INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

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AIRCRAFT PRODUCTS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS Document No: Revision: C Dated: JUL-23-2014 FOR TANIS BATTERY HEAT SYSTEMS INSTALLED ON LEAD ACID AND Ni-CAD BATTERIES Registration No.

1 AIRCRAFT PRODUCTS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS Document No: Revision: C Dated: JUL FOR TANIS BATTERY HEAT SYSTEMS INSTALLED ON LEAD ACID AND Ni-CAD BATTERIES Registration No. Serial No. This supplement must be attached to the applicable Approved Maintenance Manual when the Tanis Preheat System is installed. Information in this manual supplements or supersedes the basic manual only in those areas listed. (Supporting information to be recorded as indicated in Tables 1 and 2, Section 16.) PROPRIETARY DATA Tanis Aircraft Products proprietary rights are included in the information disclosed herein. The recipient by accepting this document agrees that neither this document nor the information disclosed herein nor any part thereof shall be reproduced or transferred to other documents or used or disclosed to others for manufacturing or for any other purpose except as specifically authorized in writing by Tanis Aircraft Products.

2 RECORD OF REVISIONS When updated, this document is changed in its entirety. ICA REV DATE DESCRIPTION BY RELEASE C JUL Add TLP3039, TLP3046, and Figure 1. DNE B NOV Add connector configuration and update figures DNE DNE A JAN Initial Release DNE DNE DOCUMENTATION SUPPORT It is the responsibility of the user of this, and other document, to verify the latest revision is being used. Revision updates may be obtained by contacting: Tanis Aircraft Products CONTENTS RECORD OF REVISIONS... 2 DOCUMENTATION SUPPORT PURPOSE AIRWORTHINESS LIMITATIONS RECORD OF REVISIONS DESCRIPTION CONTROL AND OPERATION REMOVAL AND REPLACEMENT SERVICING INFORMATION MAINTENANCE AND INSPECTION LIST OF SPECIAL TOOLS DATA SPECIAL INSPECTION REQUIREMENTS RECOMMENDED OVERHAUL INTERVALS FOR COMMUTER CATEGORY AIRCRAFT APPLICATION OF PROTECTIVE TREATMENTS FUNCTIONAL SYSTEM CHECK - TROUBLESHOOTING TABLES AND FIGURES... 8 Page 2 of 12

3 1. PURPOSE The purpose of this ICA is to aid the operator in creating an acceptable maintenance program for the preheat system installed on the aircraft battery(s), one that complies with standard aviation processes and airframe manufacturer s recommendations. This document contains the necessary information to aid in this process, and to perform required maintenance and inspections procedures. Documents, tables, and figures, referenced are located in Section 16. Table and Figures. 2. AIRWORTHINESS LIMITATIONS This system does not change Airworthiness Limitations. The Airworthiness Limitations section of the FAA specifies inspections and other maintenance required under and of the Federal Aviation Regulations unless an alternative program has been FAA approved. 3. RECORD OF REVISIONS It is the responsibility of the user of this document to verify the latest revision is being used, and that installation documents associated with the installation of the kit are maintained and recorded in Table 1 of this document. Revision updates and additional copies may be obtained by contacting: Tanis Aircraft Products When the latest update is received, the previous revision in its entirety should be discarded. Verify all pages of the document are marked as the latest revision, and Tables 1 and 2 are updated accordingly. 4. DESCRIPTION The battery heat kit consists cabling with thermal control (thermostat), circuit protection, and element(s). The kit may be installed independently or in conjunction with the primary Tanis preheat system as the power source. The kit may incorporate more than one battery heat element. When interconnected with primary heating system (engine preheat) circuit protection is provided by primary preheat system, and may be fused as depicted in Figure 7. The battery element is installed around the circumference of the battery. Depending on the complexity of the installation, a non-heating adaptor panel (TB02645) may be incorporated for fitting around terminal and sensor contacts. Plug and placard depict voltage requirements, 115 Volt or 230 Volt. Wiring for the system is red with black connectors. Battery element thermal control cable assembly connects element(s) power connector, and thermal control located near the battery. The thermal control senses ambient temperature of the battery environment and limits operation to a preset temperature. Page 3 of 12

