-
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Table of Contents
Paragraph
e
1.0
1.1
1.2
1.3
1.4
1.5
1.6
2.0
2.1
2.1.2
2.2
2.2.1
2.2.2
2.2.2.1
2.2.2.2
3.0
3.1
3.1.1
3.1.2
3.1.3
3.1.3.1
3.1.3.2
3.2
3.2.1
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.9.1
3.9.2
3.9.2.1
3.9.3
3.9.3.1
3.9.4
3.9.5
3.10
3.11
3.11.1
3.12
3.12.1
3.12.2
3.12.3
3.12.4
3.12.5
3.12.6
3.13
Page Number
Title
INTRODUCTION
Purpose
Publications
Regulations
Modifications
Technical Assistance
Terms
DESCRIPTION
De-Icing System Components
Component Operation
De-Icing System Operation
De-Icing System Differences
De-Icer Heating Sequence
Dual Element De-Icers
Single Element De-Icers
INSTALLATION
Introduction
Electrical Capacity
Weight and Balance
Aircraft Component Removal/Modification
Removal
Modification
De-Icer Installation
Hartzell Compact Propeller Modification and De-Icer Installation
Balance WeiQhts
Lead Strap Clamps or Restrainers
Rubber Restrainer Straps
Timer Installation
Ammeter, Switch, Circuit Breaker (Optional) Installation
Brush Assembly Mounting Bracket Installation
Slip Ring and Slip Ring Starter Ring Gear Assembly Installation
Installation of Hardware on Modified Spinner Bulkhead
Slip Ring Assembly Installation
Slip Ring Assembly Wiring
Slip Ring/Starter Ring Gear Assembly_Installation
Slip Ring/Starter Ring Gear Assembly Wiring
Hose Clamps
Slip Ring Alignment
Propeller Installation
Brush Assemblv Installation
Brush Assembly Alignment
System Wiring
Timer Wiring
Ammeter (Optional) Wiring
Switch or Circuit Breaker/Switch LOptionall Wiril}g
Circuit Breaker (Optional) Wiring
Engine Firewall Connector (Optional) Wiring
Brush Assembly Wiring
Post-Installation Inspection
4
4
4
4
4
4
4
5
5
5
6
6
6
6
7
9
9
9
9
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1
/30-60-02 Page
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----.------~----~--~-.--.-..-'
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Table of Contents
Title
Paragraph
4.0
4.1
4.2
4.2.1
4.2.2
4.2.2.1
4.2.2.2
4.2.2.3
4.2.2.4
4.2.2.5
4.2.2.6
4.2.2.7
4.2.2.8
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.5.1
4.4.5.2
4.4.5.3
4.4.5.4
4.4.6
Page Number
MAINTENANCE
Current Drain
Required Inspections
50 Hour Inspection
100 Hour Inspection
De-Icer Inspection
Slip Ring Inspection
Brush Assembly Inspection
Timer Test
Ammeter (Optional) Test
Circuit Breaker and Switch (Optional) Test
Wiring
Other
Troubleshooting
HeJoful Tios
De-Icer Resistance Check
Slip Ring Alignment Check
Brush Assembly Resistance Check
Ammeter (Optional) Check
Repair Procedures
Electrical Repairs
Mechanical Repairs
Switch, Circuit Breaker, Ammeter (Optional), Wire Harness Repairs
Brush Assembly Repairs
Sli~ Rin_g_ Re~airs
Slip Ring Stud Repairs
Non-Concentricity
Slip Ring Lead Wire Repairs
Slip Ring Replacement
De-Icer Replacement
Charts and Tables
Title
Table 1
Table 2
Slip Ring Cross Reference Chart
Timer Operation Specifications
Troubleshooting Chart
34
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34
35
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37
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41-44
Page 2
30-60-02 Nov
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Table of Contents
Figure
Title
1
2
3
4
5
6
7
Typical Twin Engine De-Icing System Schematic
Twin Engine De-Icing Cycle with Dual Element De-Icers
Twin Engine De-Icing Cycle with Single Element De-Icers
Hartzell Compact Propeller - Counterweight Modification
Hartzell Compact Propeller - Lead Configuration
Hartzell Compact Propeller - Assembly/Wiring at Spinner Bulkhead
Hartzell Compact Propeller - Assembly/wiring at Slip Ring/Starter
Ring Gear Assembly
Modified Balance Weight/Lead Strap Clamp (P/N 4E1725) Installation
Lead Strap Clamp (P/N 2E1063-4) Installation
Lead Strap Clamp (P/N 2E1200-4) Installation
Nylon Tie Strap Installation
Lead Strap Clamp (P/N 3E1375) Installation
Restrainer Strap (P/N 2E1290/2E1291) Installation
Lead Strap Clamp (P/N 2E1285-1 ,-2) Installation
Lead Strap Clamp (P/N 2E1 087-3) Installation
Restrainer Strap Installation
Terminal Clamp (P/N 3E1883-2/3E1848-1 /3E1848-2) Installation
Rubber Restrainer (2E1291/3E1470) Installation
Timer Mounting Methods
Typical Brush Assembly Mountina Bracket Installation
Typical Brush Assembly Mounting Bracket Installations
Typical Brush Assembly Mounting Bracket Installation
Typical Brush Assembly Mounting Bracket Installation
Typical Brush Assembly Mounting Bracket Installation
Tvoical Soinner Bulkhead Connectina Hardware - Terminal Strio
Typical Spinner Bulkhead Connecting Hardware - Terminal Blocks
Lead Clip/Cable Clamp Installation
Terminal Strip Variations
Slip Ring Assembly Mounted on Spinner Bulkhead
Slip RinQ Assembly Installation on Crankshaft/Propeller Hub FlanQe
Slip Ring Assembly Installation on Crankshaft/Propeller Hub Flange
Typical Slip Ring/Starter Ring Gear Assembly Installation
Positioning Spinner Adapter Ring
Slip Ring/Starter Ring Gear Assembly Installation
Hose Clamos
Checking Slip Ring Run-Out
Brush Alignment - Projection
Brush Alignment - Face
Angular Brush Alignment Adjustment Method
Anaular Brush Alianment Adiustment Method
Angular Brush Alignment Adjustment Method
Engine Firewall Connector
Measuring Minimum Dimensions and Machining Instructions for
Slip Ring Assembly and Slip Ring/Starter Ring Gear Assembly
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Page Number
5
7
8
10
10
10
11
12
13
13
13
14
14
15
15
16
17
18
19
20
20
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36
Page 3
30-60-02 Nov
15/92
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Section 1.0 - Introduction
1.1
Purpose
This publication provides installation, maintenance and repair information for BFGoodrich electrothermal
propeller de-icing systems and components installed on a variety of general aviation aircraft. Each system
and its components are designed for a unique application, although operation, installation, maintenance
and repair procedures may be common or similar. The Aircraft Manual applicable to your aircraft model
contains information not included in this manual.
Information about de-icing systems and/or components not manufactured by
BFGoodrich must be obtained from the component or aircraft manufacturer.
1.2
Publications
This manual is intended for use in conjunction with the following documents:
1. Aircraft and Propeller Manufacturer's manuals and instructions applicable to your system
2. BFGoodrich General Arrangement Drawing applicable to your system.
3. BFGoodrich Report S9-728,lnstallation & Removal Procedures: Electrically Heated De-Icers for
Aircraft Propellers.
4. Aircraft and Propeller Manufacturer's manuals and instructions applicable to your system.
5. BFGoodrich Propeller De-Icing Systems Replacement Parts List.
6. BFGoodrich Slip Ring Reference Chart.
1.3
Regulations
De-icing system installation, maintenance and repair must comply with FAA Advisory Circular 43 and
superseding FAA releases. Safety wiring must be installed in accordance with C.A.R. Part 18 [Ref. C.A.R.
18.30-6(3)] and MS33S40.
1.4
Modifications
Caution: Aircraft manufacturers sometimes modify a BFGoodrich de-icing system,
making the instructions in this manual incomplete or not applicable.
1.5
Technical Assistance
For technical assistance call 1-800-334-2377 (United States, Canada and Puerto Rico) or 216-374-3743/
3706 (international locations), or write:
BFGoodrich Aerospace De-Icing Systems
1555 Corporate Woods Parkway
Uniontown, Ohio 44685
1.6
Definition of Terms
"Drawing" ................ .. the applicable BFGoodrich General Arrangement Drawing.
"Brush Assembly" .... . modular brush assembly or brush block assembly, except as specifically
distinguished. Note that brush assembly installation figures may be illustrated
as brush block assemblies, but are valid for mpdular brush assemblies also.
"Optional" ................ . the component or procedure is not applicable to every de-icing system.
