru the wing.

NOTE: Ensure the self-locking nut on the top of the stud securing the wire terminal is tight. This is your only chance to check this, as you will not have access to the studs once they are installed in the wing.

Prepare the electrical hard points for later installation into the wing. The hard points will be bonded to the wing surface using two part epoxy and will be cut at a later point to make sure they are flush with the outer wing surface.

To prepare the hard points, thread the terminal stud into the threaded insulator. Apply two-part epoxy to the middle threads of the brass stud and the phenolic insulator. Thread the stud into the insulator orienting the hex of the brass stud into the recess of the insulator. Allow the epoxy to cure before continuing with the stud installation. Please refer to Figures 18 and 19.

- Ensure no epoxy is on the electrical contact points or threads.



Figure 18: Apply mixed two part epoxy to both mating surfaces

Figure 19: Assembled hard point attachment



6.0 POWER WIRING INSTALLATION The power conductors should be terminated using proper crimp ring terminals. The wires should be bundled and strain relived by the use of clamps, wire ties, wire retainers bonded in place, and pooled epoxy. Refer to AC 43.13-1 or other source of acceptable practice for wiring routing and bundling practices.

Refer to Kelly Aerospace drawings DI-00035 and DI-00037 for routing paths.

6.1 Left Wing Wiring

Using provided spiral wrap. Wrap the positive wires.

When routing all wires ensure that there is a line connected that will allow you to pull the wire or terminal back out through the original hole. This will allow you to start over if wires are twisted inside the wing. Making a continuous loop of line will aid in pulling wires thru the wing (we suggest several colors of weed trimmer line). Route one line from the wingtip to inboard access hole, route the second from the outboard access hole (fuel vent panel) to the inboard access hole, and route a third from the wingtip to the access hole. Make each line a different color to distinguish which line to pull.

Figure 20 on the following page displays the interior of the wing.

NOTE: Do not route wires along radio antenna leads and take special care around fuel lines.



Figure 20: Wing interior



6.1.1 Negative Stud Connection

NOTE: Refer to Drawing DI-00035 for the 350 or DI-00037 for the 400.

NOTE: Pull negative wires first.

Route the two negative wires from the stud location to the access panel where they will be connected to the HCM’s later. See Figures 21 and 22.

Figure 21: Outboard negative wire

Figure 22: Inboard negative wire



6.1.2 Positive Wires

(Positive wire must be spiral wrapped, included with the kit) Connect the wire end of the positive 6 gauge wire to the line loop and feed it in through the wing tip. Pull the positive down to the inboard positive stud location where you will install a second positive wire that runs through the clear plastic tubing to the terminal block on the right side of the cabin. Insure the positive wire runs along the leading edge of the wing. See Figure 23.

Figure 23: Positive wire routing

6.1.3 Negative Wire from Access Panel to Terminal Block

Using the gap behind the landing light secure the negative jumper wire.

Figure 24: Negative wire routing



6.1.4 Negative Jumper Wire

Use the gap behind the landing light to secure the negative jumper wire.

Figure 25: Connect the heaters adjacent to the landing light

6.1.5 Pull the Data wire

Run the data wire from the cockpit area to the wing. Position the connector at the location of the controller, leaving enough cable to connect it to the controller and secure it in place. Run the cable along the right side of the aircraft to the co-pilot’s seat area and under the cabin area along the existing wire bundle. Do not run the cable along the power wires. The cable will be fished through the existing wire conduit just ahead of the spar to the fuel vent access area and attached to a terminal strip. The data wire is connected to one side of the terminal strip. Normal sequence is orange, blue, and white with the last terminal used for the ground or shield wire. This installation is after the module bracket is installed with the modules for the respective heater in place. You should now have two negative wires extending out of the outboard access hole area and marked as to outboard and inboard. These two wires will be mounted to the heater control modules (labeled “heater”). The long negative wire is the ground wire, and will go to the ground position of one module with a jumper connected to the second module. You should attach the data wire to the terminal strip.



6.2 Right Wing Wiring

Repeat the following steps for the left wing but leave out the negative jumper wire.

6.2.1 Securing the Wires and Stud Installation

Pull the power wire towards the navigation light hole approx 3 “. This will move the stud out of the way to get a tie wrap around the wires. Next, push .020 wires up the .250 holes at the bottom of the wing that you drilled and snag with a fish wire out the power stud hole for each position drilled. Use a 12” tie wrap and leave a large loop around the wire. Do not pull the tie wrap closed at this time. Poke two holes through the tie wrap end; pull the safety wire to the furthest hole away from power stud. Shaking the wire keeps the tie wrap moving and prevents it from snagging and pulling closed on the spiral wrap. Once all tie wraps are in place over the holes, pull power wire back into position and pull tie wraps to secure them. Once this is done on the right and left wings, you can epoxy all studs and tie wraps in place. Place a bolt back in the stud and push up the stud from its hole. Inject enough epoxy to form a bulge around the phenolic as it is pulled in place. See Figure 29. Push up the tie wraps and inject enough epoxy to form a wrap a round of epoxy enveloping the wires and pull down on the tie wrap positioning the wires. Place weight on the ends of the tie wrap to put strain on the wires to keep them pulled tight against the inner wing leading edge while epoxy cures. When cured, cut tie wraps even with wing and fill in with epoxy and sand smooth.

Figure 26: Countersink mounting hole

Kelly Aerospace has the tools available to countersink the hard points



Figure 27: Position terminal studs in mounting holes

Thread the Retaining Nut, DI-00065, onto the terminal stud. Leave the nut loose so that the terminal stud can be moved axially 1/8” to ¼”. See Figure 28.

Figure 28: Thread retaining nut onto terminal stud



Slightly lift the terminal stud into the wing and inject two-part epoxy where the terminal stud is going to sit. After the epoxy has been injected, pull the terminal stud flush against the inner surface and tighten the retaining nut with a pick or awl. See Figure 28. Insure stud is perpendicular lower wing surface. Heater screw should be level with the underside of the wing.

Figure 29: Inject epoxy around the terminal stud

Smooth the epoxy and remove any excess. Allow the epoxy to fully cure before continuing with the trimming operation. Refer to Kelly Aerospace drawing DI-00089 for details. Drill a 0.563” hole in the center of an 8” x 8” x 0.020” aluminum sheet. The aluminum sheet will be used as a guard while trimming the terminal stud to length. After the epoxy has cured, place the aluminum guard over the terminal stud and bend the aluminum sheet to the leading edge shape.



Figure 30: Trim the terminal stud

Using a hacksaw, trim the terminal stud to the lower surface of the wing. Be careful not to damage the surface of the wing. Remove the aluminum guard. Because of the thickness of the aluminum sheet the terminal stud will protrude from the surface. File the area so that the terminal stud and surrounding epoxy blend smoothly with the outer surface. Refer to Figures 30 and 31.

Figure 31: Sand rough areas of epoxy



Once the studs have been trimmed, use a piloted countersink micro-stop (#6) to grind down the brass and start a countersink. Ensure that you move the tool fore and aft to keep the stud flush with the under wing surface. Using a piloted countersink in a micro-stop cage, countersink the terminal stud for an MS24693C-294 screw. Set the micro-stop so that the countersink is 0.090” below the skin surface. This will account for the deice heater thickness and allow the screw to remain flush. See Figure 32.

Figure 32: Piloted countersink micro-stop tool

Clean the area of debris. Sand any remaining rough surfaces. The area should be as smooth as possible.

NOTE: Do not expose any wire mesh

in this area of the studs. Check for mesh using the mega ohm test procedure explained in section

11. 6.3 RTD’s for Left and Right wing (4 Locations)

CAUTION: DO NOT MODIFY THE LEAD LENGTH OF THE RTD PIGTAIL. ALTERING OF

THE RTD LEAD LENGTH WILL CAUSE ERRORS IN THE TEMPERATURE SENSING OF THE RTD.

Going thru the RTD hole, grab the loop line going to the outboard access and pull it thru the RTD hole. Tie another line to this loop and pull it thru to the access area. Take a length of loom mesh and insert the sensor end into the loom about half way up loom. Secure the loom meshes to the line just pulled and pull the loom out the RTD hole with the RTD inside. Be careful not to damage the RTD.

The RTD sensor is mounted in the appropriate ¼” diameter hole per drawing DI-00082.



File the leading edge of the mounting area to create a 1/16” recess that the RTD will sit in. Be careful not to penetrate the grounding mesh under the gel coat. See Figure 33.

Figure 33: File leading edge for RTD placement

Run a fish line through the RTD mounting hole to the access panel opening where the associated heater control module is located. Attach a 3’ long piece of nylon over braid to the safety wire fish line. Pull the nylon over braid through the RTD hole in the leading edge. Insert the RTD sensing end into the nylon over braid at the access hole and carefully pull the RTD through the mounting hole. Bend the sensor at the rear leads so that the RTD will rest in the filed depression. The white side of sensor should face outward. See Figures 34 through 36.



Figure 34: Insert RTD into nylon over braid

Figure 35: Pull RTD through leading edge hole



Figure 36: RTD in mounting recess

Place masking tape around the RTD. The flat portion of the RTD is the sensor front. Place two part epoxy in the depression. Secure a piece of aluminum tape over the RTD extending at least ½” beyond the edges of the RTD and lay the RTD into the epoxy while carefully adhering the tape to the surface of the leading edge. Smooth the epoxy by using a roller. Remove the aluminum tape after epoxy cures and then remove the masking tape. Smooth the epoxy after curing. Refer to Figure 37.

Figure 37: After curing smooth the epoxy



The plug end of the RTD pigtail will be attached to the associated Heater Control Module. Tie wrap the excess RTD lead to adjacent structure or wire bundles using acceptable aircraft practices.

CAUTION: DO NOT MODIFY THE LEAD LENGTH OF THE RTD PIGTAIL.

ALTERING OF THE RTD LEAD LENGTH WILL CAUSE ERRORS IN

THE TEMPERATURE SENSING.

NOTE: The RTD’s and negative leads from the aircraft deicer heater should

go to the same Heater Control Module.



7.0 HORIZONTAL STABILIZER

7.1 Horizontal Stabilizer Preparation and Mounting Hole Placement

The left and right horizontal stabilizers are mirror images of each other. The access and mounting hole locations are indicated on drawing DI-00082 Page 4.

NOTE: Verify that the proper drawing sheet

is being followed. Drawing DI-00082 consists of several pages and is used for the 350 and 400 aircraft. Tail Installation

instructions refer to page 4.

Drill the required mounting hole locations in the left and right horizontal stabilizer per the instructions on Kelly Aerospace drawing DI-00082 Page 4 and DI-00095.

The power terminal, or electrical hard points, are located from the leading edge on the bottom of the stabilizer and drilled to 1.00” diameter See Kelly Aerospace drawing DI-00090. The rubber gap seal should be left on the edge of the horizontal stabilizer. Place a known thickness item in the top web of the rib. Add this thickness to the drawing dimension to position the stud location. Ensure you take your measurements from the rib not the edge of the stabilizer with the rubber seal on. Transfer the measurement from the inboard rib web to the lower leading edge surface using straight edges and calipers or depth scale. See Figures 38 through 41 and refer to drawing DI-00095.

