Power plant installation definition
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1 Power plant installation definition Viper SD-4 LSA Doc-Nr: TOM-TC-01-C1-010 Issue: C Date: 23.FEB 2016 EASA.21J.ELA RE: PROJECT N VIPER SD-4 Page: 1 of 29 Viper SD-4 LSA Power plant installation definition Compiled by: Verified by: Released by: Reg. Mark./ Storage Róbert Benetin Slavomír Dobrovič Róbert Benetin, Eng. Period: K.16/ during the Airworthiness dept. Head of Design Airworthiness dept. period aeroplane Date: 22.FEB 2016 Date: 23.FEB 2016 Date: 23.FEB 2016 operation Signature: Signature: Signature: Copy no.:
2 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Amendments Issue Reason Date A Initial issue 18. DEC 2015 B Added stainless safety wire description 7.JAN 2016 C Refferences chapter revised General section updated Chapter 3 added Manifold pressure and fuel flow sensor relocation definition 23.FEB 2016 References /1/ SD4-A N-1#3 Power plant unit /2/ INSTALLATION MANUAL FOR ROTAX ENGINE TYPE 912 SERIES /3/ TAC0-24 Power plant photos /4/ TOM-TC-01-DDP-9005_A Fire sleeves /5/ TOM-TC-01-DDP-4003_B Fuel, Oil and Coolant hoses /6/ TOM-TC-01-DDP-4009_A Gascolator /7/ TOM-TC-01-DDP-4010_B Electric fuel pump /8/ TOM-TC-01-DDP-4014_A Water thermometer /9/ TOM-TC-01-DDP-4015_A Oil thermometer /10/ TOM-TC-01-DDP-4016_A Air filter /11/ TOM-TC-01-DDP-4017_A Hot air hose /12/ TOM-TC-01-DDP-4018_A Drain fuel hose /13/ TOM-TC-01-DDP-4019_A Cold air hose /14/ TOM-TC-01-DDP-4020_A Fuel check valve /15/ TOM-TC-01-DDP-8013_A Airbox filter holder /16/ TOM-TC-01-DDP-8014_A Airbox chamber Page 2 of 29 K.16/during the period airplane operation
3 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Contents Amendments... 2 References... 2 Contents General Bundling definition Tie-wraps Safety wire Power plant installation Spots Power plant installation Appendix K.16/during the period airplane operation Page 3 of 29
4 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. 1 General The purpose of this document is to define and describe the overall installation of ROTAX 912 series engine to the Viper SD-4 LSA airplane. It further describes the means of how the power plant installation is attached to each other. This includes definition of cable/hose/wire attachments and spots of those attachments. Spots are shown on representative Figures. 2 Bundling definition The bundling used to fix single power plant installation is defined in Table 1. Tie-wraps are used to bundle the oil, fuel and coolant hoses and electricity wires. When the Bowden cables that operates airbox conduit flaps, cold air intake conduit flap, carburettors, are set to their position a 0.5mm thick stainless safety wire is used at their ends to secure them from unintended rotation. A 0.8 mm stainless safety wire is used to secure exhaust tubes joints from unintended movement caused by vibration and from rotation (Figure 10). It is used to secure return oil line from engine to oil tank (Figure 12) and more spots defined on Figure 9 and Figure 13. Table 1 Bundling types Bundling Type Part No. Plastic locking tie-wrap PLT1.5I-M PLT2I-M PLT1M-M Stainless safety wire ø0,5 mm ø0,8 mm Page 4 of 29 K.16/during the period airplane operation
5 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition 2.1 Tie-wraps Figure 1: Tie-wrap Manufacturer: PANDUIT United States Panduit Drive Tinley Park, IL Supplier of tie-wraps: SVK Elektronik s.r.o. Slavětínská Praha 9 Klánovice K.16/during the period airplane operation Page 5 of 29