"Slip Ring" .............. .. slip ring assembly or slip ring/starter ring gear assembly, except as specifically
distinguished.
Page 4
30-60-02 Nov
15/92
(
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Section 2.0 - Description
2.1
De-Icing System Components
A propeller de-icing system (Figure 1) consists of the following components. The quantity of each
depends on the specific application.
a.
Electrically heated de-icers, bonded to the propeller blades.
b.
A rotating slip ring to distribute power to the de-icers.
c.
A stationary brush assembly to transfer electric power to the slip ring.
d.
A timer to cycle electric power to the system in proper sequence.
e.
Ammeter, external shunt, circuit breaker switch or circuit breaker and switch, and wire
harnesses are optional components often included in the de-icing system.
1.
0
[)
;it ..
De-Icer
Slip Ring
Brush Assembly
Timer
Ammeter (optional)
Shunt (optional)
Switch (or Circuit)
Breaker Switch)
8. Wiring
9. Circuit Breaker
(optional)
10. Aircraft Power Source
2.
3.
4.
5.
6.
7.
2
FIREWALL
CONNECTOR
>,:,'!
Figure 1 - Typical Twin Engine De-Icing System Schematic
2.1.2
Component Operation
a. The propeller de-icer consists of special wire or foil, protected by fabric and rubber plies which resist
oil, erosion and abrasion. One side of the de-icer has a dull, fabric-impressioned finish to provide a good
bonding surface for adhesion to the propeller blade. The other side has a smooth, glossy finish.
b. A wire harness is often used to electrically connect one component to another. For example, a deicer wire harness may be used to connect the de-icer leads to the slip ring assembly leads.
c. The slip ring and brush assembly conduct electric power to the de-icers. The brush assembly,
typically mounted on the engine, contains spring loaded brushes which contact the rotating copper rings
of the slip ring.
d. The timer distributes power to the system in timed intervals in a specific sequence.
e. An ammeter (optional) indicates current flow in the de-icing system. The ammeter has an internal or
external shunt.
f. A switch or circuit breaker/switch (optional) is sometimes used to cut power in the case of an
overload. Some systems include an extra circuit breaker between the de-icing system and the power
supply.
g. Some aircraft include additional components as part of the de-icing system. Check the Aircraft Manual
for complete information on your system.
Page 5
30-60-02 Nov
15/92
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
2.2
De-Icing System Operation
The electrically heated propeller de-icers, combined with the centrifugal force of the rotating propeller and
airstream blast, remove accumulated ice. To conserve power and effectively remove ice, the de-icers
are heated in timed intervals in a specific sequence, rather than continuously.
.
2.2.1
De-Icing System Differences
De-icing systems differ in three areas:
1. Number of engines:
2. De-icer heating elements:
3. Slip ring type:
2.2.2
Single, twin, three or more
Single or dual: A single element de-icer has two leads (power
and ground). A dual element de-icer has three leads (inboard,
outboard and ground).
Slip ring or slip ring/starter ring gear.
De-Icer Heating Sequence
When the de-icing system is activated, power is cycled to the de-icers in timed intervals in a specific
sequence which is critical to effective ice removal. The sequence depends on whether the de-icer has
single or dual elements, and the number of engines on the aircraft.
2.2.2.1 Dual Element De-Icers
Each dual element de-icer has two electrothermal elements: inboard and outboard. A typical heating
interval for dual element de-icers is 34 seconds, although there are exceptions. Check the Aircraft Manual
for applicable interval time. Following are the heating sequences for dual element de-icer systems:
(a) Single Engine Aircraft:
Phase 1 :
Phase 2:
When the system is activated, power is cycled in this sequence:
All outboard de-icer elements for the specified interval
All inboard de-icer elements for the specified interval
This cycle may begin at either Phase, but the sequence remains the same, and continues as long as the
system is activated.
(b) Twin Engine Aircraft:*
When the de-icing system is activated, power is cycled in this sequence:
Phase 1: All outboard de-icer elements on first propeller assembly for the specified interval (Figure 2)
Phase 2: All inboard de-icer elements on first propeller assembly for the specified interval
(Figure 2)
Phase 3: All outboard de-icer elements on second propeller assembly for the specified interval (Figure 2)
Phase 4: All inboard de-icer elements on second propeller assembly for the specified interval (Figure 2)
This cycle may begin at any Phase, but the sequence remains the same, and continues as long as the system
is activated.
*NOTE: Some twin engine aircraft have two independent timers which cycle power to the deicers on each propeller assembly separately as if there were two single engine systems.
(c) Multi-engine Aircraft:
Check the Aircraft Manual for sequence information on aircraft with
three or more engines.
6
30-60-02 Page
Nov 15/92
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Figure 2 - Dual Element Twin Engine De-Icing Cycle
SLIP RINGS
- - L....... TOPQWER
L _J
SOURCE
LCIRCUIT BREAKER
SWITCH
Phase 1
Phase 2
Phase 3
Phase 4
2.2.2.2 Single Element De-Icers
Each single element de-icer has one foil element, typically heated for a 90-second interval. Following
are heating sequences for single element de-icer systems.
(a) Single Engine Aircraft:
Phase 1:
Phase 2:
When the de-icing system is activated, power is cycled in this sequence:
All de-icers for 90 seconds.
All power is shut off for 90 seconds.
This cycle may begin at either Phase, but the sequence remains the same, and continues as long as
the system is activated.
(b) Twin Engine Aircraft:
When the de-icing system is activated, power is cycled in this
sequence:
Phase 1: All de-icers on the first propeller assembly are heated for 90 seconds.
(Figure 3)
Phase 2: All de-icers on the second propeller assembly are heated for 90 seconds. (Figure 3)
This cycle may begin at either Phase, but the sequence remains the same, and continues as long as the
system is activated.
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Figure 3 • Single Element Twin Engine De-Icing Cycle
I
~TI"E'
I)
j--,
'T-.J
BUS BAR (AC)
L. __ " , - - -
BUS BAR (DC)
~CIRCUIT BREAKERS
Phase 1
BRUSH ASSY'S
I
I
I
J
~TI"E'
r- --- -,
SWITCH~
:
L _____
~
BUS BAR (AC)
---11e__!.rL-,{,-,,'..;.._....J
L..:_~
__-=--.- ""....--BUS BAR (DC)
y_J
~RCUIT BREAKERS
tJ
Phase 2
Page 8
30-60-02 Nov
15/92
t)
,/
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Section 3.0 - Installation
II NOTE:
It is recommended that the installation instructions be read entirely before proceeding, and/
that the instructions be followed in the order provided.
/
3.1
Introduction
The installation information provided in this section is for an initial de-icing system installation. When
used as a guide to install replacement components or a conversion kit, note that some procedures
may not be applicable.
3.1.1
Electrical Capacity
A de-icing system can only be installed on an aircraft with sufficient electrical capacity for continuous
propeller de-icing system operation. Check the Aircraft Manual for the required amperage, and perform
an electrical load analysis of the aircraft in accordance with FAA Advisory Circular 43.13-1, Chapter 11,·
Section 2 and superseding FAA releases, to determine if sufficient power is available.
3.1.2
Weight and Balance
De-icing system installation affects the weight and balance of the propeller(s). Consult the Aircraft Manual
for specific weight and balance information or calculate the information before proceeding with
installation.
3.1.3
Aircraft Component Removal/Modification
General information about component modification/removal necessary to install de-icing system components is provided in this manual. Check the Aircraft Manual for more specific detail.
CAUTION: Disconnect the aircraft battery before proceeding.
3.1.3.1 Removal
1.
Remove the propeller(s), and feather, if applicable, per the propeller manufacturer's instructions.
2.
Remove the starter ring gear on aircraft so equipped; it will be replaced with a slip ring/
starter ring gear.
3.
Remove engine cowlings, nacelle covers, shrouds, fairings, fuselage/interior panels as required.
3.1.3.2 Modification
The spinner bulkhead must be modified on aircraft so equipped. Using the dimensions provided in the
Aircraft Manual, layout and drill the required holes in the spinner bulkhead. Layout the holes on a plane
parallel to the plane of rotation ofthe spinner bulkhead, and drill wire feed through the holes perpendicular
to that plane. Drill all other holes perpendicular to the bulkhead surface, unless otherwise specified in the
Aircraft Manual. Maintain tolerances of +/- 1/64 on fractions, +/- .005 on decimals and +/- 1/2° on radial
locations when laying out and drilling holes on the spinner bulkhead. In systems using a slip ring/starter
ring gear, the spinner adapter ring sometimes requires modification. Instructions are provided in
Paragraph 3.9.3.
.