Figure 38: Transfer distance from web gap seal to center of

electrical hardpoint



Figure 39: Transfer distance from gap seal

Figure 40: Mark centerline of electrical hardpoint



Figure 41: Measure to center of mounting holes

Stabilizers Left and Right, Measure from the inboard rib face 1.0” outboard and 2.50” aft of leading edge and make a mark. Measure 69.0” outboard from rib and 2.50” aft of leading edge and make a mark. Verify your mark positions by measuring from stud center to stud center for the long heater is 68.0” for the 350 and for the 400.

A 1.00” diameter-mounting hole is drilled thru the skin of the horizontal stabilizer per drawing DI-00082. The hole for the electrical hard point is drilled thru to provide electrical isolation from the carbon fiber skin of the horizontal stabilizer. Terminal Stud, DI-00064, is centered in the mounting hole. The nut for the stud is not used in the installation of the stabilizers.

CAUTION: WEAR PROTECTIVE MASK WHILE

DRILLING STABILIZER HOLES.

Occasionally you will find interior hat section material on the interior of the stabilizer. As you drill the outboard stud hole, cut away any material with a small die grinder or Dremmel tool. Provide the stud with proper clearance.



Figure 42: Drill mounting hole in horizontal stabilizer

7.2 Left and Right Horizontal Stabilizer RTD Installation

Measure 10.5” outboard from the stabilizer butt rib. Mark the location on the apex of the leading edge. Drill a .250” hole for the 350 and 400’.s

The RTD mounting location is drilled to 0.300” or 5/16” diameter. The RTD is mounted 10.5” from the inboard rib location. See drawing DI-00095. Access holes for routing wires are also indicated on the drawing. When drilling these holes exercise care not to delaminate the fiberglass structure. Use sharp drills and diamond impregnated hole saws and do not force the tools. The holes should have clean edges with minimal chipping of the gel coat.

The inboard rib is drilled and slotted to allow the power wires to be fed around the front spar of the horizontal stabilizer. Mark the centerline of the hole and slot pattern. Drill the proper diameter holes (1.25”) and then file the edges of the slot to create a smooth opening. Draw a line between the two stud locations to mark where you need to drill. Drill two (2) ¼” holes equally spaced between the studs to inject foam. See Figures 43, 44, 45 and 46.

Bevel lower radius of holes to eliminate sharp edges, this will prevent the wire that hangs out from being cut.

CAUTION: WEAR A PROTECTIVE MASK WHILE DRILLING



Figure 43: Mark centerline of access holes in rib

Figure 44: Drill the slot holes



Figure 45: File the slot sides

Figure 46: Drill an access hole



7.3 Horizontal Stabilizer Power Wires

The #6 power wires are attached to the terminal stud prior to the wires being pulled thru the horizontal stabilizer. Refer to drawings DI-00082, DI-00035, DI-00037 and DI-00095 for electrical connections and hole locations. Remember to epoxy the phenolic to the brass prior to assembly of the wire to the stud. Position an electric boot over the stud and tie wrap end. Cut the #6 wires to length and install crimp ring terminals. Place heat shrink insulators over the crimp ring terminals. Remember to secure the self-locking nut over the wire terminals. Once the studs are positioned into the stabilizer, you cannot get access to tighten the terminals

Do not wrap power wire with spiral wrap.

Run a piece of trimmer line approximately 12’ long, with a loop on the end, in the outer terminal stud hole near the stabilizer tip. Using a fiberglass electrician’s fish rod, or local procured equivalent, pull the trimmer wire out of the access hole in the root rib web near the leading edge. Place a loop on the other end of the safety wire and feed the loop into the outer terminal stud hole toward the end of the front spar. Working from the horizontal stabilizer forward mounting sleeve, snag the trimmer line with the fiberglass electricians fish. Pull the trimmer line out of the forward-mounting sleeve. Be careful to keep the middle of the trimmer line protruding from the outer terminal hole.

Carefully pull the end of the #6 lead into the horizontal stabilizer forward mounting sleeve and around the end of the front spar. Working with the trimmer wire protruding from the outer terminal hole, pull the wire around the spar. Once the end of the wire reaches the terminal stud hole, continue pulling the wire using the end of the trimmer line protruding from the access hole in the rib. Work the trimmer line through the terminal-mounting hole until the terminal stud is at the hole.

The inner terminal stud is the negative connection; this can be placed by hand through access hole after the positive wire is in place. Bond the terminal stud in place. Ensure you have adequate clearance around hard point to prevent any shorting to the carbon fiber or mesh area. Once bonded in place check with an ohmmeter to insure no shorting exists between mesh and studs.

Fabricate a holding fixture out of aluminum bent into a hat-shape. The holding fixture should be at least �1.50” and allow access for injecting the epoxy. A hole in the center of the fixture will allow a bolt to go into the terminal stud. The bolt holds the fixture against the outside skin and the terminal stud phenolic insulator against the inside surface.

Inject the two-part epoxy into the 1.00” cavity while holding the terminal stud against the inner surface. The terminal stud should be centered in the 1.00” hole. See Figure 47.



Figure 47: Use a temporary bridge to hold the stud in place

while applying epoxy

Slide the ¾” clear plastic tube over the #6 positive wire. Push the tube through the access hole in the rib web all the way to the outer terminal stud. The tube should extend just beyond the rib web. See Figure 48.

Insert small pieces of foam packing into the tube, and push them in with a fiberglass rod, spacing them about 12 to 18 inches apart to anchor the wire against the side of the tube, this will prevent wire chafing.

Figure 48: Routing the power wire



Figure 49: Materials needed for two-part expanding foam

Figure 50: Inject foam into horizontal stabilizer

Mix expanding foam and inject. Mix equal amounts of the foam and mix only small amounts. Foam expands 30 times mixed amounts and will expand rapidly once mixed together. Use a syringe (local procurable) to inject the foam into stabilizer. Place the horizontal stabilizer (trailing edge up) so the foam will flow around the clear tube. The foam will encase the clear tube and support the #6 wire.



Epoxy terminal stud. Smooth the epoxy and remove any excess. Allow the epoxy to fully cure before continuing with the trimming operation. Insure a dimension between studs is 68”.

Refer to Kelly Aerospace drawing DI-00090 for details.

Drill a 0.563” hole in the center of an 8” x 8” x 0.020” aluminum sheet. The aluminum sheet will be used as a guard while trimming the terminal stud to length.

After the epoxy has cured, place the aluminum guard over the terminal stud and bend the aluminum sheet to the leading edge shape.

Using a hacksaw, trim the terminal stud to the lower surface of the wing. Be careful not to damage the surface of the wing. Remove the aluminum guard. See Figure 51.

Figure 51: Use a hacksaw to trim the stud

Because of the thickness of the aluminum sheet the terminal stud will protrude from the surface. File the area so that the terminal stud and surrounding epoxy blend smoothly with the outer surface.

Using a piloted countersink in a micro-stop cage, countersink the terminal stud for an MS24693C-294 screw. Set the micro-stop so that the countersink is 0.020” below the skin surface. This will account for the deice heater thickness and allow the screw to remain flush after installation.

Clean the area of debris. Sand any remaining rough surfaces. The area should be dressed out and as smooth as possible. Hipot studs before installation. Instructions are in section 16.0.



7.4 RTD Sensor Hole Preparation and Installation

The RTD sensor is secured to the stabilizer in the same manner as previously described for the wing. Let the epoxy securing the RTD sensor dry. Route the other end out of the stabilizer where it will be connected to the HCM.

7.5 Fuselage Tail Electrical Hard-points

The Tail Insulator Kit, DI-00099, is bonded into the fuselage tail surface with two-part epoxy. Refer to drawing DI-00099 for the hole location details. Three 0.500” diameter holes are drilled on either side of the fuselage tail per the drawing. See Figure 52. Insure that you measure from the center of support tubes for your dimensions not the edge.

A 1:1 drawing is included to use as a template and place over tubes to aid placement of holes.

Figure 52: Fuselage electrical hard-point insulators (exterior)

Assemble the insulator bushings on either side of the fuselage skin at the specified hole locations. Insert the bushing and place the nylon washer on the inside and outside of fuselage over the bushing. Center bushing between washers. Apply the two-part epoxy to the insulators prior to installation. Allow the epoxy to cure. See Figure 53. Label one bushing positive and the other negative on each side keeping the same position on left and right. Scuff surfaces before epoxy is in place.



. Figure 53: Epoxied insulators

7.6 Well Nut Installation

The well nuts are used to hold the stall strips onto the wings and to create the electrical junction between the Deice Heaters and the Stall Strips. The well-nut hole locations are drilled as part of the wing mounting holes. Holes are drilled with a 5/16ths drill bit.

Caution: Ensure no lightning mesh is visible after drilling

Note: A well nut drilling tool is available through Kelly Aerospace.

After the holes are drilled, the edges of the holes are filed and sanded up to 0.090” depth that tapers to the leading edge. The recess will allow the deicer heater to be flush with the wing surface and provide an area for the electrical contact between the heater and the stall strip. The stall strip mounting screw will act as a post to attach the stall strip using two-part epoxy. Refer to Figures 54 through 58.



Figure 54: File the leading edge to a depth of .090”

Figure 55: Verify the depth of the well nut area



Figure 56: Use a straight edge to visually inspect the impression

Figure 57: When completed the well nut hole should look like this



Figure 58: Well nuts and mounting screw in position

After the well nut area has been tapered, install the well nut into the hole and apply two-part epoxy to fill the area. Apply tape around the area and use the tape to hold and shape the epoxy. See Figures 59, 60 and 61.

Figure 59: Apply masking tape around the well nut area



Figure 60: Apply epoxy to the well nut taper area

Figure 61: Smooth epoxy with tape

Allow the epoxy to fully cure. File any high or rough areas to match the wing surface. Sand the area smooth. Any roughness in the area will show after the deicer heater has been installed.

Mega-Ohm test the drilled holes to prevent a short. See section 12.0



7.7 OAT Sensor

Place the OAT sensor DI-00081, on the same location but opposite wing of the factory OAT sensor. OAT sensor is usually installed in Left Wing at factory. The NACA scoop which provides fuel tank vent air is modified by drilling a ½” diameter hole in which the OAT is mounted. The OAT is mounted into the hole with the stainless steel probe protruding into the air stream beside the NACA scoop throat.

Drill an additional hole .500 in the NACA vent area for cooling air to reach the Heater Control Modules.

Wire the OAT to the terminal strip that is just for the OAT. The strip is placed on the vent panel and leads are tie wrapped to the vent line.