4 5. CONTROL AND OPERATION Operating instructions are contained in the Operating Guide recorded in Table 1, Section 16. Connection to ground power controls operation. Do not fuel or start the aircraft with the kit connected to power. Only operate with battery fluids at operational levels. The system can be operated immediately after full engine shut down. To be of maximum benefit at temperatures below 0 C / 32 F, it should be in continual use for a minimum of 6 hours before engine start. Power requirements: Kits are available in two separate voltages, 115 volt, and 230 volt. Voltage requirements are identified by the part number, placard, and power plug type. Circuit protection is 5-Amps, not to exceed 12-Amps. Circuit protection may also be supplied through primary preheat system when interconnected. 6. REMOVAL AND REPLACEMENT Caution: Disconnect system from power when servicing. Referenced documents, tables, and figures located in Section 16. Tables and Figures. Removal: Disconnect element, remove lacing if used, and cap off and secure associated wiring, or completely remove the kit. Placard inoperative IAW applicable regulations if eligible, or defer IAW approved MEL/NEF if applicable. Replacement: Element is installed around the perimeter of vertical surface, flat side toward battery using cable-ties or appropriate lacing, ends should not overlap. When installing pull lacing gently, alternate tension between grommets to avoid damaging the element by pulling grommets out. Avoid power lugs and sensor connector. Non-heating adaptor panel (TB02645), may be used for fitting. Panel can be cut to fit around terminal and sensor contacts as needed. Elements installed on batteries in boxes may not require lacing. During installation, if required, protect the element form damage with thin cardboard or other appropriate material, once battery and element are in place remove protector. For installation were element lead is required to penetrate battery box or lid, MS grommet or equivalent, is to be installed. Wire/Cable routed with existing wire, Thermal Control is to be located in the battery compartment 6-18 inches from the battery using cable mount, and alternately it may be cable tied with existing wiring. Examples of installations and common replacement items are referenced in Section 16. Page 4 of 12

5 7. SERVICING INFORMATION There are no life limited parts. Part life is based on condition per inspection. Components are to be repaired or replaced upon failure or damage. Before reinstalling an element that has been removed, inspect overall condition and measure resistance with calibrated ohmmeter and compare reading to values listed in Table 2. Inspect pad element for signs of oil damage, abrasion or exposed heating wire.. When servicing the battery, disconnect the element connector, cap the connector on the airframe side, and secure wiring. When removing or installing a battery with an element installed, use care not to snag the element on sharp edges. Small tears and abrasions can be repaired with approved sealant, reference Instruction - Bonding for approved sealants. If any of the element wire is exposed the element should be replaced. Before applying power after maintenance procedure reconnect and perform Functional System Check, Section 15. For guidance to other service information, see Sections 6 and MAINTENANCE AND INSPECTION Supporting documents listed in Section 16. Tables and Figures. Inspections are the only form of scheduled maintenance required under normal flight conditions and operations. Maintenance and repairs are to be carried out in response to operational concerns and/or inspection discrepancies. Maintenance is to be recorded under 14 CFR Part 43.9, unless an alternative program has been approved. Repairs are to conform to applicable standards, reference b, 11. Visual and operational check is to be conducted by an appropriately rated and certified technician or maintenance/repair facility Cleaning is to be performed in accordance with battery and airframe manufacturer s recommendations Inspections intervals are to be performed at each annual or equivalently scheduled inspection. Minimum of one (1) check per 12-month cycle/annually is required. In addition, it is recommended that the system operational status be checked seasonally Inspect for security of attachment by following cable leads from the power connection point/shore power plug to the element(s). Inspect connectors and junctions for signs of heat damage or deformities. Inspect wire/cable for signs of fatigue, chafing, flexing, heat damage, and vibration, re-secure and or repair as needed. Reference AC b, Chapter 11 Sections 1, 3, 4, and 8, and Cable Kit - Wire Diagram, for additional electrical inspection and repair information Inspect element(s) for security of attachment. Replace pad element developing areas of gray/yellow. These are signs indicating that a pad has failed, or is in the process of failing. Perform replacement and/or repairs as required, refer to Sections 6 and Verify operation of the thermal control by cooling the thermal control (thermostat) to below 0 C (32 F). This may be done using an ice pack, circuit cooler spray, or other appropriate means When the thermal control is below +5 C +/- 3 C (41 F +/- 5.4 F) the circuit is closed and the ohmmeter should read resistance across the power contacts (battery element would be operational). Note: refer to 8.8 for optional controller. Page 5 of 12