Modification of the spinner dome by removal of material for clearance purposes, and the addition of rubber
restrainer straps to protect the de-icer leads, is sometimes required. Check the Aircraft Manual for
applicability and instructions. Instructions for rubber restrainer strap installation are provided in
BFGoodrich Report 59-728. The engine cowling, shroud and baffle sometimes require cut-outs for brush
assembly installation. Check the Aircraft Manual to see if modification is required for other areas or
components.
3.2
De-Icer Installation
Follow the installation instructions in BFGoodrich Report 59-728 to bond de-icers to the propeller blades.
See the Aircraft or Propeller Manufacturer's Manual or the drawing for de-icer location dimensions.
30-60-02 ~~~~~92
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
3.2.1
Hartzell Compact Propeller Modification and De-leer Installation
Drill a 9/32" diameter hole in the counterweight and chamfer it per Figure 4. File any sharp corners as
required, and cover the modified area with zinc chromate paint.
Install the de-icers per BFG Report 59-728. Slide 5/8" transflex tubing over the de-icer leads. Insert the
de-icer wire harness through the counterweight. Connect the de-icer and wire harness leads, using
window splice terminals (AMP 320559 or equivalent). Connect matching leads - GND to GND, etc.
Form wires as shown in Figure 5, and install MS3367 -1-9 tie straps in a figure eight configuration. Tighten
the tie strap and slide the tubing over the coiled wires as shown. Install MS3367 -1-9 tie straps loosely
around the counterweight and wire harness 1/4" in from the ends of the tubing. Note the position of the
tie strap buckles (Figure 6 & 7).
Install .263 transflex tubing over the de-icer wire harness up to the counterweight then route it under the
first tie strap. Tighten both tie straps. Install terminals (AMP 32442 or equivalent) on the wire harness
per standard aircraft practice.
,.-H-a-r-tz-e-II-C-o-m-pa-c-t-p-r-o-p-e-lIe-r-',
NOTE,
FILE SHARP CORNERS
AS REQUIRED. COVER
MODIFIED AREAS WITH
ZINC CHROMATE PAINT
3 ± 1/32
91J2 1.281 DIA.J THRU
CHAMFER 1/16 X 45·
BOTH SIDES
' " " ' - - - - DE·ICER LEADS
1/2 ± 1/32
MS
TIE STRAP
DE-ICER WIRE HARNESS
LEADS
Figure 4 - Counterweight Modification
Figure 5 - Lead Configuration
PROP DE·leER
z)f-- .
DE-leER WIRE HARNESS_
NOTE: WHEN ATTACHING HARNESS TO TERMINAL
SCREWS CONNECT "OUT8D TO OUTSO",
'INBD TO INBD" AND "OND TO GNO",
'METHOD OF ATTACHING DE·ICERWIRE HARNESS MAY VARY
DEPENDING ON AIRCRAFT APPLICATION.
Figure 6 - Assembly and Wiring Details - Spinner Bulkhead
10
30-60-02 Page
Nov 15/92
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
I Hartzell Compact Propeller (continued) I
MS3367-2-9 TIE STRAP
BUCKLE LOCATIONS
DE-ICER
,
~~~~~~-TERMINAL AMP 32442 OR EQUIV,
MS3367-1-9 TIE STRAP
BUCKLE LOCATION
~
,
SLIP RING/STARTER RING
GEAR ASSEMBLY
-fa -§-~-a
CUSHION MATERIAL
~- -~ 6'i jlltl+Mlffllltlll ~
1
TERMINAL STUD
DE-ICER WIRE
HARNESS
SLIP RING
WIRE HARNESS
SPINNER
ADAPTER
RING
DE-ICER
WIRE
HARNESS
Figure 7 - Assembly and Wiring Details - Slip Ring/Starter Ring Gear Assembly
11
30-60-02 Page
Nov 15/92
'
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
3.3
Balance Weights
Record the number, type and location of the balance weights installed onthe hub. Remove the weights
and attaching parts, and set them aside for later reassembly. If balance weights are required over or under
the lead strap clamp, use AN960 washers for shims, trimmed to fit.
In some installations, modification of the balance weights or replacement with new balance weights is
required to avoid interference with the de-icer leads. Follow the propeller manufacturer's recommendations for the maximum number of balance weights, and check the Aircraft Manual for modification
instructions.
When the mounting positions of a balance weight and lead strap clamp coincide (Figure 8 & 12), use longer
screws to accommodate the extra thickness. Make sure there is sufficient thread engagement (2-3
threads beyond nut), that the screws do not bottom out in the hole, or contact the spinner dome in any pitch
position.
",--.--;-- MODIFIED BALANCE WEIGHT
CLAMP--~..TA
Figure 8 - Modified Balance Weight/Lead Strap Clamp (P/N 4E1725) Installation
3.4
Lead Strap Clamps or Restrainers
A clamp or restrainer is required at the inboard end of the de-icer to prevent loosening of the de-icer bond
when centrifugal force acts on the lead strap. Typical clamp and restrainer arrangements are shown in
Figures 8-18. Use the hardware provided in the installation kit to attach the clamp or restrainer through
existing holes in the hub. Secure the de-icer or wire harness leads to the clamp as shown in the Aircraft
Manual or drawing.
Caution: When a lead strap clamp is used, it must not squeeze the leads tightly
enough to cause damage, or cause enough tension to pull the de-icer bond
loose. Excessive twisting of the leads can result in broken wires.
3.5
Rubber Restrainer Straps
Rubber restrainer straps on a single propeller must be located the same distance from the hub to maintain
propeller balance (Figures 13 & 18). Check the Aircraft or Propeller Manufacturer's Manual for the correct
dimension.
Page 12
30-60-02 Nov
15/92
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
LEAD STRAP CLAMP
~----i-SCREW
2 PER
CLAMP
TAPPED HOLES FOR
Figure 9 - lead Strap Clamp (PIN 2E1063-4) Installation
Figure 10 - lead Strap Clamp (PIN 2E1200-4) Installation
NORMAL ROTATING
PROPELLER SHOWN;
COUNTER ROTATING
PROPELLER OPPOSITE
NOTE:
DE-leER STRAP SHOULD BE
PULLED TAUT AS SHOWN
WHEN APPLYING FILLER
AND SEALER.
NOTE
DO NOT ALLOW
STRAP TO HANG
DRAW UP STRAP
--\-4I---d-;Z:~~~
AND CUT OFF EXCESS
~~~~~~~~- HUB
UPON EDGE OF
:I;
(-~'---
,
3/16±1/32
BUCKLE LOCATION
PROPELLER IN LOW PITCH
POSITION
BUCKLE LOCATION
PROPELLER IN FEATHERED POSITION
Figure 11 - Nylon Tie Strap Installation
13
30-60-02 Page
Nov 15/92
,
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
IEI291 SLEEVE STANDOFF
.150
-,;::-.=__---r-- AN960 WASH ERS
SCREW
LEAD STRAP CLAMP 3EI375
--------,
McCAULEY PROPELLER
SHOWN
USE APPROPRIATE LENGTH
SCREW AS REQUIRED
NOTE: IF TWO MOUNTING HOLES OF BALANCE WEIGHT COINCIDE WITH THOSE OF LEAD STRAP CLAMP, MODIFY
BALANCE WEIGHTTO CLAMP CONFIGURATION TO AVOID INTERFERENCE WITH DE-ICER LEAD STRAP. ADD
MODIFIED BALANCE WEIGHTS TO REPLACE WEIGHT REMOVED IN MODIFICATION. ON BEECH MODEL 58.
WHEN BALANCE WEIGHTS COINCIDE WITH BOTH LEAD STRAP CLAMP MOUNTING HOLES. MOUNT WEIGHTS
UNDER CLAMP. WHEN WEIGHTS COINCIDE WITH ONE CLAMP MOUNTING HOLE. INSTALL UP TO 4 WEIGHTS
UNDER CLAMP AND SHIM TO .150" HEIGHT. WHERE MORE THAN 4 WEIGHTS ARE USED, INSTALL THEM
OVER THE CLAMP.