7.8 Shunt and Power Terminal Block

The shunt, p/n 76327-125 is mounted in front of the Power Terminal Block. The Power Terminal Block, MS27212-4-2, with the shunt is installed behind the front passenger kick trim panel. It is suggested that the shunt and terminal block be coupled with a copper strip fabricated prior to placing the shunt and terminal block in the aircraft. Some modification to the copper strip is necessary and it is easier to work with these parts outside the aircraft. Place the shunt so that the screws are up. You will connect two 1 amp inline fuses to these screws. Verify clearances to the trim panel and surrounding equipment prior to installation. Mount the shunt and terminal block in the open area to the right of the passenger seat in a clear area. The Shunt and Terminal Block are mounted with two-part epoxy. Scuff up mating surfaces prior to installing for better bond. Affix the terminal block in place while the epoxy cures. See Figure 62.

Figure 62: Shunt



7.9 Alternator to Terminal Block

A #6 wire is run from the alternator positive terminal through the firewall and to a 125 Amp 50 mV shunt located behind the passenger kick panel. If A/C system is installed remove the lines and use the top hole for wire pass through. Plug lower hole. If hole is not drilled, drill the hole I/A/W Sl-05-010A page 12.

Figure 63: Power wire through firewall

A bus bar is run from the shunt to the power distribution terminal block. Some bending will be required. See Figure 64.

Figure 64: Buss bar between shunt and power distribution

terminal



The #6 positive conductors are routed from the left, right, and tail to terminal block forward terminal. A #6 wire is run from the ground terminal on the alternator through the firewall to the power distribution terminal block ground stud. The ground wires are run from the terminal block to the Heater Control Modules terminal marked (ground) located in the left wing, right wing, and rear fuselage.

7.10 Power Wires between Terminal Block and Tail

(17 feet of power wire)

The ELT should be removed to gain access to the rear of the fuselage.

A #6 wire is run from the Terminal Block positive terminal along the right side of the fuselage through the bottom gap space, (not the hole for the push pull tube) to the rear insulator on the right side of the fuselage tail. Attach a #6 jumper wire from the rear insulator on the right side of the fuselage to the rear insulator on the left side of the fuselage.

A #6 wire is run from the Terminal Block negative terminal along the right side of the fuselage to the “ground” terminal of one Heater Control Modules in the tail of the fuselage. Attach a jumper #6 negative wire from the first module to the second module “ground” terminal. Connect the negative #6 wire from the stabilizer to the respective “ground” terminal on the vertical fin exterior and from the fin interior terminal to the respective right or left module terminal postmarked “heater”. Refer to drawing DI-00035 for the 350 and drawing DI-00037 for the 400.

NOTE: When installing the leads to the HCM’s, ensure that the bottom nut on the terminal posts is torqued to no more than 25 in-lbs. Then, when installing the top nut hold the bottom nut, with wrench, in place and using a calibrated

torque wrench tighten the top nut to no more than 45 in-lbs.



Figure 65: View toward rear bulkhead with power wires

Figure 66: Route power wires through the fuselage

The two #6 wires are attached to the wire bundle running along the fuselage. Use wire ties and tie blocks to secure the wires and prevent the wires from contacting flight controls. See Figures 67, 68, and 69.



Figure 67: Secure wires with wire ties and tie blocks

Figure 68: Secure wires with wire ties



Figure 69: Secure wire bundle to the fuselage

The control wire harness should be routed at the same time as the power wires using the #6 wires to guide the control harness.

Reinstall the ELT after securing the wire bundles.

NOTE: The RTD’s and power leads from the same side of the aircraft

deicer heater should go to the same Heater Control Module.

Place the RTD connector through the bottom hole per drawing DI-00099 and connect it to the respective Heater Control Module.



8.0 CONTROL WIRING HARNESSES

8.1 Selector Switch Hole and Harness Connection

Mount the Control Switch in the Engine Instrument Panel (EIP) to the left of the Amp Meter. The switch should be in line with the centerline of the amp meter. The switch is mounted in a 0.689” x 0.689” square cutout.

It is recommended that an instrument panel cutout tool be used to create the proper sized opening in the EIP.

An alternate mounting location may be required due to installed equipment. When choosing an alternate mounting site keep the switch within a 30 degree field of view of the pilot. Do not install in such a location to inhibit the pilot from viewing the annunciators in a normal instrument scan. Refer to Figure 68.

The switch is connected to the wiring harness by a connector and is addressed in the wiring section or this manual. Install the placard “Deice” next to the switch. See Figure 70.

Figure 70- Use an instrument panel cutout tool to make

the annunciator holes



Figure 71- Placard placement

The other end of the harness has connector P-DI-24 attached which connects the Switch to the Controller Harness.

8.2 Controller Harness and Aircraft Interfaces

The aircraft interfaces to the deice system are made with the Switch to Controller Harness, DI-00067. The Controller Harness has connector J-DI-24 on one end. This connector mates with P-DI-24, which is connected to the selector switch. See Figures 72 and 73.

Figure 72: Connect the wire harness to the selector switch



Figure 73: Replace the panel making sure not to damage

the selector switch

The five (5) 12’ long wires are routed along the left side of the fuselage from the electronics bay under the rear seat. Properly secure the wires while routing. Terminate the five wires at the Deice Controller into connector P-DI-2. The wires are labeled for proper pin orientation. Seat connector P-DI-2 into the Deice Controller per schematic DI-00067. See Figure 74.

Figure 74: Route harness down the left side of the fuselage



Connect the wire designated “Lamp Test” from J-DI-24 pin C of the Controller Harness to the Lamp Test wire marked L124-J67-04, the wire runs between J67 NAV/COM Bypass Switch and J44 Trim Connector. Splice into the wire at a convenient location behind the instrument panel. See Figure 75.

Figure 75: Splice into the “Lamp Test” wire

Connect the wire designated “Dimmer” to the Lamp Dimmer switch on the instrument panel by connecting the wire to a terminal on the LT-1 bus on the fire wall. Refer to the AMM and AEM for bus location.

Connect the wire designated “NAV Light Power” to the Position Light switch on the instrument panel. Uses a female disconnect crimped on to the wire and attach the wire to the OFF terminal of the Position Light switch. With the ships busses powered and the position light switch in the OFF position, this terminal should supply buss voltage to the Deice selector switches. Refer to wiring schematic DI-00034 for details on Page 1.

Connect the wire designated “Bus Power” from J-DI-24 pin D to the 2 Amp circuit breaker installed in the circuit breaker panel and attached to the Avionics Bus. See Figure 76.



Figure 76: Circuit breaker panel

Figure 77: Oxygen circuit breaker detail

The Oxygen C/B is moved over one position 2amp Airframe Deice C/B is mounted on the Avionics Buss



Connect the wire from J-DI-24 pin E and re wire GF-P1 pin F to the Field Isolation relay contact A as indicated on the wiring schematic DI-00034 on Page 1.

Connect the two, 1 amp fuse holders to the 125 Amp shunt near the power terminal block. Connect one fuse holder to each terminal of the shunt. Run the leads from the fuse holders back to the electronics bay under the rear seat of the aircraft and terminate the wires at the Deice Controller. Insert the wire from the high side of the shunt (feed from the alternator) to connector P-DI-1 pin 1. Insert the wire from the low side of the shunt (terminal block side) to connector P-DI-1 pin 2. See Figure 78.

Figure 78: Shunt placement and wiring



8.3 Alternator Field Relay Harness

Mount the alternator field relay in the electronics bay under the rear seat. Secure the relay to the relay-mounting panel with two screws. The relay should be on the backside of the panel. See Figure 79.

Figure 79: Mount alternator field relay

Connect the wire from the alternator field terminal 1 to the 7.5 Amp ALT 3 Field circuit breaker in the circuit breaker panel. Run a wire from the ALT 3 Field circuit breaker back to pin 7 on the Field Isolation Relay.

Figure 80: Location for 7.5 amp ALT 3 field circuit breaker



Figure 81: Bend the buss bar to make room for the new

circuit breaker

Place diode DI-00121-F between pins A and B on the relay. See drawing DI-00034.

Connect a wire from the alternator field terminal 2 to connector P-DI-1 pin 4. Route the wire from the alternator through the firewall along the right side of the fuselage to the Deice Controller in the electronics bay under the rear seat of the aircraft.

Attach a fuse holder with a 10 Amp fuse to the positive terminal stud of the power Terminal Block. Attach a second wire to the negative terminal stud of the power Terminal Block. Route the wires along the right side of the fuselage to the Deice Controller in the electronics bay. Attach the positive lead to connector P-DI-1 pin 8. Connect the negative lead to the ground stud, then from the ground stud to connector P-DI-1 pin 7.

Attach the ground lead from the field control relay to a suitable ground stud in the electronics bay.

The orange wire from GF-P1-E to the field control relay terminal B. Ground stud or splice must only connect to the deice ground plane.

Attach a wire from connector P-DI-1 pin 5 to the deice ground stud or splice in the electronics bay near the Deice Controller.

For DI-1 connector installation, refer to drawing DI-00066.

To make room for the 7.5 amp C/B, bend or cut the buss bar. The 7.5 amp ALT 3 Field C/B is not connected to the buss



8.4 OAT and Heater Control Module Data Cable Harnesses

The Heater Control Module, HCM, and Deice Control Module, DCM, are interconnected by a three-conductor cable with a grounded over-braid. The cables are supplied in the kit. One end of the cable has a connector attached which plugs into the controller. The other end of the cable is routed from the electronics bay under the rear seat to the applicable HCM through the existing wire conduit, not along the same route as the power wires.

Epoxy a terminal strip to the access panel where the OAT is located. See Figure 82.

Run the HCM and OAT data cables at the same time.

The HCM and OAT connectors are terminated on the terminal strip. Refer to the applicable wiring schematic for proper pin orientation. See DI-00069 and DI-00070.

Figure 82: Terminal strip



8.5 OAT Wiring Data Cable Harness

The wire harness, DI-00070, is routed from the electronics bay along the belly of the fuselage to the access opening to the Right wing. The wire harness continues along the front of the spar through the original aircraft conduit to the access opening in the bottom of the Right wing.

Connect harness with terminal ends to terminal strip and then to the heater control module.

Attach the connector to the OAT sensor. Check the lock ring on the connector to verify proper seating. See Figure 83.

Figure 83: Connect the wire harness to the OAT

Properly secure the cable along its length. The cable must not interfere with the fuel vent line or other equipment. Secure the cables using best practices. Refer to AC43.13 or other approved sources.

Drill a hole in corner of bracket to tie wrap the fuel vent.



8.6 Left Wing HCM Data Cable Harness

The wire harness, DI-00069 A, is routed from the electronics bay along the belly of the fuselage to the access opening to the left wing. The wire harness continues along the front of the spar through the original aircraft conduit to the access opening in the bottom of the left wing.

Connect harness with terminal ends to terminal strip and then to the heater control module.

Figure 84: Attach control harness to HCM left wing


8.7 Right Wing HCM Data Cable Harness

The wire harness, DI-00069-C, is routed from the electronics bay along the belly of the fuselage to the access opening to the right wing. The wire harness continues along the front of the spar through the original aircraft conduit to the access opening in the bottom of the right wing.

Connect connector pigtails to terminal strip. Refer to drawing DI-00069 for pin out designations. Attach ring terminals to wing wiring harness DI-00069-C. Securely connect the wires onto the terminal strip mounted inside the wing.