6 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Table 2 PLT1.5I-M69 locking tie definition ( ) Material Flame Retardant Nylon 6.6 Color Cross Section Locking Style Ivory Intermediate Locking Min. Loop Tensile Strength Lbs. (N) 40 (178) Continuous Use Temperature Range -76 (-60 ) (100 ) Plenum-Rated Tool No Length In (mm) 5.6 (142) Thickness In (mm) (1.1) GTS, GTSL, GS2B, PTS, PPTS, STS2 Bundle Diameter Range In. (mm) 0.06 (1.5) (35) CE Compliant CSA Certified UL Compliant (Type 1, 11) UL Listed (File #E56854) UL Recognized (File #E56854) Application Installation Temperature Operating Temperature Part Features Yes Yes Yes No Yes Thickness (mm) 1.1 UV Resistant General -4 F (-20 C) - 32 F (0 C) -76 F (-60 C) F (100 C) One-piece locking wedge for consistent performance and reliability. Low thread force and high loop tensile strength. No Width In (mm) (3.6) RoHS Compliancy Status Compliant Page 6 of 29 K.16/during the period airplane operation
7 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Table 3 PLT2I-M69 locking tie definition ( ) Material Flame Retardant Nylon 6.6 Color Cross Section Ivory Length (In.) 8.0 Length (mm) 203 Locking Style Intermediate Locking Width (In.) Width (mm) 3.6 Min. Loop Tensile Strength Lbs. (N) 40 (178) Continuous Use Temperature Range Plenum-Rated Tool -76 (-60 ) (100 ) No Length In (mm) 8.0 (203) Thickness In (mm) (1.1) GTS, GTSL, GS2B, PTS, PPTS, STS2 Bundle Diameter Range In. (mm) 0.06 (1.5) (51) CE Compliant CSA Certified UL Compliant (Type 1, 11) UL Listed (File #E56854) UL Recognized (File #E56854) Yes Yes Yes No Yes Installation Temperature Operating Temperature Part Features RoHS Compliancy Status -4 F (-20 C) - 32 F (0 C) -76 F (-60 C) F (100 C) One-piece locking wedge for consistent performance and reliability. Low thread force and high loop tensile strength. Compliant K.16/during the period airplane operation Page 7 of 29
8 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Table 4 PLT1M-M69 locking tie definition ( ) Material Flame Retardant Nylon 6.6 Color Cross Section Ivory Length (In.) 3.9 Length (mm) 99 Locking Style Miniature Locking Width (In.) Width (mm) 2.5 Min. Loop Tensile Strength Lbs. (N) 18 (80) Continuous Use Temperature Range -76 (-60 ) (100 ) Plenum-Rated Tool No Length In (mm) 3.9 (99) Thickness In (mm) (1.1) GTS, GTSL, GS2B, PTS, PPTS, STS2 Bundle Diameter Range In. (mm) 0.06 (1.5) (22) CE Compliant CSA Certified Yes Yes Mil. Std. Part Number UL Compliant (Type 1, 11) Yes UL Compliant (Type 2, 21) UL Listed (File #E56854) UL Recognized (File #E56854) Installation Temperature Operating Temperature Part Features RoHS Compliancy Status No Yes -4 F (-20 C) - 32 F (0 C) -76 F (-60 C) F (100 C) One-piece locking wedge for consistent performance and reliability. Low thread force and high loop tensile strength. Compliant Page 8 of 29 K.16/during the period airplane operation
9 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition 2.2 Safety wire Figure 2: Stainless safety wire Manufacturer: AERO LOGISTICS s.r.o. Trieda 1. mája , Spišská Nová Ves Slovakia Meeting regulation: MS C and ASTMA 580 K.16/during the period airplane operation Page 9 of 29
10 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. 3 Power plant installation For ROTAX 912 series to the Viper SD-4 fuselage installation please refer to drawing No. SD4-A N-1 revision 3 and to TOM-TC-01-SM-08_B Bolted joints procedure. This document serves to provide a clearer picture of how the power plant hoses and wires should be guided and attached by different means. 4 Spots This chapter defines which power plan installation is attached to which installation. Figures are used to define the bundling position. Table 5 serves as guidance for attached Figures to help to define each line and attachment. Table 5: Description of power plant installation Pos. Description 1 fuel line from gascolator to fuel vacuum pump /5/ 2 oil line from oil to oil reservoir /5/ 3 fuel line to fuel pressure sensor /5/ 4 fuel restrictor line /5/ 5 fuel line from fuel flow sensor to carburettors /5/ 6 draining of carburettor float chamber 7 oil line to oil thermometer /5/ 8 carburettor suction compensation line 9 oil expansion reservoir draining line 10 oil line from oil cooler /5/ 11 oil line from oil thermometer to oil pump /5/ 12 oil line from oil thermometer to oil cooler /5/ 13 fuel line