Figure 12 - Lead Strap Clamp (PIN 3E1375) Installation
3/8" + 0
-1/16
RESTRAINER STRAP 2E1290--_
RESTRAINER STRAP 2El291 ---';'""'---i~1
BOND TO BLADE RETENTION
",+_+~~_-.;J~_ _ _ _ _ _';"'~_ _ _:¥
FERRULEBETWEENEDGESO~F~_~~==~~~==========~~========~~~~t===~~
3/4 COUNTER WEIGHT GROOVE
AND BUTT AGAINST OUTER EDGE)
Figure 13 - Restrainer Strap (PIN 2E1290/2E1291) Installation
Page 14
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
OUTBOARD END OF DE-ICER TO BE CENTERED
ON
OF LEADING EDGE OF BLADE.
ct
LOCATION OF TRAILING
EDGE OF DE-ICER
EDGE OF STRAP CLAMP----f--.l
SCREW, NUT & WASHER
THIS EDGE OF STRAP CLAMP TO BE PARALLEL TO
<t OF BLADE
Figure 14 - Lead Strap Clamp (PIN 2E1285-1 ,-2) Installation
Figure 15 - Lead Strap (PIN 2E1087-3) Installation
15
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
STRAP
RESTRAINER
WASHER
NOTE: PROPELLER BLADE IS SHOWN
IN FEATHERED POSITION. WHEN
PROPELLER IS IN LOW PITCH
POSITION, STRAP RESTRAINER
SHOULD HAVE A MINIMUM OF
5/8-INCH CLEARANCE TO
BLADE AT ~ OF STRAP
RESTRAINER.
SPINNER BULKHEAD
(WHEN USED) - - - - ,
o
a::
~ ..
<t
~
a::
o
PROP.
DE-ICER
u..
GRAY PLASTIC BONDED
TO SHINY SIDE OF
DE-ICER STRAP IN
THIS AREA.
WASHER (IF REQUIRED)
BOL T ----II~L-.,},.)
R. H. INSTALLATION SHOWN; L. H. OPPOSITE
INSTALL ATION
1. INSERT SPACER AS SHOWN AGAINST PROPELLER HUB.
2, POSITION STRAP RESTRAINER LEG AGAINST SPACER.
3. CHECK FOR CLEARANCE BETWEEN OTHER LEG OF STRAP RESTRAINER AND
PROPELLER HUB. IF ANY, INSTALL WASHERS FOR SNUG FIT.
4. INSTALL BOLT. DO NOT USE WASHER UNDER BOL T HEAD.
5. IF NO SPINNER BULKHEAD IS USED, INSTALL WASHERS AS REQUIRED
(MINIMUM ONE) TO PREVENT NUT FROM BOTTOMING OUT ON BOLT.
6. POSITION STRAP RESTRAINER TO MAINTAIN CLEARANCE AS SHOWN.
NOTE:
STRAP RESTRAINERS SHOULD BE
INSTALLED AS SHIPPED -IN
MATCHED SETS BY COLOR.
YELLOW PARTS ARE INSTALLED ON
NORMALLY ROTATING (R.H.)
PROPELLERS.
BLUE PARTS ARE INSTALLED ON
COUNTERROTATING (L.H.)
PROPELLERS.
Figure 16 - Restrainer Strap Installation
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
NOTE: TAPPED HOLES ON TOP OF CLAMP
ARE FOR BALANCE WEIGHT INSTALLATION.
FOR CLAMPS WITH "THROUGH" HOLES, DO
NOT ALLOW BALANCE WEIGHT MOUNTING
SCREWS TO CONTACT WIRES UNDER CLAMP.
SCREW,WASHER
(TYP. 2 PLACES)
,,___--1/
SCREW. WASHER
SAFETY
WIRE
SAFETY
WIRE
,
UNDERSIDE OF CLAMP
HOOK-UP PROCEDURE
. DE-ICER
TERMINAL
DE-ICER WIRE
HARNESS
TERMINAL
WASHER
DE-ICER WIRE HARNESS
NUT-TORQUE
TO 8INCH-LBS" MAX.
TERMINAL CLAMP 3E1883-2
BULGE OR FLAT AREA ON HARNESS
BETWEEN TERMINAL SCREWS AND
CLAMP. TYP_ BOTH ENDS OF WIRE
HARNESS
SCREW, WASHER
(TYP.2 PLACES)
DE-ICER
~.",,'.
CLAMP
DE-ICER WIRE HARNESS
SCREW
TERMINAL
CLAMP
NOTE: HARNESS SHOULD BE
PULLED DOWN AND
AWAY FROM BLADE BY
TIE STRAP
UNDERSIDE OF CLAMP
SHOWING HOOK-UP PROCEDURE
BUCKLE
NOTE: TERMINAL CLAMP 3E1848-1 SHOWN;
TERMINAL CLAMP 3E1848-1
INSTALL TIE STRAP AS SHOWN HERE.
Figure 17 -Terminal Clamp (PIN 3E1883-2/3E1848-1) Installation
17
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
I
I~
rt
RESTRAINER
STRAP"
_ _ _ _ _ _ _ _ _ _ .JI
I,
"CENTERLINE OF RESTRAINER
STRAP SHOULD LIE AS CLOSE
AS POSSIBLE TO THE INBOARD
EDGE OF THE DE·ICER.
PROP DE-ICER
START IN THIS AREA (APPROX.
90° FROM DE-ICER LEAD
STRAP) AND WRAP AROUND PROP
BLADE SO A DOUBLE THICKNESS
WILL COVER THE DE-ICER
,.
,.
LEAD STRAP. TRIM RESTRAINER /
STRAP SO IT WILL END
APPROXIMATELY AS SHOWN
Hi------+-RESTRAINER
STRAP
I
I
\
~
... ...
Figure 18 - Rubber Restrainer Strap (2E1291/3E1470) Installation
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30-60-02 Nov
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..
-~-----.---~.....,....---.-
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
3.6
Timer Installation
Locate the timer as specified in the Aircraft Manual or if not specified, locate it in an appropriate available
space, where there is no interference with existing equipment. Timer leads must be at least 8" away from
radio input leads. Check the Aircraft Manual or drawing for timer installation dimensions.
Install the timer per one of the following methods (Figure 19).
Bulkhead:
Use the timer as a template to locate holes for the attachment hardware
and attach the timer directly to the bulkhead.
Adjustable mounting plate: Use the mounting plate over the stringers or ribs as a template for
locating the attachment hardware. Attach the mounting plate, then use
the timer as a template for locating the attachment hardware on the
mounting plate. Attach the timer to the mounting plate. If the mounting
plate does not overlap the timer case completely, use spacer washers
between the timer and the plate.
One piece mounting plate:
Use the mounting plate over the stringers or ribs as a template for
locating the attachment hardware. Attach the timer to the mounting
plate.
SCREW, WASHERS AND LOCKNUT
TIMER
SCREW, LOCKWASHER AND RIVNUT
BULKHEAD
BULKHEAD TYPE
SCREW, WASHERS AND LOCKNUT
r---,--....
t - - - - TIMER
SCREW, LOCKWASHER AND RIVNUT
MOUNTING PLATE
SCREW, WASHERS AND LOCKNUT
SCREW, WASHERS AND LOCKNUT
ADJUSTABLE MOUNTING PLATE TYPE
r--'--,...f-----TIMER
SCREW, WASHERS AND LOCKNUT
SCREW, LOCKWASHER AND RIVNUT
~=;~;;;====i=~~~~~- SCREW, WASHERS AND LOCKNUT
ONE-PIECE MOUNTING PLATE TYPE
NOTE:
FOR RIVNUT INSTALLATION, USE BFG RIVNUT
"SPEED HEADER" PIN C·6000, OR
EQUIVALENT.
Figure 19 - Timer Mounting Methods
19
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
3.7
Ammeter, SWitch, Circuit Breaker (Optional) Installation
When optional components are specified, locate them consistent with FAA Part 23, Section 23.1321, anI
per the following general guidelines. Check the Aircraft Manual or drawing for installation dimensions anI
terminal size for optional components.
Install the ammeter in the instrument panel. When an external shunt is used, install it so that
the wire length between the ammeter and external shunt does not exceed 6'. Install the switch
and ammeter near each other. When a warning placard is applicable, install it adjacent to the
switch, in full view of the pilot, or as specified in the Aircraft Manual.
Check the Aircraft Manual for circuit breaker mounting location.
3.8
Brush Assembly Mounting Bracket Installation
Remove the engine hardware and attach the brush assembly mounting bracket, using the hardware
provided. (Figures 20-24) The remainder of the brush assembly is installed after slip ring installation
(Paragraph 3.11).
BRUSH & BRACKET ASSEMBL Y
Figure 20 -Typical Brush Assembly Mounting Bracket Installation
GROMMET (WHEN USED) - LOOP
WIRE HARNESS THRU CLAMP AS
SHOWN OR TRIM TO FIT.
ClAMP
BOLT
SUPPORT ROD
GROMMET
(WHEN USED)
BOLT
Figure 21 - Typical Brush Assembly Mounting Bracket Installations
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
MOUNTING
BRACKET
USE ADDITIONAL WASHERS
""--___--:~-AS SHOWN FOR AL TERNATE
SCREW INSTALLATION
Figure 22 - Typical Brush Assembly Mounting Bracket Installation
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
MOUNTING BRACKET
BRUSH ASSY.