Inboard side

Outboard Side

Tie wrap to bracket to prevent chaffing



8.8 Tail HCM Data Cable Harness

The wire harness, DI-00069 B, is routed from the electronics bay along the belly of the fuselage to the tail.

Connect harness with terminal ends to terminal strip and then to the heater control module. The terminal strip is mounted on the side of the vent panel with epoxy. Attach the connector to one of the Heater Control Modules. Check the lock ring on the connector to verify proper seating.

Properly secure the cable along its length. The cable must not interfere with operation of flight controls or other equipment. Secure the cables using best practices. Refer to AC43.13 or other approved sources.

8.9 Summarized Electrical Harness Pin-outs

8.9.1 DI-1 Connector

Refer to drawing DI-00066 Connector is placed in the aft baggage compartment lower area. Route cable down the right and left side of the aircraft as required. Pin 1 goes to right side of aircraft thru 1 amp fuse to the forward shunt screw. Pin 2 goes to right side of aircraft thru 1 amp fuse to the rear shunt screw. Pin 3 goes to pin 4 of isolation control relay. Pin 4 goes to alternator field negative terminal #2. Pin 5 goes to negative terminal on the deice terminal block. Pin 6 goes to avionics bus 2-amp circuit breaker. Pin 7 goes to negative terminal on the deice terminal block. Pin 8 goes thru 10-amp fuse on right side of aircraft to the positive terminal of the

terminal block right side of aircraft. Pin 9 is not used.

Figure 85: Rear view of DI-1

NOTE: In some field installs pins 7 and 9 have been switched, check to ensure

proper assembly.



8.9.2 J-DI-24 Connector

Refer to drawing DI-00067. From J-DI-24 connect pins C, D, E, AND F. Connector is placed at the switch and wired in behind the instrument panel. Pin C must be connected to the pin 4 of J67 NAV com switch. Pin D must be connected to the 2-amp circuit breaker. Pin E must be connected to positive wire of the isolation control relay coil on terminal A. Pin F “dimmer” must be connected to LT-1 dimmer power supply (right side of interior instrument panel.) Pin F “NAV light switch” must be connected to the open position of the NAV light switch (normally off position) upper right terminal as viewed from the rear of the switch.

Note: To verify the correct terminal, buss voltage should be available with

power on at the switch

Ground Wires are 16 awg unless otherwise indicated for these connectors.



8.9.3 Wire Harnesses for Wings and Tail

Refer to drawing DI-00069. The wire harness for each wing and tail are numbered in the kit. Left wing will be marked DI-00069 A Right wing will be marked DI-00069 C Tail harness will be marked DI-00069 B Note: Same procedure for wings and tail apply. After running the data cables into the outer wing access panel terminate all wires as indicated. Pin out each harness to identify each wire. Attach pin 1 to terminal strip first position and note color. Attach pin 2 to terminal strip second position and note color. Attach pin 3 to terminal strip third position and note color. Pin 4 not used. Pin 5 is the shield attached to 4th position of terminal strip. You will attach the jumper harnesses to the terminal strips corresponding pins, which in turn connects to the HCM’s.

8.9.4 Wire Harness to OAT

Refer to DI-00070; the OAT harness hook up is similar to wings and tail harness.



9.0 ALTERNATOR INSTALLATION

9.1 350 and 400 Alternator Bracket Installation

Remove the scat tubing on the rear of the engine to gain access to the starter adaptor drive, refer to Kelly Aerospace Drawing AL-00030. Relocate any wiring or other equipment that may interfere with the alternator installation. Refer to one of the following Columbia Service Letters (SL-05-010A, SL-05-009A, SL-05-024 or SL-06-017) for relocation of wire harness. Ensure that the service letter you are using is for your aircrafts serial number. Add plug to original hole P/N 9563K85 to the aft side of the bulkhead, tangs forward and silicon in place. Cut new hole I/A/W Columbia Service Letter 05-010A page 13.

Install the alternator bracket, part numbers AL-00047, to the back right side of the engine per Kelly Aerospace drawing AL-00030. Use the provided bolts MS20074-06-12 or 37C150HCS8Y and lock washers MS35338-141. Torque all fasteners per TCM service manual recommendations or as listed on AL-00030. Ensure that the bushing is pressed outward to allow for maximum number of shim washers to be installed. After torquing the lock nut, ensure there is a gap in-between the washer (by the lock nut) and the casting. Using the NAS washers listed below; place them between the bushing and casting to shim the alternator. Ensure that the pulley’s are within .015” alignment. See Figures 86 and 87. Torque the alternator through bolt to TCM specs and torque AL-00030-T to 220-260 in lbs (in 2 places).

Figure 86: Alternator bracket to be mounted on the rear of the engine

Use original Continental thru bolt

Insert NAS washers to shim the alternator. Ensure there is a gap between the washer and casting. A floating bushing is used to prevent casting failure.

Use the following washers to shim the alternator NAS1149F-0763P NAS1149F-0732P NAS1149F-0716P



Figure 87: Alternator bracket with alternator attached

NOTE: Ensure that the bushing in the right flange is not bottomed out on the right face to

prevent overstressing the flange.

Figure 88: Tensioner rod and bracket



9.2 Alternator Drive Pulley Installation

Install the alternator drive pulley, AL-00028, to the starter adaptor drive shaft on the back of the engine. Place a Nordloc (AL-00030-N) washer and existing nut on the threaded end of the starter adaptor drive shaft. Lubricate the threads with clean 50 weight engine oil and torque to 450-500 in-lbs. Continental service bulletin M89-6 allows the drive shaft to be shimmed. Check the service bulletin if shimming of the drive shaft is desired. See Figure 89.

Caution: Do not over-torque drive pulley nut

450-500 in-lbs MAX

Figure 89: Drive Pulley

Place the alternator into the alternator brackets on the rear of the engine. Insert an AN7-42A bolt through the alternator pivot. Place the belt cutter, AL-00025; an AN960-716 washer and MS21042-7 nut onto the pivot bolt. Due not tighten at this time.

Insert the tensioner Rod Assembly, AL-00027, into the Alternator tensioner Bracket. Place the Spacer, AL-00026, AN6-22A bolt with an AN960-616 washer into the mounting hole. Attach the other end of the tensioner Rod to the alternator. Place belt cutter so that in-board flat is up against the bracket and pin is in hole. Insure that enough clearance between cutter and alternator fan.



9.3 Alternator Pulley Alignment

After the alternator has been installed with the mounting bracket and tensioner but before any bolt tightening has occurred alignment of the drive pulleys can be checked and if needed, corrected. Using a straight edge the alignment of the pulleys can be determined. Using any combination of the included washers (NAS1149F-0763P, -0732P, -0716P) on the pivot bolt, between the flanges, the alignment can be adjusted to properly align the pulleys to within .015”. If the pulleys are not within tolerance excessive belt wear will ensue. On the pivot bolt, in between the flanges, as much of the space as possible needs to be filled using the above mentioned washers.

Next tighten the lock nut on the pivot bolt to firmly seat the bolt, washers and alternator on the bracket. The floating bushing in the forward flange should slide through and make firm contact with the washers between the flanges. Ensure that during tightening the floating bushing does not “bottom out” on the forward face of the forward flange. If the bushing does “bottom out” remove the alternator bracket and inspect for cracking on the base of the forward flange, replace if needed. If there is no evidence of stress “reset” the bushing and re-install with an appropriate washer configuration.

After the above has been completed loosen the locknut and re-torque nut to 270-300 in-lbs. See Figure 90. Tighten AL-00030-V to 220-260 in lbs and AL-00030-Y to 160-190 in lbs. After all nuts and bolts have been tightened recheck alignment to ensure proper installation.

NOTE: Ensure proper clearance between belt cutter and fan blade

prior to turning propeller. If clearance is inadequate, fan blades

will be damaged.

Figure 90: Insert tensioner rods



9.4 Set Belt tension

Using the tensioner rod and alternator torque tool to set the tensioning slip torque to 300 in-lbs. Tighten nuts on tensioning barrel and re-check slip torque to ensure it is still 300 in-lbs. Fly the aircraft for 1 hour and reset tensioning slip torque to 300 in-lbs, after cool down to ambient temperature. Recheck pulley alignment using a straight edge. Even if the EVADE system is never operated, after every 25 hours of flight time the belt tension must be reset to 300 in-lbs.

Figure 91: Installed alternator being tensioned

Figure 92: Use a calibrated torque wrench and alternator torque

tool to determine the belt tension

CAUTION: DO NOT USE THE ALTERNATOR DRIVE NUT TO CHECK BELT TENSION. USE KELLY AEROSPACE

ALTERNATOR TORQUE TOOL (AL-00034) TO CHECK ALTERNATOR BELT BREAKAWAY TORQUE.



After adjusting the belt tension, tighten the alternator pivot bolt securely. Torque the jam nuts on the Tensioner Rod to hold the proper adjustment.

10.0 DEICE CONTROL MODULE In the electronics bay under the rear seat is an aluminum mounting plate. Locate the Deice Control Module, DI-00079, on the aluminum plate so that clearance is maintained for access to the electrical connections. Mark the two mounting holes on the aluminum plate. Drill the mounting holes into the aluminum plate and attach two proper size nutserts to the plate. The use of nutserts will aid in attaching and servicing the Deice Control Module.

Secure the Deice Control Module to the aluminum plate using two bolts through the two center mounting holes. See Figure 93.

Figure 93: Drill mounting holes for the de-ice controller



11.0 HEATER CONTROL MODULE (HCM) AND BRACKETS

11.1 Right Wing Heater Control Module

Align the Heater Module Bracket, DI-00061, to the internal upper wing surface. Orient the bracket so that the Heater Modules will be visible and the electrical connections can easily be made.

Install the Heater Module Mounting Bracket onto the wing internal surface using two-part epoxy. To ensure a good bond make sure to scuff the mating surfaces before applying epoxy. Use tape as clamps to hold the mounting bracket in place while the epoxy cures. See Figure 94.

Figure 94: Mount wing heater module bracket



Attach two Heater Control Modules, DI-00080, to the mounting bracket after the epoxy has fully cured. Use two #8 screws to attach each Heater Control Module. Tighten the screws securely. See Figure 95.

Figure 95: HCM mounted in wing

11.2 Left Wing Heater Control Module

Align the Heater Module Bracket, DI-00061, to the internal upper wing surface. Orient the bracket so that the Heater Modules will be visible and the electrical connections can easily be made.

Install the Heater Module Mounting Bracket onto the wing internal surface using two-part epoxy. Be sure to scuff the mating surfaces before applying epoxy then use tape and clamps to hold the mounting bracket in place while the epoxy cures.

Attach two Heater Control Modules, DI-00080, to the mounting bracket after the epoxy has fully cured. Use two #8 screws to attach each Heater Control Module. Tighten the screws securely.



11.3 Empennage Heater Control Module

Open the access panel on the right side of the fuselage near the horizontal stabilizer.