from fuel vacuum pump to fuel pressure and fuel flow sensors and to restrictor line 14 oil reservoir draining line 15 fuel line bypass /5//7/ 16 warm air distribution line /11/ 17 warm air intake line /11/ 18 hot engine oil to oil reservoir line /5/ 19 drip tray gasket and airbox draining line 20 fuel line to carburettors /5/ 21 coolant from cooler 22 spark plug line 23 power line for right carburettor 24 vacuum fuel pump draining line /12/ 25 oil line from oil cooler 26 oil line to oil cooler 27 cold air intake lane /13/ 28 water from cylinder head to water cooler /5/ 29 cylinder head cooling line /5/ Page 10 of 29 K.16/during the period airplane operation
11 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Pos. Description 30 manifold pressure sensor line 31 Airbox mixing chamber conduit flap Bowden cable 32 Airbox air filter /10/ 33 left carburettor Bowden cable 34 exhaust tubes connection (spring type secured with safety wire) 35 exhaust tubes joint connection (spring type secured with safety wire) 36 exhaust tubes connection counter-rotation safety wire 37 airbox scout (warm air intake) 38 water thermostat 39 fuel line to LHS carburettor K.16/during the period airplane operation Page 11 of 29
12 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. 4.1 Power plant installation Figure 3: Viper SD-4 LSA Power plant installation Table 6: Figure 3 guidance Pos. Description 1 fuel line from gascolator to fuel vacuum pump 13 fuel line from fuel vacuum pump to fuel pressure and fuel flow sensors and to restrictor line 21 coolant from cooler 22 spark plug line 23 power line for right carburettor 24 vacuum fuel pump draining line 25 oil line from oil cooler 26 oil line to oil cooler 27 cold air intake lane Figure 3 describes front right side of the Viper SD-4 LSA power plant installation. On the most right hand side there is a propellers hub. Right after propellers hub there is an engine reduction gearbox. Bellow that is oil cooler. The oil flow comes from left line and exits via right line. On the engine gearbox there is a fuel vacuum pump which is drained to the aft part of the engine compartment via green draining line attached by several plastic locking tie-wraps. Page 12 of 29 K.16/during the period airplane operation
13 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 4: Viper SD-4 LSA Power plant installation Table 7: Figure 4 guidance Pos. Description 1 fuel line from gascolator to fuel vacuum pump 3 fuel line to fuel pressure sensor 5 fuel line from fuel flow sensor to carburettors 7 oil line to oil thermometer 13 fuel line from fuel vacuum pump to fuel pressure and fuel flow sensors and to restrictor line 14 oil reservoir draining line 15 fuel line bypass 16 warm air distribution line 17 warm air intake line 18 hot engine oil to oil reservoir line 19 drip tray gasket and airbox draining line 20 fuel line to carburettors 21 coolant from cooler mm safety stainless wire application K.16/during the period airplane operation Page 13 of 29
14 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. As seen on Figure 4 most of the fuel lines are attached by plastic locking tie-wraps. Fuel lines are covered by orange fire-proof sleeves /4/ ended up with fire-proof sealing tape. Figure 5: Viper SD-4 LSA Power plant installation Pos. Description 5 fuel line from fuel flow sensor to carburettors 6 draining of carburettor float chamber 10 Oil line from oil cooler 16 warm air distribution line 17 warm air intake line 19 drip tray gasket and airbox draining line 24 vacuum fuel pump draining line 27 cold air intake 28 water from cylinder head to water cooler 29 cylinder head cooling line 30 manifold pressure sensor line 38 water thermostat 39 fuel line to LHS carburettor Page 14 of 29 K.16/during the period airplane operation