6 8.7. When the thermal control is in a condition above the trip point, the circuit should read open (battery element would not be operational) For Thermal Control replacement, use TLP (+5 C). This kit comes with corresponding socket connector kit TCS2598 for installation if required. Optional preset controller available for non-standard installations (TLP C). Refer to Figures in Section 16, for example of installed Thermal Control and wire diagram For fuse replacement, disconnect system from power and replace fuse(s). Direct replacement fuses TU amp TU amp. Alternates: Bussmann ABC-5- Amp 1.25 x 0.25 ceramic tube fuses, alternate glass tube fuses AGC Battery systems interconnected with other system may have circuit protection provided by primary system, refer to wire diagram Section Once inspection has been completed, perform a Functional System Check, Section LIST OF SPECIAL TOOLS Required: Ohmmeter certified to traceable standard is required for inspection and troubleshooting. Suggested tools for system repairs include: Deutsch contact remover tool: DT-RT1 Tanis 4 way indent crimp tool: TU02793, Alternate crimp tool, DMC: AF8-TH DATA Supporting figures, tables and documents listed in Section 16. Tables and Figures. 11. SPECIAL INSPECTION REQUIREMENTS In addition to special inspection events, as defined by aircraft maintenance manual and this ICA, inspect in the event of a hard landing, lightning strike, or water immersion. 230 Volt kits are supplied with plug adapter receptacle (TP ), field installed on extension cord supplied by the operator following instructions TN RECOMMENDED OVERHAUL INTERVALS No recommended overhaul intervals exist for this system. 13. FOR COMMUTER CATEGORY AIRCRAFT No changes are required. 14. APPLICATION OF PROTECTIVE TREATMENTS No protective treatments required. Page 6 of 12

7 15. FUNCTIONAL SYSTEM CHECK - TROUBLESHOOTING Before proceeding, verify system is not powered, or connected to power source. Verify element(s) are properly connected. Follow in sequence, record as indicated, and check off when completed. If a discrepancy is found, correct before proceeding to the next step. Detailed installation and operation documents listed in Table 1. For assistance in correcting discrepancy, refer to Troubleshooting table listed in Table 4. [ ] Check the system as follows: 1) [ ] Verify engine to airframe bonding is as per OEM requirements. 2) [ ] Verify ground bonding by checking for continuity between power connection/power plug, ground pin 3, (Figure 1), and airframe. 3) [ ] Using an ohmmeter, verify there is no continuity between power pins 1 and 2, and the ground pin 3. 4) [ ] Close thermal control by freezing (0 C) and measure resistance at power connection pins 1 and 2, ahead of thermal control, and record:. 5) [ ] With thermal control closed connect the system to appropriate power source and test battery element for warmth. Battery element can be touched as wattage density is low. Page 7 of 12

8 16. TABLES AND FIGURES ICA TABLE 1 - Reference Documents. Record additional document per installation. TN02793 TN02788 Instruction - Connector Instruction - Bonding Instruction - Indicator Light Instruction - Preheat Installation Operating Guide - Preheat System Cable Kit - Wire Diagram TABLE 2 - Electrical Values +/- 10%. Record as indicated in table below. To calculate the specific wattage of an individual element or installed system, measure total resistance between the contacts 1 and 2, Figure 1, and use the following formula. Voltage squared, divided by Resistance = Wattage (V 2 /R=W). To calculate resistance value of an element using the part numbers the digits after the dash (-) callout voltage and the numbers after the slash (/) callout wattage. Voltage squared, divided by Wattage = Resistance (V 2 /W=R). Installed system voltage: Qt. Element P/N: Wattage Ohms (TBP /60) (60) (220.4) TABLE 3 - Listing of common battery system parts. Note: Battery system and cabling assemblies vary by installation. Verify power connection before ordering replacement parts. TLP TLP3039 TLP2762 TLP P TP S18G-115 TP S18G-230 TU02782 CB92 Thermal Control Replacement Kit (w/connector) Power Indicator Light (LED) Single Battery Cabling (w/control and fusing) Dual Battery Cabling (w/control and fusing) Power Plug - 18 inch lead socket connector Volt Power Plug - 18 inch lead socket connector Volt Cable Mount - Click Bond (CB9120) Cable Mount Installation Kit Page 8 of 12