~"",,"- SPACER-WASHER
SPACER
ENGINE THRUST
BEARING COVER PLA TE
Figure 23 - Typical Brush Assembly Mounting Bracket Installation
WASHER
--"==',-
SCR EW---;El::::::i._ _
I-_====--f.......
--BRUSH ASSEMBLY
Figure 24 - Typical Brush Assembly Mounting Bracket Installation
22
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
3.9
Slip Ring and Slip Ring/Starter Ring Gear Assembly Installation
3.9.1
Installation of Hardware on Modified Spinner Bulkhead
Install the connecting hardware provided, usually a terminal strip or block, on the modified spinner
bulkhead. Figures 25 - 28 show typical connections. Note that in each case the de-icer or wire harness
leads are securely clamped. When called for in the Aircraft Manual, install rivnuts or grommets as
specified before installing the terminal strip or block with the hardware specified.
ITypical Spinner Bulkhead Connecting Hardware I
1 4 - - - - DE-ICER LEAD
~~~~r;;,....II:"" "'""'=="'_-GROMMET
LEAD CLIP
ASSEMBLY
SCREWS & WASHERS
TERMINAL STRIP
SLIP RING
LEAD WIRES
Figure 25 - Terminal Strip
Figure 26 - Terminal Block
)
NOTE: BULGE
DE-ICER WIRE
HARNESS
E-ICER LEAD STRAP
~;~-C:::JiI"'.c:
LOCK WASH ER
BRASS NUT -;
, WASHER
LOCK WASHER ~I'l=~
WIRE HARNESS
WASHER
LOCKNU,
SPINNER BULKHEAD
TERMINAL STRIP
l
SLIP RING LEADS
SCREW. WASHER (RIVNUT ON BACK OF
BULKHEAD)
)
o
Figure 27 - Lead Clip and Cable Clamp Installations
23
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
TO SLIP RING
RIVNUT
DE-leER
LEAD
RIVNUT
DE-ICER
LEAD
LEAD CLIP
ASSEMBLY
3.9.2
Figure 28 - Terminal Strip Variations
Slip Ring Assembly Installation
Install the slip ring assembly as specified in the Aircraft Manual per one of the two installation methods
described in this paragraph.
Installation on the spinner bulkhead (Figures 29): Feed the slip ring leads through the holes drilled
in the spinner bulkhead during the modification procedure (Paragraph 3.1.3.2). If specified in
the Aircraft Manual, install rubber grommets. Secure the slip ring assembly to the bulkhead with
appropriate hardware. Hand ream the mounting holes for satisfactory alignment. Torque the bolts for
a snug fit.
Installation on the crankshaft or propeller hub flange: Position the slip ring assembly on the
crankshaft or propeller hub flange as specified in the Aircraft Manual (Figure 30 & 31).
3.9.2.1 Slip Ring Assembly Wiring
Connect the slip ring leads as specified in the Aircraft Manual, either directly to the terminal strips, blocks
or studs, or using a slip ring wire harness.
Connect the de-icer or wire harness leads to the terminal strips, blocks or studs, and hold them in place
with lead clips, as specified in the Aircraft Manual. Leave no slack in the de-icer or wire harness leads
between the terminals and the clips, and securely retain the leads as specified in the Aircraft Manual. Do
not twist the leads more than 1800 when aligning them.
30-60-02 Page 24
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
'i ."
" "Cl;., ,
"
V
"
SCREW
SLIP RING ASSEMBLY
.0.'.
.-~
•.• """~
•
FEED THRU LEADS
•
. ,
~.:'
/WASHERS (SEE DETAIL)
/
SPINNER BULKHEAD
0 @)
~
i>
I1J
,.~ .. ~
0
~ //," ~
e e. • I/,//,<P~' \
)
I
e
(/( ~U~ /;r~~~ERMTG
\ ~;G:f'~/ /
'"
,,'
12.'.'
~ ___ "
_--1..----------_
FLAT WASHERS
,~
. ~./.. '()r'~
BELLEVILLE WASHER
~ .. ~ ®
@
SLIP RING ASSEMBly
J
SLIP RING ASS'Y INSTALLATION USING FLAT & STAR
WASHERS OR BELLEVILLE WASHERS.
~
@ ~
@
~
@~@
~
I SPI,"'",ULK""'L]I
Ii)
@
@
®
$
{
WASHER
~~.-( . ~..'l ® ~,/
EXTERNAL TOOTH
STARWAS""
/
LEAD STRAP
CLAMP
DE-ICER
~
NUT
."j
~., (
~
i '..... ~'--'-../
G&
' ___~"""'«IIJ/
..'I
.. .-l:::>..
./~::~..
/..
=:;~
'''-
:/
..,!!)/A··::.......·l
.
.!;f;j
~ "/
>y;}'" ''<.~~( ~
.
.'~'
//
~
\
.--.......
Figure 29 - Slip Ring Assembly Mounted on Spinner Bulkhead
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
SLIP RING ASSEMBL Y
WASHER
WASHER
BOL T
Figure 30 - Slip Ring Assembly
Installation Method on
Crankshaft or Propeller Hub Flange
MOUNTING PLATE
NUT
CRANKSHAfT FLANGE
SliP RING ASSEMBLY
FLAT WASHER/STAR
WASHER/FLAT WASHER
Figure 31 - Slip Ring Assembly
Installation Method on
Crankshaft or Propeller Hub Flange
BOLT
• MOUNTING LUG OR
SPLIT MOUNTING
PLATE
LOCATION OF
COUNTERBORE,
AS APPLICABLE
Page 26
30-60-02 Nov 15/92
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
3.9.3
Slip Ring/Starter Ring Gear Assembly Installation (Figure 32)
When there is a.spinner adapter ring, remove it from the original starter ring gear and position it over the
slip ring/starter ring gear assembly as it will be mounted. When the slip ring is installed outside the pulley
on the starter ring gear, file* the spinner adapter ring as required to provide at least 1/16" clearance
between the spinner adapter ring and the slip ring terminals, making sure all filed clearance areas have
smooth and flowing radii. (Figure 33)
*CAUTION:
Before filing make sure the spinner adapter ring is properly aligned on
the slip ring/starter ring gear assembly, by matching the location of the
spinner attaching nuts on the adapter ring flange.
When the slip ring is installed inside the pulley on the starter ring gear, there should be no interference
between the adapter ring and the starter ring gear. Attach the adapter ring to the slip ring/starter ring gear
assembly with the original bolts and finger tighten. (The bolts will be torqued later.) Install the slip ring/
starter ring gear assembly on the crankshaft.
When there is no adapter ring, there is a hub extension and the slip ring/starter ring gear assembly is
installed between the crankshaft flange and the hub extension (Figure 34). Secure the hub extension
and install the propeller assembly in accordance with Propeller Manufacturer's or Aircraft Manual.
DE-ICER LEAD
GND.
)
VIEW B-B
INBD.
"\fooI1----CUSHION MAT'l TO EXTEND
BEYOND lEAD CLIP 1/8" MIN.
lEAD CLIP
OUTBD.--~
\
---
o
BRASS NUT
lOCKWASHER
DE-ICER LEAD WIRE
SLIP RING-STARTER
RING GEAR
SECT. SHOWING DE-ICER LEAD HOOK-UP
TYP.9 PLACES
)
o
Figure 32 - Typical Slip Ring/Starter Ring Gear Assembly Installation
27
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
1/16" TERMINAL CLEARANCE REQ'D
SLIP RING TERMINAL
SLIP RING TERMINAL
SPINNER ADAPTER RING
Figure 33 - Positioning Spinner Adapter Ring
PROP. DE-I
SLIP RING - STARTER
RING GEAR ASSEMBLY
-:~
LEADSTRAP
RESTRAINER
WASHER
Figure 34 - Slip Ring/Starter Ring Gear Assembly Installation
28
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
3.9.3.1 Slip Ring/Starter Ring Gear Assembly Wiring
A. With a spinner adapter ring, the de-icer or wire harness leads connect to integral terminal studs (Figures
32 & 33) or attached terminal strips or blocks on the slip ring/starter ring gear assembly, using the adapter
ring attachment bolts (Figure 26).
B. With terminal strips or blocks, the slip ring/starter ring gear assembly leads and the de-icer or wire harness leads both connect to the strips or blocks. When the slip ring/starter ring gear assembly has integral
terminal studs, only the de-icer or wire harness leads connect to the studs, using 10-12 inch-Ibs. torque
to tighten the nuts. Be sure to connect matching leads or matching studs and leads: GND to GND, etc.
Do not twist the de-icer or wire harness leads more than 180 0 when aligning them to the terminals.