15 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 6: SD-4 LSA power plant installation Pos. Description 1 fuel line from gascolator to fuel vacuum pump 2 oil line from oil to oil reservoir 3 fuel line to fuel pressure sensor 4 fuel restrictor line 5 fuel line from fuel flow sensor to carburettors 6 draining of carburettor float chamber 7 oil line to oil thermometer 8 carburettor suction compensation line 9 oil expansion reservoir draining line 10 oil line from oil cooler 11 oil line from oil thermometer to oil pump 12 oil line from oil thermometer to oil cooler 31 Airbox mixing chamber conduit flap Bowden cable 32 Airbox air filter 33 left carburettor Bowden cable K.16/during the period airplane operation Page 15 of 29
16 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Note Fuel flow pressure (5) and manifold pressure position (not visible on this Figure) not conforming to the Type Definition. For correct installation definition please refer to Figure 26. Figure 7: Stainless safety wire application Page 16 of 29 K.16/during the period airplane operation
17 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 8: Stainless safety wire application Figure 9: Stainless safety wire application K.16/during the period airplane operation Page 17 of 29
18 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Figure 10: Exhaust tubes connection secured by 0,8mm stainless wire Figure 11: Exhaust tubes anti rotation attachment Page 18 of 29 K.16/during the period airplane operation
19 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 12: Oil line return line Figure 13: Stainless safety wire application K.16/during the period airplane operation Page 19 of 29
20 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Appendix This appendix contains overall and close-up look pictures of power plant unit hoses, cables, wires. Figure 14: right side Figure 15: left side Page 20 of 29 K.16/during the period airplane operation
21 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 16: Top view Manifold pressure line not according to TD (red colour). TD marked with green colour (see Figure 26). K.16/during the period airplane operation Page 21 of 29
22 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Figure 17: front look Figure 18: reduction gearbox Page 22 of 29 K.16/during the period airplane operation
23 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 19: left side closer look Figure 20: left side firewall top part K.16/during the period airplane operation Page 23 of 29
24 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Figure 21: left side firewall - bottom part Figure 22: cabin heat distribution hose Page 24 of 29 K.16/during the period airplane operation
25 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 23: Left (fuel pump draining + airbox draining) Right (airbox warm air intake) K.16/during the period airplane operation Page 25 of 29
26 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Figure 24: Left (firewall right side overall look) Right (electric fuel pump closer look) Page 26 of 29 K.16/during the period airplane operation
27 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 25: firewall top part overall look Fuel flow sensor and fuel pressure sensor not in line with TD. Fuel flow sensor and manifold pressure sensor should be installed according to SD4-A N-1#1 (Figure 26). Figure 26: Type design definition of correct manifold pressure sensor and fuel flow sensor Fuel flow sensor attached by a 2 (M66) plastic tie wraps to the oil line. K.16/during the period airplane operation Page 27 of 29
28 Viper SD-4 LSA Power plant installation definition TOMARK, s.r.o. Figure 27: airbox + control cables (green/white electric cable inserted to the airbox NOT PART of TD) Figure 28: Engine suspension frame and power plant guidance Page 28 of 29 K.16/during the period airplane operation
29 TOMARK, s.r.o. Viper SD-4 LSA Power plant installation definition Figure 29: Water thermostat installation K.16/during the period airplane operation Page 29 of 29
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