Align the Heater Module Bracket Tail, DI-00055, to the internal surface of the fuselage. Orient the bracket so that the Heater Modules will be visible and the electrical connections can easily be made. Install HCM’s in their respective position prior to installing bracket. This will save time in the positioning of the modules in the confined space available.

Install the Heater Module Mounting Bracket onto the fuselage internal side surfaces using two-part epoxy. Be sure to scuff the mating surfaces before applying epoxy then use tape and clamps to hold the mounting bracket in place while the epoxy cures. See Figure 96.

Figure 96: Tail heater module bracket mount

11.4 (2) Amp Thermawing System Circuit Breaker

A two Amp circuit breaker is used to provide power to the Thermawing Deice System Controller. The De-Ice Circuit Breaker, P/N 7277-2-2, is located in the Circuit Breaker Panel, connected to the avionics bus.

Remove the Circuit Breaker Panel per the instructions in the AMM.

Install the circuit breaker in an empty slot on the avionics bus. Leave the panel open to allow the routing of the wire harness.



11.5 (7.5) Amp Alternator Field Circuit Breaker

A 7.5 Amp circuit breaker is used to provide protection to the alternator field from a regulator runaway. The alternator field Circuit Breaker, P/N 7277-2-7.5, is located in the Circuit Breaker Panel in the top row at the forward most position. If another circuit breaker is occupying this location, it must be relocated along with the placard. The 7.5 amp circuit breaker is not connected to any buss, it is wired in series between the alternator and the ALT 3 Field Isolation relay and then to the Deice Control Module.

Remove the Circuit Breaker Panel per the instructions in the AMM.

Install the circuit breaker in the top row at the forward most position. Bend or cut off the bus bar to isolate the circuit breaker from the aircraft bus. See Figure 97.

Figure 97: Bend buss bar to isolate the circuit breaker

The circuit breaker is wired in line to the alternator field wire which runs from the deice controller along the left side of the fuselage.

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13.0 GROUND FAULT SENSOR (GFS) Secure the GFS shunt p/n DI-00121-AO to upper aft section of the engine baffle as shown in Figure 96. Using supplied nuts (MS21042-08), Screw (MS35206-247) and two washers (AN960-8L). The GFS shunt should be installed on the rear facing side of the engine baffle centered above the engine. If the GFS shunt install location is not available due to the installation of another component, the shunt should be located in the closest convenient location on the top side of the baffle (rear facing).

Figure 98: GFS shunt installed in the correct location

Using Drawing DI-00034 page 1 of 10 as a reference, connect the alternator terminal on the shunt to a 6 gauge wire as shown in Figure 99. Terminate the other end to the negative terminal on the alternator. Connect the other shunt terminal using a 6 gauge wire to engine ground.

Mount the GFS Sensor P/N DI-00206 near the controller in the rear avionics compartment. Take the shield ground wire off the ground fault sensor and secure it to deice ground.



Route Wire Harness P/N DI-00208 from the GFS Shunt to the GFS sensor. Splice wire GF-P1-A to the deice controller Pin 5 on plug DI-2. Route wires from pin B, C (both labeled shunt), and D (labeled ground) to the GFS Shunt. Wrap the ground wire in a continuous spiral around the sleeved wires labeled “Shunt”.

Using drawing DI-00034 and DI-00208 as a reference complete the following connections.

Connect the wire from pin B (white) to the alternator side of the shunt.

Connect the wire from pin C (white/blue) to the engine side of the shunt.

Connect the black ground wrapped in a spiral from pin D to the alternator side of the shunt (same as white wire from pin B).

Connect the orange wire from pin E to the Pin B on the relay (DI-00121).

Connect the Red wire from pin F to Pin A on the relay (DI-00121).

Figure 99: Shunt wiring detail

To Negative Terminal on Alternator

To Engine Ground

White and Blue from Pin B

White from Pin C

Black Ground from Pin D



14.0 WING DEICE HEATER AND STALL STRIP INSTALLATION COLUMBIA 350/400

The Deicer Heaters are installed per Kelly Aerospace Report NC-05-003. Use the applicable deicer heater drawing to align the electrical hard points with the conductors on the heaters.

Use the appropriate leading edge templates to mark the center of the parting strip on the leading edge of the flight surface.

The installation of the terminal studs, power wiring, and RTD’s are covered in the applicable sections of this manual. All electrical terminal studs or electrical hard points should be completed and checked before installing the deicer heaters.

Note: Use Toluene to remove all waxes from the surface of the leading edge. If the surface is glossy or smooth, lightly scuff the surface with scotch-brite to provide a

‘tooth’ for the adhesive.

Place a Tedlar® washer around studs. Refer to section 20.1 for more details.



14.1 Wing Deice Heater Part Numbers- 350

Heater Location Part Number

Left wing outboard DI-00040

Left wing inboard DI-00044

Right wing outboard DI-00042

Right wing inboard DI-00046

14.2 Wing Deice Heater Part Numbers- 400

Heater Location Part Number







14.3 Wing Deice Heater Installation- 350/400

Thoroughly clean the area where the heater will be installed.

Mark the centerline and boundary of the deicer heater on the wing. Use the appropriate templates to mark the centerline at the indicated wing stations. Draw a straight line between the marks using a straight edge. Ensure the line runs through the center of the well nuts that attach the stall strips.

Place the heater on the wing aligning the centerlines. With the heater still in place, carefully lift the bottom corners and mark the electrical connections on the deicer heater. Remove the heater from the wing and place on a sturdy flat work surface. Using a razor knife, carefully trim the heater backing, white side, where the electrical connections are marked. Trim approximately 1” long from the heater backing at each electrical connection. Only remove enough material to cover stud area only. Removing more material exposing more copper will increase the risk of shorting out the heater if mesh is exposed next to the stud.

Install the heaters according to Kelly Aerospace Thermawing Deice Heater Installation Guide document number (NC-05-003). The current revision of the install guide can be found at: www.airplanedeice.com .

After the heater is installed, locate the depression in the heater at the electrical contact. Using an awl or pick make a hole in the center of the electrical contact. Enlarge the hole opening so that the inner threads of the terminal are visible. Trim off any loose or jagged pieces of heater material so that the edges of the hole are smooth. Install an MS24693C-294 countersunk screw into each electrical terminal. Tighten the screw securely. The head of the screw should be flush with the wing surface. Please see Figures 100-104.

CAUTION: ONLY CUT OFF THE LAYERS ABOVE

THE COPPER; CUTTING OFF THE COPPER WILL DAMAGE THE CARBON HEATING

ELEMENT AND POSSIBLY THE TEDLAR OUTER LAYER RENDERING THE HEATER

INOPERABLE.



Figure 100: Locate the stud

Figure 101: Make an impression in the heater

Figure 102: Puncture heater with a sharp instrument



Figure 103: Insert connector screw

Figure 104: Installed connection screw



14.4 Stall Strip Part Numbers- 350

Stall Strip Location Part Number



14.5 Stall Strip Part Numbers- 400

Stall Strip Location Part Number


Left wing inboard (mid wing) DI-00096

Left Wing inboard (wing root) DI-00098


Right wing inboard (mid wing) DI-00096

Right wing inboard (wing root) DI-00098



14.6 Stall Strip Installation- 350/400

Locate the stall strip well nuts in the leading edge of the wing. With an awl or pick, carefully puncture the heater at the well nut.

Using a razor knife trim the gray Tedlar® material down to the copper strip. Trim approximately ½” square from the area exposing the copper strip.

To verify the alignment of the stall strip, refer to drawing DI-00082. Double check alignment with the templates made prior to stall strip removal.

Place the stall strip so that the two #6 terminals are on the bottom of the leading edge. Puncture the copper with an awl or pick so that the internal threads of the well nuts are accessible. Install (2) #6 screws with (2) stainless steel washers in the well nuts. Carefully tighten the screws keeping the terminals from twisting. When installing the attachment screws the following order must be followed: screw, star washer, ring terminal, flat washer, with the flat washer contacting the copper. Fill the depressions in the stall strip completely with epoxy. Rotate the stall strip until it contacts the leading edge of the wing. Using masking tape and alignment guides, fixture the stall strip at the proper angle. Clean up any excess epoxy. Allow to dry.

With the proper solvent, shape the epoxy along the edge of the stall strip to provide a slight fillet at the wing/stall strip junction. Allow the epoxy to cure before final finishing and painting.



15.0 HORIZONTAL STABILIZER DEICE HEATER INSTALLATION LANCAIR 350 AND 400

Remove the horizontal stabilizers from the fuselage per the AMM. Work with the horizontal stabilizers on a bench to facilitate deicer heater installation.

The Horizontal Stabilizer Deicer Heaters (Part number DI-00048) are installed per Kelly Aerospace Report NC-05-003. Use Kelly Aerospace drawing DI-00082 to align the electrical hard points with the conductors on the heaters.

Use the appropriate leading edge templates to mark the center of the parting strip on the leading edge of the flight surface.

The installation of the terminal studs, power wiring, and RTD’s are covered in the applicable sections of this manual. All electrical terminal studs or electrical hard points should be completed and checked before installing the deice heaters.

Mark the centerline and boundary of the deice heater on the wing. Use the appropriate templates to mark the centerline at the indicated wing stations. Draw a straight line between the marks using a straight edge or carpenters chalk line. Place the heater in place by aligning the marks. With the heater still in place, carefully lift the bottom corners and mark the electrical connections on the deice heater. Remove the heater from the horizontal stabilizer and place on a sturdy flat work surface. Using a razor knife, carefully trim the heater backing, white side, where the electrical connections are marked. Trim approximately 1” long from the heater backing at each electrical connection.

After the heater is installed, locate the depression in the heater at the electrical contact. Using an awl or pick make a hole in the center of the electrical contact. Enlarge the hole opening so that the inner threads of the terminal are visible. Trim off any loose or jagged pieces of heater material so that the edges of the hole are smooth.

Install an MS24693C-294 countersunk screw into each electrical terminal. Tighten the screw securely. The head of the screw should be flush with the wing surface.

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NOTE: If the HCM’s are not isolated they WILL be permanently damaged!

Figure 106: HCM’s ready for HiPot test

16.2 Connect Hipot Ground

Connect the return of the HiPot to the engine aircraft ground. See figure 112.

Figure 107: Properly grounded HiPot negative lead

Disconnect the 3 positive power wires from the shunt located on the right side of the cabin. Set the Hipot to 1000 Volts and upper amperage limit to 20 mA. Run the test for one minute. Take the positive cable from the Hipot and have it touch the positive wire for the right wing. See Figure 113.

Terminals Disconnected

Engine Ground Attach Point



Figure 108: Wires disconnected before HiPot test

Watch the mA readout on the Hipot. If the reading is above 20mA, the test failed and the installer will have to locate the short. If the readout is less than 20mA, the installer will repeat the test for the left wing and the tail. If a short is detected and you are not able to locate its origin, contact Columbia Technical Support.

After completing the Hipot testing, when re-installing the leads to the HCM’s, ensure that the bottom nut on the terminal posts is torqued to no more than 25 in-lbs. Then, when installing the top nut hold the bottom nut in place and using a calibrated torque wrench tighten the top nut to no more than 45 in-lbs.