9 TABLE 4 - Troubleshooting Battery system are typically installed in conjunction with a complete preheat system, for that reason a complete system troubleshooting guide is listed. Individual elements are tested disconnected from the system, measuring resistance across the element contacts; values listed in preheat installation instruction, and Table 2. For further assistance, contact Tanis Aircraft Products. SYMPTOM PROBABLE CAUSE MAINTENANCE ACTION Circuit protection blown. Reset breaker or replace fuse. Connect to better AC power Voltage is out of range. source. Indicator light does not Shore power cord not Connect cord and check power light when attached to providing power. at source (wall). shore power. Check connections and wire Broken wire. junction. Shore power plug damaged. Repair and/or replace plug. Check element with Ohmmeter. Faulty element(s). System preheats See section 12 Data for values. minimally, but one Connect to better AC power Voltage is out of range. component or more is source. not heating properly. Check connections and wire to Broken wire element. Smoke or odor occurs on newly installed system. Smoke or odor occurs on system that has been installed for at least a month. Circuit protection or GFI on ground shore power continually trips. Battery heat element does not heat. Off gassing occurs normally on newly installed system. Heat element is failing (yellow/grey area on pad). Heat element contaminated. Damaged system (shorted wire). Temperature is above freezing. Thermal control (thermostat) is broken. Check system for proper install. Disconnect power, remove and replace heat element. Check the rest of the system for proper installation. Remove power and clean element. Check entire system for damage or short. None. Battery heater is thermostatically controlled, does not heat if ambient temperature is above freezing. Check function of thermal control by cooling to below freezing. If not functioning, replace. Page 9 of 12

acceptable. Figure 2 - Common plug configurations. Kit may be configured with power indicator light.

10 Figure 1 - Shore power plug types and placards. Standard Tanis placard shown, appropriate alternate stating Tanis System and required voltage acceptable. Figure 2 - Common plug configurations. Kit may be configured with power indicator light. When the battery system is installed independent of main preheat kit plug is to be properly secured with clamps, bracketing or optional flush plug. Page 10 of 12

Figure 4 - Example battery heat elements

11 Figure 3 - Mounting options and clamp positions shown for connectors, indicator light, junction, and dual fused link. Figure 4 - Example battery heat elements installed. Refer to Servicing Information Section 7, for element installation procedures. Element is fitted around circumference of battery and ends are not to overlap, elements vary in length, width, and wattage, based on battery and installation requirements INCH 7.75 INCH 9.75 INCH 7.75 INCH EXAMPLE OF BATTERY ELEMENTS INSTALLED ON MAIN AND AUXILIARY BATTERIES IN DEHAVILLAND DHC-8 LOCATED ON SHELF Z (L.H.S.). Figure 5 - Example of dual battery configuration. Controller mounted in battery compartment 6-18 inches from the batteries. Page 11 of 12

Figure 6 - Example thermal control installed using cable mount, alternately it may be cable tied with existing wiring. Controller should be mounted 6-18 inches from the battery.

12 Figure 6 - Example thermal control installed using cable mount, alternately it may be cable tied with existing wiring. Controller should be mounted 6-18 inches from the battery. Replacement kit listed in Table 3. POWER BLK WHT THERMAL CONTROL OPTION: DUAL FUSE AND INDICATOR LIGHT/SPARE LEAD OFF LOAD SIDE. NOTE: CONNECTOR CONFIGURATION VARIES. CIRCUIT PROTECTION: 5-AMP INLINE FUSE OR PROVIDED BY PRIMARY SYSTEM. CABLE/WIRE 18 OR 20 GAUGE BATTERY ELEMENT(S) Figure 7 - Typical wire diagram. Systems with more than one element may distribute power through terminal block/junction. Dual fuse options are available. Power indicator light may be incorporated off load side of circuit protection. ***** NOTHING FOLLOWS ***** Page 12 of 12

Instructions for Continued Airworthiness

Forced Aeromotive Technologies Instructions for Continued Airworthiness Supercharged IO-550-N Engines Installed On NOTICE This document must be referenced on Block 8 of FAA form 337 and added to the aircraft