Secure the de-icer or wire harness leads with lead clips, and install cushions (Figures 7 & 32), when
specified in the Aircraft Manual. Leave no slack in the leads between the terminals and clips.
When terminal strips, clips or other hardware are installed using the same bolts which attach the adapter
ring to the slip ring/starter ring gear assembly, make sure there is sufficient thread engagement (2-3
threads minimum beyond nut). On aircraft with spinner bulkheads, a slip ring wire harness is installed on
the slip ring/starter ring gear assembly terminal studs, connects to the de-icer or wire harness leads, is
routed across the hub extension, and connects to terminal strips or studs on the modified spinner bulkhead (Figure 34). Secure the de-icer or wire harness leads with lead clips. Leave no slack in the leads
between the terminals and clips.
3.9.4 Hose Clamps
When an aircraft has hub extensions with slip
ring leads or a wire harness routed along the
hub, hose clamps are sometimes used to hold
the wiring against the hub (Figure 34). If so,
drill the cap guards on the hose clamps with a
No. 56 drill as shown in Figure 35. Drill both
sides
ofthe cap guards in line with and near the
DRfU. CAP GUARD
AND SAFETY WIRE
screw slot base. Position clamps, spacers and
AT INSTALLATION
cushions as applicable per the Aircraft Manual. Position the worm screw housings 180 0
opposite each other on the hub extension. Do
not place the wire harness in tension when
HOSE CLA,I,-IP CUSHION
tightening the clamps. Torque the worm screws
(WHEN USED)
to 35-55 inch-Ibs. and safety wire them.
Figure 35 - Hose Clamps
)
3.9.5
Alignment
After installation, check slip ring alignment by attaching
a dial indicator gauge to the engine and placing the
pointer on the copper slip ring (Figure 36). Grasp the
propeller blade and rotate it slowly, noting any deviations of the rings from a true plane. Exert uniform push
or pull on the propeller assembly to make sure that runout readings are accurate. The total run-out reading
must not exceed .0050" (+/-.0025") for piston engines,
or .0080" (+/-0040") for turbine engines. Additionally,
run-out readings must not exceed .0020" within any 4"
arc of slip ring travel for either type of engine.
Figure 36 - Checking Slip Ring Run-Out
~----------------------------~
Page 29
30-60-02 Nov
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)
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
When a slip ring/starter ring gear assembly is used, or when the slip ring assembly used is mounted
between the crankshaft flange and propeller hub, and the run-out reading is unacceptable, check for
dirt on the ring gear mounting surfaces or slip ring holder and clean as required. If the run-out reading
is still unacceptable, return the slip ring to BFGoodrich (through point of purchase) for evaluation.
When the slip ring is mounted on the spinner bulkhead*, and the run-out reading is unacceptable, vary
torque on the attachment bolts within the limits specified by the propeller or aircraft manufacturer, or
within the standard limits for the bolts used. Most slip ring installations include a compression washer
arrangement, which allows proper ring adjustment by varying the torque applied to the attaching
hardware (Figure 29).
*CAUTION: The torque adjustment/shim procedures cannot be used for slip rings
mounted between the crankshaft flange and propeller hub.
I,
3.10
Propeller Assembly Installation
Install the spinner bulkhead and propeller assembly per the Propeller Manufacturer's or Aircraft
Manual.
3.11
Brush Assembly Installation
Position the brush assembly on the mounting bracket which was installed per Paragraph 3.8,
careful not to exert any side load on the brushes which can cause damage. Install the attachment
hardware but do not torque at this time.
3.11.1
Brush Assembly Alignment
Brush assembly alignment is critical to smooth, efficient and quiet electric power transfer from the
brushes to the slip rings. There are three necessary alignments.
Projection
The distance between the brush assembly and the slip ring should be between 1/32"
and 3/32" (Figure 37). Adjust the distance as required by loosening the hardware
attaching the brush assembly, and holding the brushes in while retightening the
hardware. Slotted holes are usually provided for this purpose.
Face
The entire face of each brush must contact the copper ring throughout full 360 degree
slip ring rotation (Figure 38). Face alignment can be adjusted by the loosening and
retightening procedure described above. Another way to adjust face alignment isto
use shims between the brush assembly and the mounting bracket. Make the shims
of metal layers .003" thick, not to exceed a .020" thickness overall.
Angular
Cock brushes at a 2° angle from the perpendicular on the copper rings (Figure 37).
If desired, an alignment template (BFG PIN 3E2238) can be used as a guide for this
procedure. Adjust as required using the methods shown in Figures 39-41.
SLIP RING ASSY
,
f1l16.11/3 2 \
I PROP ROTATION>
\'°1'
,
i
4 ~
I
/~
'}'l
NOTE: AFTER 2-3 HOURS
THERE SHOULD BE AT LEAST
80% CONT ACT BETWEEN
NEW BRUSHES AND SLIP
RINGS; AFTER 5-6 HOURS
100% CONTACT.
BRUSH ASSY.
Figure 37 - Brush Alignment - Projection
Page 30
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
~?!SSSS~~
INCORRECT
Figure 38 - Brush Alignment - Face
)
~
__-BRUSH
ASSY.
MOUNTING
BRACKET
Figure 40 - Angular Brush Alignment
Adjustment Method
THRUST
BEARING
PLATE
Figure 39 - Angular Brush Alignment
Adjustment Method
)
Figure 41 - Angular Brush Alignment
Adjustment Method
31
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
3.12
System Wiring
Consult the Aircraft Manual for specific wiring instructions and schematic. The following general
guidelines apply to all applications:
1.
Secure or trim all excess wire.
2.
When wire harnesses are not provided, follow color coding and minimum wire sizes as
specified in the Aircraft Manual to fabricate them.
3.
Make sure there is no interference with existing controls or equipment. Keep wires
at least 8" away from radio input leads and/or moving cables.
4.
When soldering, solder flow (wicking) must not extend onto any portion of the lead which
is flexed.Use non-corrosive flux. Wipe or flush flux from the leads and connector pins
after soldering.
5.
Route wiring to avoid contact with hot components or areas.
6.
Firmly support and/or retain all wiring.
CAUTION:
Follow Aircraft Manual procedures and FAA Advisory Circular 43.132
when cutting holes into pressurized compartments to install wiring.
Holes must be air tight to the pressure specified by the manufacturer.
3.12.1 Timer Wiring
The timer has a box mounted receptacle or terminal strip. The timer wire harness connector plug or
terminals connect the timer to the de-icing system. If the timer wire harness is not provided, consult the
Aircraft Manual for appropriate connector plugs or terminals, proper wire size and color coding for
fabrication. Attach the timer ground wire to the timer mounting screw or adjacent ground point.
CAUTION:
When the timer is not properly grounded, the de-icing
system will not function correctly.
3.12.2 Ammeter (Optional) Wiring
Attach the timer wire harness to the negative ammeter terminal with solder or with a crimp-on terminal.
If there is an external shunt, connect the shunt terminals to the ammeter and timer per the Aircraft Manual.
3.12.3 Switch or Circuit Breaker/Switch (Optional) Wiring
Connect the positive side of the ammeter or shunt to the bottom terminal of the switch or circuit breaker/
switch with the wire harness provided or with the correct size and color wire. Connect the wire from the
top terminal of the ammeter or shunt to the bus bar if no other components are used. Use crimp-on
terminals or solder.
3.12.4 Circuit Breaker (Optional) Wiring
Connect the switch or circuit breaker/switch to the circuit breaker with a wire harness or the correct size
and color wire per the Aircraft Manual. Connect the circuit breaker to the bus bar. Attach the wires with
crimp-on terminals or solder them.
3.12.5 Engine Firewall Connector (Optional) Wiring
When an electrical connector through the engine firewall is required, use an MS3100 plus MS31 06 or
MS31 08 style connector (Figure 42). When connectors through other panels or bulkheads are specified,
use a doubler when the panel is not rigid enough to support the connector. Use the receptacle as a
template to locate the attachment hardware.
I
II
I!
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
DOUBLER (AS REQUIRED)
PLUG
ATTACHED WITH 4 RIVETS
OR SCREWS, NUTS AND WASHERS
------e-r
SOLDER CONNECTION
REQUIRED (INTERNAL)
CLAMP -""'~SI
~T"~,;/O'----GROUND (WHEN SPECIFIED)
1 4 - - - - ENGINE WIRE HARNESS
Figure 42 - Engine Firewall Connector
3.12.6 Brush Assembly Wiring
)
I~
'0·
Use a wire harness, if provided, or solder a connector plug MS31 OBA 1OSL:3S or MS31 06A 1OSL-3S (or
crimp-on terminal lugs) to connect the brush assembly to the engine wire harness. Assemble a connector
plug (or terminal lugs) to the brush assembly receptacle or terminal pins. Make sure the ground wire from
the brush assembly is attached to ground.