Disconnected + Power Wire

Positive Hipot touching positive wire



17.0 OPERATION AND TESTING Before operating the system, ensure that all electrical connections are secure. The system requires power from the dedicated alternator in order to complete a full test, but an initial test as described below can verify system integrity prior to engine operation. All components were tested at the factory prior to shipment. The following tests seek any faults in the field wiring and installation, and should be run following initial installation or any major maintenance of the system.

17.1 Required Equipment

System diagnostics beyond the built-in test functionality require the following additional equipment:

Ammeter- 12V ±2V power source capable of at least 1 amp

Ohmmeter- Field Diagnostic Cable (part number DI-00140)

17.2 Diagnostic Display

Diagnostic Display described below. Use the Field Diagnostic Cable to connect the Diagnostic Display to the Diagnostic Port (“Diag”) on the side of the Controller to verify the complete system health.

The Diagnostic Display can be any terminal capable of displaying the text generated by the Controller. Basic requirements are the ability to accept RS-232 serial ASCII text at 19,200 BPS and display it in a 132-column format. Due to the large volume of rapidly generated data, capabilities for back scroll and capture to a text file are highly desirable. A standard laptop computer running Windows HyperTerminal and having a standard DE-9 (sometimes erroneously called out as DB-9) RS-232 serial port fulfills this requirement. Laptop computers manufactured after approximately 2002 often do not have such a serial port, but adapter cables to provide such a serial port via USB are readily available. Configure the terminal for 19,200 BPS data rate, 1 stop bit, no parity, no handshake, and 132-column display. For HyperTerminal, these settings are made under the <File><Properties><Connect To><Configure> menu. You must “disconnect” using the Call menu before changing settings, and reconnect again using the Call menu after establishing the settings. Then use the <File><Properties><Settings> menu to select VT100 emulation, and select 132-column mode under <Terminal Setup>.

17.3 Power Wiring Integrity Check

Any open in the power wiring will be detected harmlessly by the Deice System’s built-in tests. However, a short or a reversed connection in the power wiring can cause damage to the system before the Controller can shut it down. The following test verifies the bulk of the power wiring and detects most of the likely installation errors.

With the aircraft unpowered, connect the 12V power source negative lead to the deice alternator negative output stud. Connect the positive lead through the ammeter to the positive output terminal of the deice alternator and note the current reading, then disconnect the power source. Any current reading in excess of 100mA indicates a



problem with the power wiring. Most likely causes are a mechanical short between the positive leads and either the negative leads or aircraft ground, or one or more HCM’s wired with the Heater and Ground terminals reversed.

Use the Ohmmeter to verify a solid connection between the deice alternator negative output terminal and the aircraft bus ground. Resistance in either direction should be less than one ohm.

17.4 Initial Powerup Check

Position the Diagnostic Display in a convenient location and connect it to the Controller via the Field Diagnostic Cable. Standard straight-through PC serial cables may be used as required to extend the cable to any length up to 100’. Enable data capture to a text file if desired, and then apply power to the Avionics Bus to power the Controller. Several pages of internal power-up diagnostics will be generated, and then the system will begin streaming data in columns. Either turn off the Avionics Bus when this columnar data starts, and scroll back to find the configuration table, or use a text editor to locate the final configuration table via the captured data file. Search for “Start PwrUp Test” to find the data, in an area that should look like:

N,Loc,Bus,Couplr, Int, Ext,Sq,Of,Model,Manuf Date,Watts, Ohms ,Ratio, Wet ,Shed 0, LO,Lft,021618,777F,FFFF, 0,DE, 80,2005-04-01, 7500, 0.44, 4.20, 2.00, 5.20 1, RT,Fus,021773,8192,FFFF, 1,E9, 80,2005-03-23, 7500, 0.61, 4.20, 2.00, 5.20 2, LT,Fus,020A25,7336,FFFF, 2,DD, 80,2005-06-02, 7500, 0.61, 4.20, 2.00, 5.20 3, RI,Rgt,020C17,7A2B,FFFF, 3,EB, 80,2005-06-02, 7500, 0.70, 4.20, 2.00, 5.20 4, LI,Lft,020AD1,759B,FFFF, 4,E2, 80,2005-06-02, 7500, 0.62, 4.20, 2.00, 5.20 5, RO,Rgt,021115,8253,FFFF, 5,E1, 80,2005-04-01, 7500, 0.44, 4.20, 2.00, 5.20 6, OA,OAT, , ,81B9, ,F6, 81,2005-04-15 6 htrs 0 Cpl CRC? 0 Int CRC? 6 Ext CRC? Start PwrUp Test Stack 4749 bytes HCM temps: 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, XSM, Time,DT,C,M, OAT,Vbus,Powr,Adj,Vfld,Ifl,Vdeic,Ideic, Ohms,Watt,Intgr,Prqst,Targt, LO, RT, LT, RI, LI, RO



PNW, 7.0, 0,0,0, 76.8,13.4, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.3, 0.0, 0.0, 0.0, 0.0, 0.0 PNW, 7.1, 0,1,0, 76.5,13.4, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.3, 82.7, 0.0, 0.0, 0.0, 0.0 PNW, 7.2, 0,2,0, 76.8,13.3, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.3, 82.7, 84.8, 0.0, 0.0, 0.0 PNW, 7.3, 0,3,0, 76.5,13.5, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.3, 82.7, 84.8, 91.8, 0.0, 0.0 PNW, 7.5, 0,4,0, 76.8,13.5, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.3, 82.7, 84.8, 91.8, 91.7, 0.0 PNW, 7.6, 0,5,0, 76.9,13.6, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.3, 82.7, 84.8, 91.8, 91.7, 95.6 PNW, 7.7, 0,0,0, 76.5,13.5, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.0, 82.7, 84.8, 91.8, 91.7, 95.6 PNW, 7.8, 0,1,0, 76.5,13.6, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.0, 83.1, 84.8, 91.8, 91.7, 95.6 PNW, 7.9, 0,2,0, 76.8,13.4, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.0, 83.1, 84.7, 91.8, 91.7, 95.6 PNW, 8.0, 0,3,0, 76.8,13.6, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.0, 83.1, 84.7, 92.0, 91.7, 95.6 PNW, 8.2, 0,4,0, 76.5,13.6, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.0, 83.1, 84.7, 92.0, 92.0, 95.6 PNW, 8.3, 0,5,0, 76.8,13.5, 0, 82, 0.8,0.0, 1.5, 0.1,--.--, 0, 0, 0, 0.0, 93.0, 83.1, 84.7, 92.0, 92.0, 95.6

The first table shows the system configuration as read from the various components the Controller finds connected at power-up. Note particularly the first three columns of that table, duplicated here:

N,Loc,Bus,Couplr, Int, 0, LO,Lft,021618,777F, 1, RT,Fus,021773,8192, 2, LT,Fus,020A25,7336, 3, RI,Rgt,020C17,7A2B, 4, LI,Lft,020AD1,759B, 5, RO,Rgt,021115,8253, 6, OA,OAT, , ,

Lines zero thru five represent the six HCM’s. LO stands for Left Outboard, RI for Right Inboard, LT stands for Left Tail, etc. Verify the bus designator as to which bus communicates with the particular device. Lft indicates left wing, Fus indicates fuselage



(equivalently, “tail” or “empennage”), and Rgt indicates right wing. If devices are missing from the table, manually verify the wiring to the affected units.

Next verify the actual data being captured by the system in the streaming data. The 6th column gives the measured OAT, which should be close to ambient but can be affected by placement of the OAT sensor on the bottom of the wing (in the shade). The 7th column shows the measured avionics bus voltage. The final 6 columns show the measured temperature of the parting strips of each heater. Like the OAT, the parting strip temperatures should roughly agree with ambient but can be affected by placement in a static situation on the ground. Direct sunlight in particular can raise the temperature by tens of degrees.

At the completion of this test, remove the Field Diagnostic Cable and any other accessories that were used. Secure all hardware and properly close all access panels removed during installation or inspection.

17.5 Operational Test

A full operational test of the system requires that the engine-driven deice alternator is turning. Position the aircraft in a safe location for a static engine run-up, chock and/or tie down the aircraft as appropriate, and ensure qualified personnel are at the controls. With the Deice selector switch disabled, perform a normal start and activate the avionics bus. Set engine speed to 1700 RPM and enable the Deice selector switch. The Deice Controller will perform a self-test. The ‘ON’ and ‘FAIL’ annunciators will flash alternately during the self-test. With normal engine power and normal system operation, the self-test should complete in approximately 30 seconds. After the self test, the ‘AIRFRAME’ annunciator will remain illuminated whenever the deice control switch is selected on.

If the self-test detects a problem in the system, the ‘AIRFRAME’ and ‘ON’ annunciators will extinguish and the ‘FAIL’ annunciator will illuminate. The system is latched in this condition; disabling deicing with the Selector switch does not reset the fault until power is removed from the system.

It is recommended that the Thermawing Deice System be tested prior to every flight. To maximize the longevity of the system, dry air use should be minimized. It is suggested that the system be turned off when not needed or when clearing the runway after landing.

17.6 Weight and Balance

A weight and balance calculation should be accomplished for the particular aircraft installation. The component weights for the calculations are based on the supplied equipment. If alternate equipment is used the weights of the subsisted devices should be used for the weight and balance calculation. Refer to the weight and balance work sheet at the end of this manual.

It is recommended that the aircraft be weighed after the installation to accurately determine the weight and balance.



17.6.1 Lancair 350 Thermawing Deice System Weight and Balance

Thermawing Deice System Weight and Balance

Columbia 350 Model: SN:

Item Weight

(oz.) Arm (in.)

Moment (in.lb.)

De-Ice Controller 30.7 150.0 287.8

Circuit Breaker - Qty. 2 1.8 79.0 8.9

Selector Switch 1.1 78.0 5.4

Lamp Test Harness 4.5 74.0 20.8

Relay - Field isolation relay 1.8 150.0 16.9

Alternator, spacers, fan , pulley, washer, nut 282.5 58.7 1036.4

Engine Drive Pulley 14.5 62.0 56.2

Alternator Top Mount Bracket 28.4 58.0 103.0

Alternator Tensioner Bracket 14.3 59.0 52.7

Belt Cutter 5.1 61.5 19.6

Tensioner Rod 13.1 60.0 49.1

Alternator Belt 3.1 62.0 12.0

Shunt - Deice 3.3 86.0 17.7

Distribution Terminal Block 4.5 89.8 25.3

Heater module Mounting Bracket Lt 2.7 124.0 20.9

Heater module Mounting Bracket Rt 2.7 124.0 20.9

Heater module Mounting Bracket Tail 2.3 247.3 35.5

Heater modules Left Wing - Qty. 2 8.6 124.0 66.7

Heater modules Right Wing - Qty. 2 8.6 124.0 66.7

Heater modules Tail - Qty. 2 8.6 247.3 132.9

Terminal Strip Tail - Qty. 1 0.5 248.0 7.8



Terminal Strip Wings - Qty. 2 1.0 124.0 7.8

OAT sensor 0.4 117.8 2.9

Ground Fault Sensor Assembly 7.8 168.0 81.9

Shunt - GFS 2.8 52.0 9.1

Heaters 0.0

Heater Left Wing Outboard 7.0 101.2 44.3

Heater Left Wing Inboard 6.0 99.8 37.4

Heater Left Wing Center 2.0 100.0 12.5

Heater Right Wing Outboard 7.0 101.2 44.3

Heater Right Wing Inboard 9.0 100.3 56.4

Heater Tail Left 7.0 253.9 111.1

Heater Right Tail 7.0 253.9 111.1

Stall Strips 5.5 96.0 33.0

Studs - Electrical Connection

Heater Left Wing Outboard - Studs 4.6 101.3 29.1

Heater Left Wing Inboard - Studs 4.6 99.5 28.6

Heater Left Wing Center - Studs 4.6 100.5 28.9

Heater Right Wing Inboard - Studs 4.6 100.3 28.8

Heater Right Wing Inboard _ Studs 4.6 101.3 29.1

Tail Heater - Studs - Qty. 4 9 243.0 136.7

Wiring - And Harnesses

No. 6 wire harness with lugs 192.0 105.0 1260.0

Shielded harness to all modules 32.0 105.0 210.0

Control harness 16.0 100.0 100.0

GFS Harness 5.0 100.0 31.3

ounces 782.2 4497.4

lbs 48.89 4497.4

System center of gravity 92.00



17.6.2 Lancair 400 Thermawing Deice System Weight and Balance

Thermawing Deice System Weight and Balance

Columbia 400 Model: SN:

Item Weight

(oz.) Arm (in.)

Moment (in.lb.)

De-Ice Controller 30.7 150.0 287.8

Circuit Breaker - Qty. 2 1.8 79.0 8.9

Selector Switch 1.1 78.0 5.4

Lamp Test Harness 4.5 74.0 20.8

Relay - Field isolation relay 1.8 150.0 16.9

Alternator, spacers, fan , pulley, washer, nut 282.5 58.7 1036.4

Engine Drive Pulley 14.5 62.0 56.2

Alternator Top Mount Bracket 28.4 58.0 103.0

Alternator Tensioner Bracket 14.3 59.0 52.7

Belt Cutter 5.1 61.5 19.6

Tensioner Rod 13.1 60.0 49.1

Alternator Belt 3.1 62.0 12.0

Shunt - Deice 3.3 86.0 17.7

Distribution Terminal Block 4.5 89.8 25.3

Heater module Mounting Bracket Lt 2.7 124.0 20.9

Heater module Mounting Bracket Rt 2.7 124.0 20.9

Heater module Mounting Bracket Tail 2.3 247.3 35.5

Heater modules Left Wing - Qty. 2 8.6 124.0 66.7

Heater modules Right Wing - Qty. 2 8.6 124.0 66.7

Heater modules Tail - Qty. 2 8.6 247.3 132.9

Terminal Strip Tail - Qty. 1 0.5 248.0 7.8



Terminal Strip Wings - Qty. 2 1.0 124.0 7.8

OAT sensor 0.4 117.8 2.9

Ground Fault Sensor Assembly 7.8 168.0 81.9

Shunt - GFS 2.8 52.0 9.1

Heaters 0.0

Heater Left Wing Outboard 7.0 101.2 44.3

Heater Left Wing Inboard 6.0 99.8 37.4

Heater Left Wing Center 2.0 100.0 12.5

Heater Right Wing Outboard 7.0 101.2 44.3

Heater Right Wing Inboard 9.0 100.3 56.4

Heater Tail Left 7.0 253.9 111.1

Heater Right Tail 7.0 253.9 111.1

Stall Strips 5.5 97.5 33.5

Studs - Electrical Connection

Heater Left Wing Outboard - Studs 4.6 101.3 29.1

Heater Left Wing Inboard - Studs 4.6 99.5 28.6

Heater Left Wing Center - Studs 4.6 100.5 28.9

Heater Right Wing Inboard - Studs 4.6 100.3 28.8

Heater Right Wing Inboard _ Studs 4.6 101.3 29.1

Tail Heater - Studs - Qty. 4 9 243.0 136.7

Wiring - And Harnesses

No. 6 wire harness with lugs 192.0 105.0 1260.0

Shielded harness to all modules 32.0 105.0 210.0

Control harness 16.0 100.0 100.0

GFS Harness 5.0 100.0 31.3

ounces 782.2 4497.9

lbs 48.89 4497.9

System center of gravity 92.01



18.0 LEADING EDGE REINFORCEMENT TAPE INSTALLATION

18.1 Required tools Pen Razor Knife Cutting board Paper towel Leading edge material

Figure 109: Required materials for leading edge reinforcement installation

18.2 Measure

Measure leading edge length.

Figure 110: Measure area to be covered



18.3 Mark Length

Mark leading edge tape with pen.

Figure 111: Mark length of heater

18.4 Cut to Length

Use a cutting board to cut leading edge tape to length required.

Figure 112: Use a cutting board to prevent damage to wing



18.5 Peel Backing

Remove release paper from leading edge tape.

Figure 113: Remove release paper

18.6 Attach one end

Apply heat to activate adhesive backing on leading edge tape. Apply heat to one corner and attach to leading edge.

Figure 114: Attach one corner then stretch across to ensure fit



18.7 Attach Remainder

Apply heat to remainder of leading edge material until adhesive is tacky.

Figure 115: Apply heat to adhesive tape

18.8 Attach to Heater Surface

While continuing to apply heat to the leading edge tape, begin to attach the material in lengthwise strokes. Bubbles, wrinkles and blemishes should be worked out as well as possible while avoiding damage to either the heater underneath or the leading edge tape. The use of hard edged tools is not recommended.

Figure 116: Apply heat while firmly pressing down to attach leading edge tape



18.9 Verify Installation After application the leading edge tape should be flush and smooth with no discernable imperfections.

Figure 117: Forward view of installation

Figure 118: Side view of finished installation



Figure 119: Detail of copper bus after leading edge tape installation



19.0 FINAL ASSEMBLY Verify all wire connections are tight and wires are properly secured and routed.

Verify deice heaters are properly bonded.

All glues and sealants are fully cured.

Circuit Breaker panel and interior trim panels are installed per the AMM.

Instrument panel reassembled per the AMM

Replace the access covers on the left and right wings

Replace the NAV lights on the left and right wing tips

Replace the landing light and taxi light and lens on the left wing

Re-install the Horizontal Stabilizers

Replace the access cover on the fuselage right side near the horizontal stabilizer

Cowling is installed per the AMM.

Any equipment removed during servicing has been reinstalled.



20.0 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA)

20.1 Introduction

The Kelly Aerospace Thermawing Deice System is designed to remove ice from the leading edge of the wings and horizontal stabilizers of the aircraft. The system is intended as an aid during inadvertent flight in icing conditions. The system is not intended to allow flight into known icing conditions.

20.2 Description

The Kelly Aerospace Thermawing Deice System Kit is comprised of the Thermawing electrically heated deice heaters, a dedicated alternator including drive pulley and belt, Deicer Control Module, Heater Control Modules, Control Switch with integral annunciator, 2 amp circuit breaker, current limiter, and miscellaneous mounts, covers, hardware and wire.

20.3 Control, Operation Information

The pilot controls the system via the Thermawing De-Ice Control Switch. After setting the Control Switch to the ‘ON’ position, the controller will conduct a self-test and then illuminate the ‘AIRFRAME’ annunciator in green. The system operates automatically by sensing the outside air temperature and other system inputs. When the system enters operational mode the ‘ON’ annunciator will illuminate in green.

20.4 Maintenance Instructions Perform a system functional test after any maintenance is performed on the propeller deice system.

NOTE: Before inspections or maintenance are performed it is the responsibility of the

owner/operator and maintenance agency to assure that they are in possession of the latest revision of the applicable documentation and

drawings.



20.5 TROUBLESHOOTING

Fault conditions are divided into two broad categories. Hard faults indicate that safe operation of the system cannot continue without repair, and lock out system operation until the next power cycle. Note that operation of the Deice Selector switch does not remove power from the system. Soft faults indicate that the Controller has detected either a temporary condition that prevents operation of the system, or a partial failure that degrades the ice removal capability of the system.

20.5.1 Soft Faults

In case of a soft fault, the ‘FAIL’ annunciator illuminates and the ‘AIRFRAME’ annunciator remains illuminated. The following conditions can cause a soft fault indication:

20.5.1.1 Low Aircraft Bus Voltage The system requires a minimum of 11V from the Avionics Bus to guarantee safe operation. If the Avionics Bus falls below this level, the Controller will cease operation but continue to monitor for restoration of proper power, and will then resume operation without operator intervention. Note that this condition suggests problems outside of the Deice system, such as failure of the ship’s alternator.

20.5.1.2 Low Deice Alternator Output If the output of the deice alternator drops significantly below the commanded power, the system enters a soft fault state. Deicing may or may not be effective in this condition. The most common cause would be low engine RPM, as during a rapid descent at idle power, or during landing rollout. This condition can also occur if the system is left enabled, at icing temperatures, after the engine run-up is complete and the engine has been returned to idle power while awaiting takeoff or departure clearance. Normal operation will resume without operator intervention when alternator operation returns to normal.

20.5.1.3 Heater Failure A failure of a heater can be sensed by the system in several ways. Operation will continue with no deicing on the affected heater(s), but the system should be serviced to correct the fault and restore full system capability.



20.5.2 Hard Faults

In a hard fault condition, the ‘FAIL’ annunciator illuminates and the ‘AIRFRAME’ annunciator extinguishes. The system is completely disabled until the next power cycle. A fault code and textual description is saved in nonvolatile memory for maintenance use. To retrieve the fault code, connect the Field Diagnostic Cable and the Diagnostic Display as described above, and apply power to the Controller. The Controller will display the software identification and version number, followed by a line beginning with “Last Flt:”. On this same line will appear a fault code followed by further information in text form. The fault codes that can occur are listed below.

20.5.2.1 ftNone No previous fault has been recorded.

20.5.2.2 ftDeiceVolt The deice alternator is not producing any significant power, suggesting a broken belt, a failed alternator, or an open or short in the deice alternator field circuit or output circuit.

20.5.2.3 ftHtrOvrTemp A specific heater will be named and the measured temperature at the time of the fault will be specified. Troubleshoot for a failed temperature sensor or a failed HCM on the indicated heater.

20.5.2.4 ftOverCurr Deice alternator output exceeded 80A during the Powerup Test or 150A at any other time. Troubleshoot for a short in the power wiring or one or more failed HCM’s.

20.5.2.5 ftHiResist A specific heater appears to have increased its resistance substantially above nominal. Troubleshoot for an open power connection, an open heater, or a failed (open) HCM in that position.

20.5.2.6 ftLoResist A specific heater appears to have decreased its resistance substantially below nominal. Troubleshoot for a shorted power connection, a short between the heater and the airframe, or a failed (shorted) HCM in any position other than the indicated heater.