3.13
Post-Installation Inspection
1. Visually check the completed installation. Check the de-icers for wrinkling or loose spots. Check
all connections for integrity and snugness. Move the propeller assembly from full low pitch through
feathering position (and reverse pitch where applicable). The de-icer or wire harness leads should
not be placed in tension when the propeller assembly is moved through the full pitch range.
2. Check for radio noise or radio compass interference by operating the engine at near take-off power
with the radio gear on, while turning the de-icing system on and off. When noise or interference
occurs with the system on, and does not occur with the system off, troubleshoot per Table 2.
3. Check brush alignment and adjust as required per Paragraph 3.11.1
4. Check de-icer resistance per BFGoodrich Report 59-72B.
5. Test the timer per Paragraph 4.2.2.4.
6. Perform the de-icer heat test per Paragraph 4.2.1.
)
33
30-60-02 Page
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~)
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
SECTION 4.0 - MAINTENANCE
4.1
Current Drain
The type and quantity of de-icers determine the system current drain. Optional components - ammeter,
switch and circuit breaker - are designed to operate at that current. Therefore only the components
specified for a particular aircraft can be used on that aircraft without affecting de-icing system operation.
Consult the BFGoodrich Replacement Parts List and the parts list in the Aircraft Manual before ordering
replacement components.
4.2
Required Inspections
When checking system operation, use an auxiliary power supply. When an auxiliary power unit (APU)
is not available, do a continuity check in place of the inspection points requiring power.
WARNING: Do not operate the de-icers continuously for more than 5 mintues above
100°F ambient temperature without allowing them to cool down completely.
4.2.1
50 Hour Inspection
On turbine engines, check for fuel and/or oil leakage onto the brushes and slip rings. Fuel and/or oil
contamination cause excessive brush wear and slip ring grooving. Stop all leaks and remove any buildup between the copper rings that can cause electrical shorting. Clean and refurbish or replace brushes
and/or slip rings, as required.
Remove the spinner dome and open access doors as required to facilitate wiring inspection.
A properly calibrated ammeter is required for the next procedure. When the system has no
ammeter, temporarily install a test ammeter in the timer power input line. Check the Aircraft Manual for
the operating range of the de-icing system. Have an assistant observe the ammeter with the de-icing
system activated, and flex the accessible wiring, especially the de-icer, wire harness and slip ring leads,
the firewall electrical connectors and associated wiring. Ammeter needle movement out of the shaded
range, (other than normal flicker from cycling of certain timers), indicates a short or open circuit. Pinpoint
the location of the problem by checking the continuity of the wiring while flexing and prodding the
suspected area. Correct as required.
Perform the de-icer heat test to confirm proper heating sequence (Paragraph 2.2.2). Have an assistant
activate the system. Feel the de-icer area which should be heated during each Phase of the cycle. Have
an assistant record the ammeter reading and call out each Phase to verify the sequence. (With certain
timers, the ammeter needle will flicker when the timer cycles to each Phase.) Temperature rise should
be noticeable to the touch when the de-icer heats. Hot spots indicate surface damage or loose bond which
require de-icer replacement or rebonding.
I
I
Reinstall the spinner dome if it was removed.
Lock the brakes and operate the engine at near take-off power. Activate the de-icing system and observe
the ammeter for 2 minutes 12 seconds. The needle should rest within the shaded area, throughout the
complete cycle. (With certain timers, the ammeter needle may flicker out of the shaded area as the timer
cycles to each Phase.)
4.2.2
100 Hour Inspection
If applicable, feather the propellers. Remove the spinner dome and open access doors as required.
CAUTION:
Do not run up the engine with the spinner dome removed.
De-icer or wire harness lead failure can occur.
Page 34
30-60-02 Nov
15/92
iii
(
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
4.2.2.1 De-Icer Inspection
Visually check the de-icers for wrinkled, loose or torn areas, particularly around the outboard end and
where the de-icer or wire harness leads pass under a lead strap clamp or restrainer (if used). Look for
abrasion or cuts, especially along the leading edge and the flat or thrust face. Check that the lead strap
and terminal clamps, tie straps or restrainers are secure and properly installed. (Refer to Figures 8-18.)
Look for cracks or other damage. Check that screws are safety-wired.
Check that the de-icer or wire harness leads are not placed in tension. When tension exists, check for
slack between the lead clip and terminal studs, or between the lead strap clamp or restrainer and the deicer. If there is no slack, or when tension still exists after eliminating the slack, check the de-icer location
dimension in the Aircraft or Propeller Manufacturer's Manual or the drawing and the correct de-icer part
number per the Aircraft Manual and BFGoodrich Replacement Parts List. If the location dimension is
incorrect, remove the de-icer and rebond it at the correct dimension. (Remember: All de-icers on a
propeller assembly must be located the same distance from the hub for rotational balance.) If
the wrong de-icer part number is installed, replace it with the correct part number.
When de-icer wire harnesses are used, check that the terminals and terminal studs are not shorting out
to each other or the propeller hub. Inspect the wire harnesses for chafing or shorting. Remove the source
of chafing as required, and refurbish or replace the wire harnesses as required.
Check that the lead clips and terminal screw assemblies are in good repair.
Perform the de-icer heat test per Paragraph 4.2.1.
4.2.2.2 Slip Ring Inspection
)
Visually and by touch check the slip ring for excessive wear, roughened surface, cracks, burned or
discolored areas, and oil, grease and/or dirt deposits. Clean as required.
When slip ring wear is uneven or wobble is noticed, check slip ring run-out per Paragraph 3.9.5, and
adjust, reface or replace the slip ring (Figure 43) as required.
4.2.2.3 Brush Assembly Inspection
Check the mounting bracket, brush block or brush modules for cracks, deformation and other damage.
Replace as required. Check for grease, fuel and/or carbon deposits on the brush assembly and between
the brushes. Clean with methyl ethyl ketone (MEK) and refurbish as required. Repair the source of oil
or fuel leakage.
()
Measure brush wear per BFGoodrich Report 68-04-714, and replace brushes worn beyond the specified
limit. Check for uneven wear, chipping or breakage on brushes, and replace as required. Check brush
assembly alignment per Paragraph 3.11.1 and adjust as required per Figures 39-41.
)
Page 35
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.i{.·\
V
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
MACHINE LIP OF SLIP RING HOLDER TO SAME
HEIGHT AS EPOXY UNDERCUT
DO NOT MACHINE ANY PORTION
OF STARTER RING GEAR.
MOUNTING SURFACE.-..::;;.-----.
II
t
PROCEDURE:
1.
2
3.
4.
Thoroughly clean the slip ring or starter ring gear assembly with MEK before beginning resurfacing procedure.
Check the flatness of the slip ring or starter ring gear assembly mounting surface. The mounting surface must
be flat within .005" overall.
Locate the slip ring assembly concentrically in a lathe so that there is no more than :002" wobble or run-out over
360 0 rotation.
Take a light cut for a smooth finish (29-35 micro-inches). A tool with a 1/64" to 1/32" edge is recommended.
Cut no deeper than necessary to remove surface damage. Do not machine past the dimension given in the
Slip Ring Cross Reference Chart on the following page; this dimension is measured from the mounting surface.
CAUTION:
5.
6.
Insure that the contact surfaces of the slip rings are parallel within 0.005" and flat within 0.005" overall- deviation
not to exceed 0.002" over a 4" arc.
Undercut insulation between and around the slip rings .020 and .030", as necessary. The slip ring holder outer
edge must be undercut to the same dimension as the insulation. Do not machine the outer edge of a slip ring
holder which contains synchrophasing targets, and do not machine any portion of the starter ring gear.
CAUTION:
7.
8.
9.
IN MACHINING, DO NOT ALLOW THE TEMPERATURE OF THE SLIP RINGS TO EXCEED 20f1' F.
WHEN UNDERCUTTING THE INSULA TlON, THE WIDTH OF THE SLIP RINGS MUST NOT BE
REDUCED MORE THAN 0.005".
Deburr the slip ring edges.
To assure an accurate finish, use emery paper.
Check the insulation resistance between the slip rings and to the metal holder with a "megger". With 500 VDC
applied, the resistance must be at least 0.5 megohms after one minute.
Figure 43
Measuring Minimum Dimensions and Machining Instructions
Slip Ring Assembly and Slip Ring/Starter Ring Gear Assembly
I
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I
II:
1
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
SLIP RING REFERENCE CHART
SLIP RING MINIMUM MACHINING DIMENSIONS
CAUTION: INSURE THAT CORRECT PART NUMBER IS USED WHEN FINDING X, V OR Z DIMENSION.