20.5.2.7 ftOverVolt The deice alternator output voltage is excessive during heating of a specific heater. Troubleshoot for an open in the power wiring or a failed (open) HCM, especially on the indicated heater.



20.5.2.8 ftIntrnlErr An internal error has occurred in the Controller. Record the error message and contact the factory.

20.5.2.9 ftBadTemp During the Powerup Test, either the average of all temperature sensors was out of range, or the OAT sensor disagreed with the average of the heater temperature sensors before power was applied. Troubleshoot for a defective OAT sensor.

20.5.2.10 ftRtdOpen The indicated temperature sensor (RTD) appears to have a break in the wiring. Troubleshoot for a disconnected temperature sensor, a break in the wiring between the HCM and the RTD, or a failed RTD.

20.5.2.11 ftRtdShort The indicated temperature sensor (RTD) appears to have a short in the wiring. Troubleshoot for a short between the HCM and the RTD, or a failed RTD.

20.5.2.12 ftExcitatn The indicated temperature sensor (RTD) is not receiving the correct excitation current. Troubleshoot for a failed RTD or HCM.

20.5.2.13 ftConfigErr No HCM’s were found during powerup configuration. Check for correct wiring of the HCM and OAT cables.

20.5.2.14 ftWatchdog An internal error has occurred in the Controller. Record the error message and contact the factory.

20.5.2.15 ftRamFail An internal error has occurred in the Controller. Record the error message and contact the factory.

20.5.2.16 ftFailedHtr More than two heaters have been identified as failed. The most likely single failure in this case is a shorted HCM on some heater other than the three identified as failed. Alternately, troubleshoot for multiple failed heaters and/or HCM’s, which is only likely if the system has flown for an extended time after a single heater failure, or if there has been a significant electrical event such as a very close lightning strike or even a direct strike.



20.5.2.17 GFS Trip Ground Fault Sensor Trip, same indication as hard fault except it is generated by the Ground Fault Sensor System:

WITH

Ground Fault Sensor Trip also disables the system until the next power cycle. The indication is identical to a Hard Fault and can be identified by turning off the De-Ice switch. With the De-Ice switch in the OFF position and the FAIL light illuminated, this indicates a GFS Trip. When the GFS trips, it locks open the Field Isolation Relay and the FAIL light remains illuminated. Maintenance can verify a GFS sensor trip by an illuminated light on the GFS sensor. One reset may be attempted if desired by pulling the 2A Deice Controller circuit breaker and resetting the circuit breaker after at least 10 seconds.

FAIL

Airframe De-Ice Switch selected

OFF



20.6 Hr/Annual

Using the tensioner rod and alternator torque tool to set the tensioning slip torque to 300 in-lbs. Tighten nuts on tensioning barrel and re-check slip torque to ensure it is still 300 in-lbs. Fly the aircraft for 1 hour and reset tensioning slip torque to 300 in-lbs. Recheck pulley alignment using a straight edge. Even if the EVADE system is never operated, after every 25 hours of flight time the belt tension must be reset to 300 in-lbs.

Remove necessary access covers including engine upper cowl and interior trim panels per the AMM.

20.6.1 Deice Heaters

Visually inspect the heaters for general condition, wrinkles, loose or torn areas. Check for abrasion or cuts along leading edge of flight surface and on edges of heater. Look for hot spots or blistering along the copper strips at each end of the heaters, and along the parting strip areas. Inspect the heater electrical connections for looseness, or tears around the electrical connection areas. Verify all hardware is properly secured.

20.6.2 Control Switch / Annunciator

With aircraft power on, verify annunciator bulbs are operating by pressing the ‘LAMP TEST’ switch. Replace bulbs as necessary

20.6.3 Lamp Test

There are diodes in the wire harnesses P/N DI-00067 and DI-00068. If after replacing bulbs the LAMP TEST is still not successful, check the diodes by using an ohmmeter and referring to the proper wiring diagram. Replace as necessary. Check switch mounting for security and loose components.

AIRFRAME

ON FAIL

NOTE: The Airframe Deice Selector Switch does NOT have to be ON to do the LAMP TEST



20.6.4 Deice Control Module

The deice control module performs a self-test of the entire system on initial activation or after a power interruption. The engine has to be running to perform a successful test. The test may be performed at any outside air temperature. When the Deice Control Switch is selected ON, the ‘AIRFRAME’ annunciator will illuminate, indicating that the switch is in the ON position, the ‘ON’ and ‘FAIL’ annunciators will flash during a self test. About 30 seconds. After the self-test is completed the ‘AIRFRAME’ annunciator will illuminate steady, indicating the DE-ICE system is powered and armed. The ‘ON’ annunciator will illuminate whenever the OAT senses a temperature at which icing can be expected. If a fault condition occurs, the ‘FAIL’ annunciator will illuminate. Two types of fault indications can be displayed.

Figure 120: Hard fault

Figure 121: Soft fault

The selector switch may be turned on at any temperature and a self-test will be performed, but the system will not operate until it senses icing conditions, temperature below 42 degrees F. Check attachment of Control Module to the electronics bay floor. Look for loose fasteners and wire harness connectors. Inspect wiring for damage or abrasion.



20.6.5 Heater Control Modules

The Heater Control Modules are tested as part of the system during the Power on Self Test. Refer to the Deice Control Module for fault indications. Check attachment of the Heater Control Modules in the wings and tail of the aircraft. Look for loose fasteners and wire harness connectors. Inspect wiring for damage or abrasion.

20.6.6 Wiring

Inspect all wiring harnesses for general condition, security abrasion, or damage. Check for loose connections at terminals. Loose connections increase resistance that causes the connection to heat up. During operation and power-up testing the total of heater resistance and associated wiring is monitored and if out of limits the system will shut down and indicate a hard fault. Check wire harness plugs for looseness.

20.6.7 De-Ice Heaters

The Thermawing Deicer Heaters are serviceable. Some minor defects may be repaired by placing a patch over the affected area. Minor damage in shedding zone: damage no bigger than the surface area of a quarter. One on the upper surface and one on the lower surface per 24 inches of heater length. Minor damage of parting Strip zone: .125 inches along the edges may be damaged. A minimum of .500 inches of undamaged width is required for a total length of 2 inches. Damage so severe that a short is created between the heating element and the grounding mesh or skin, on a power up test it will be indicated as a hard fault. If the surface and the heating element has been damaged, and the heating element material has been damaged or is missing, the heating element may still be repaired and the heater will function normally except the area where the element is missing or damaged. Parting strip is .625 inches wide, .500 inches of the parting strip width may not have any damage to the heating element; only the edges of the parting strip heating element and the outside TEDLAR® surface may be repaired. After repairs are made, and the power-up test is successful, the system may be returned to service. Repair Kits are available at Kelly Aerospace. Replacement of defective heaters with the proper Kelly Aerospace parts is recommended.



20.6.8 Control Switch / Annunciator

The Control Switch is non repairable and should be replaced with an equivalent device if found to be defective. The annunciator lamps should be replaced if burnt out with LTX 6014 bulbs or equivalent.

20.6.9 Deice Control Module

The Control Module is non repairable and should be replaced with an equivalent device if found to be defective.

20.6.10 Heater Control Module

The Heater Control Modules are non repairable and should be replaced with an equivalent device if found to be defective.

20.6.11 Ground fault sensor

The ground fault sensor is non repairable and should be replaced with an equivalent device if found to be defective.

20.6.12 RTD’s

The RTD’s are non repairable and should be replaced with an equivalent device if found to be defective. The associated deice heater will also need to be removed to gain access to the RTD. The deice heater must also be replaced at the same time. The length of the RTD lead is 48 inches and may not be altered; any change to the length will change the calibrated resistance of the RTD.

20.6.13 Shunt

The Shunt is non repairable and should be replaced with an equivalent device if found to be defective. The shunt is an electrical device and if found to be defective, the cause of the failure should be determined.

20.6.14 Alternator

The alternator overhaul and maintenance information is contained in the alternator maintenance manual. Please refer to this maintenance manual when servicing the alternator. Check the condition and security of all associated wiring in the engine compartment. Alternator mounting and tension brackets, turnbuckle, belt cutter and attaching hardware should be inspected for cracks, security and alignment. The alternator belt should be inspected for condition and replaced if any defects are detected. Check the Torque of the alternator belt; refer to section 4.8 of this manual or Kelly Aerospace drawing AL-00030 for the torque values and procedures.



20.6.15 Fuses

The fuses are non repairable and should be replaced with an equivalent device if found to be defective. The fuses are protective devices and if found to be defective, the cause of the over current condition should be determined.

20.6.16 Circuit Breaker

The circuit breaker is non repairable and should be replaced with an equivalent device if found to be defective.

20.6.17 Wiring

Wiring should be repaired using recommended practices per the AMM, AEM, AC43.13-1 or other approved sources.

20.6.18 Overhaul

There are no overhaul time limitations on the Thermawing Deice System installation. All components for the Thermawing Deice System are to be overhauled or replaced on condition.



21.0 MISCELLANEOUS

21.1 Tedlar Washer

The use of the provided Tedlar® washer’s is to prevent the lightning mesh from contacting the Thermawing graphite. For Installation ensure that you remove the protective covering that is on BOTH sides of the Tedlar®. The Tedlar® alone should only be .06” thick. Place the washer around the terminal stud and ensure that all of the copper is exposed but no paint. Then apply some heat to the Tedlar® using a heat gun. See Figure 125 for a picture of a completed Tedlar® washer install.

Figure 122: Tedlar® washer installed prior to heater

21.2 Placards

Required placards for safe operation must be located in plain sight of the pilot.

The ALT 3 FIELD placard is placed by the 7.5 amp circuit breaker on the circuit breaker panel.

Avoid use of Deice System at low engine RPM or while taxiing

Not Approved for flight into Known Icing Conditions

ALT 3 FIELD



The AIRFRAME Deice placard is installed by the 2-amp circuit breaker on the avionics panel. A placard should be placed near the field control relay in the aft electronics bay. The placard should clearly identify the field control relay. See Figure 126.

Figure 123: Field control relay placard

21.3 Removal and or Replacement information

Refer to the installation manual for removal and re-installation of components.

21.4 Diagrams

All diagrams and drawings are located on the installation CD.

NOTE: It is the responsibility of the owner/operator and maintenance agency to assure that they are in possession of the latest revision of this document and drawings. This may be obtained by contacting Kelly Aerospace by phone

(440) 951-4744, fax (440) 951-4725 or email [email protected]

AIRFRAME DEICE



21.5 Special Inspection Requirements NOTE: It is the responsibility of the owner/operator and

maintenance agency to assure that they are in possession of the latest revision of this document and drawings. This may be obtained by contacting Kelly Aerospace by phone

(440) 951-4744, fax (440) 951-4725 or email [email protected]

21.6 Application of Protective Treatments

There are no special treatments required before, during or after inspection of this system.

21.7 Data

For original equipment removed to facilitate installation, refer to OEM service manual for proper installation.

21.8 List of Special Tools

There are no special tools required for installation or inspection of this system.