)
)
Min. Dim.
X
Starter Ring Gear/
Slip Ring Assy. No.
Min. Dim.
4E1948-1
4E1964-1
4E1964-2,-3,-4
4E1974
4E1988-1
4E2087
4E2115-1,-2,-3
4E2155
4E2267
4E2276
.315
.480
.945
.410
.295
.650
.700
.650
.295
.285
4E1187
4E1212
4E1239
4E1365-1,-2,-3,-4,-6
4E1637-2
4E1673
4E1677
4E1686
4E1943-1
1.900
1.900
1.900
.515
.300
.328
.328
.475
.945
.187
.328
.421
.453
4E2324
4E2350-1
4E2362
4E2366
4E2371
4E2373
4E2375-1
4E2377-1
4E2406
4E2412
.295
.945
.285
.945
.235
.650
.235
.650
.285
.415
4E1598
4E1614,-2
4E1614-3
4E1621
4E1635
4E1650
4E1676-1,-2,-3,-4
4E1681
4E1706
4E1708
.328
.265
.945
.300
.300
.328
.187
.300
.300
.300
4E2416
4E2422
4E2438-1
4E2440
4E2442-1
4E2444-1
4E2446
4E2448-1
4E2459
4E2468
.945
.285
.380
.295
.187
.187
.295
.945
.285
.310
4E1731-1
4E1748-2
4E1803-1
4E1853-1
4E1865-1
4E1865-2,-3
4E1874-1
4E1880-1
4E1882-1
4E1918-1,
1.160
.475
1.160
.390
.475
.945
.265
.300
.265
.235
4E2501
4E2504
4E2511
4E2524
4E2551
4E2590
4E2624-1
4E2626
4E2661-1,-2,-3
4E2671-1,-2
.440
.285
.295
.425
.187
.425
.187
1.330
.275
.310
4E1923-1,-2,-3
4E1924-1,-2
4E1926-1
4E1933-1,-2,-3,-4,·5
4E1933-6,·7,-8
.295
.295
.235
.480
.945
4E2674-1,-2,-3
4E2714-1
4E2830-1
4E2863
.275
.328
.285
.714
Slip Ring
Assy. No.
Min. Dim.
X
4E1287-1,-2
4E1295-1
4E1295-2
4E1352
4E1353
4E1424
4E1448
4E1454
4E1474
4E1489
.453
.390
.453
.300
.300
.453
.328
.828
.453
.453
4E1494
4E1508
4E1518
4E1523
4E1526
4E1526-4
4E1555-1,-2,-3
4E1556
4E1575
4E1578
Slip Ring
Assy. No.
V
Z
2.875
1.920
2.960
2.875
2.960
2.825
2.960
2.875
3.015
2.875
5E1421
5E1450
5E1455-1
5E1482-1
5E1526-1
5E1541-1
5E1549-1
5E1551-1
5E1559-1
5E1561-1
5E1583-1
1.820
3.015
2.950
1.800
2.950
2.820
2.900
5E1593
5E1649
5E1819
5E1820
5E1834
5E1835
5E1837
5E1840
5E1851-1,-2
5E1857-1,-2,-3
5E1892-1
5E1895-1
5E1901-1
5E1919
5E1922
5E1925-1
5E1932-1
5E1934
5E2296
1.840
2.980
2.825
2.825
2.900
2.965
2.960
1.800
2.930
2.930
1.820
1.820
1.800
2.960
2.825
2.825
2.930
1.920
2.840
37
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
4.2.2.4 Timer Test
Testing the timer is required only when the de-icer heat test (Paragraph 4.2.1) or an abnormal current
reading indicates a system malfunction.
Check that the timer is cycling in the correct sequence by this procedure: Use an auxiliary power supply with 24 to 32 VDC output, 15-amp capacity. Use 5 amps minimum load
on each output.
1.
Remove the wire harness connector plug from the timer and jump the power input socket of the
wire harness to the timer input pin.
2.
Jump the timer ground pin to ground.
3.
Activate the de-icing system.
4.
Hold the voltmeter probe on an output pin until the voltage drops to O. Move the probe to the next
pin in the sequence shown in Table 1. Check the voltage at each pin in sequence. When
the correct sequence and internal time are verified, deactivate the system. (NOTE: Some timers
need a warm-up period, in which case the first complete cycle may be longer than specified).
5.
Check volts to ground per Table 1.
6.
If the timer operates correctly, remove the jumper wires and replace the connector plug. If the
timer operates incorrectly, return it to a BFGoodrich authorized repair facility for evaluation.
NOTE: The timer does not home when the de-icing system is deactivated. When the de-icing system
is activated, timers with manual step features cycle power to the next pin in the sequence. Timers without
manual step features require a full output sequence before cycling power to the next pin.
4.2.2.5 Ammeter (Optional) Test
When the de-icing system includes an ammeter, check it by connecting a properly calibrated test
ammeter, or volt-ohmmeter with an ammeter scale, into the de-icing system circuit between the bus bar
and the system ammeter. Activate the system and check the amperage reading on the test ammeter.
The reading should agree with the reading on the system ammeter. Deactivate the system and remove
the test ammeter or volt-ohmmeter. If the readings are different, and the de-icing system operates satisfactorily, replace the system ammeter.
4.2.2.6 Circuit Breaker and Switch (Optional) Test
When the testing in Paragraphs 4.2.2.4 & 4.2.2.5, is satisfactory, the circuit breaker and switch are
functioning correctly. When the testing is unsatisfactory, and the timer and ammeter check out
satisfactorily, repair or replace the circuit breaker and/or switch as required.
4.2.2.7 Wiring
Repeat the 50 hour inspection (Paragraph 4.2.1).
4.2.2.8 Other
Visually and by touch, check all clamps, clips, mountings, electrical connections and connectors for
tightness and electrical integrity. Check for loose, broken or missing safety wire. Adjust or replace
components or safety wire as required.
Check for radio noise or radio compass interference by operating the engine at near take-off power with
the radio gear activated, while turning the de-icing system on and off. When noise or interference occurs
with the system on, and does not occur with the system off, troubleshoot per Table 2.
Page 38
30-60-02 Nov
15/92
o
v
u
o
(\J
o
Table 1 - Timer Operation Specifications
PIN
3E1150-3
3E1150-7
3E1150-10
3E1150-12
3E1899-1
3E1964-1
and -4
3E1964-2
3E1964-3
3E1964-5
w
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o
I
o
N
3E2205-1
3E2205-3
3E2205-4
3E2205-7
3E2205-8
3E2205-9
System
Voltage
28
14
28
28
14
28
14
28
28
14
28
14
28
14
28
14
28
28
28
28
28
28
Power
Pin
Ground
Pin
Control
Pin
Manual
Step
Ammeter
Flicker*
Output
Sequence
(seconds)
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
A
A
A
B
A
G
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
B
B
N/A
B
B (slow)
Yes
Yes
No
No
No
Yes
Yes
N/A
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
N/A
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
N/A
No
No
No
No
No
No
No
No
Yes
Yes
N/A
Yes
Yes
Yes
C,O,E,F (34)
C,O,E,F (34)
C,O,E,F (34)
C,O,E,F (34)
C,O,E,F (34)
C,O,E,F (34)
C,O,E,F (34)
C (90)
C,O (34)
C,O, (34)
C,O, (20)
C,O, (20)
O,F (90)
O,F (90)
C,O (45)
C,O (45)
C,E (34)
C,E (90)
C (90 on/90 off)
0, F (90)
C, E (34)
K,M (90,90)
K.M (30.30 30dwell)
J
z"U
A
G
G
A
G
A
A
G
A
G
G
G
A
G
A
F
F
F
G
F
A
r. (f;:J~t)
Yp.~
Total
Cycle
(minutes)
2.2
2.2
2.2
2.2
2.2
2.2
2.2
1.5
1.1
1.1
0.7
0.7
3.0
3.0
1.5
1.5
1.1
3.0
3.0
3.0
1.1
3.0
1.5
~ ~ * Ammeter flicker can be subjective. If problems are suspected due to unexpected ammeter flicker or non-flicker,
~ ~ contact BFG for assistance.
m
5' 2. III
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(D
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(I)
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Insta"ation and Maintenance Manual
4.3
Troubleshooting
Use the system ammeter to troubleshoot most electrical problems, as shown in Table 2. When the deicing system does not have an ammeter, install a properly calibrated test ammeter between the bus bar
and timer to troubleshoot.
4.3.1
Helpful Tips
1.
2.
3.
4.
5.
4.3.2
Normal current range, with the engine(s) running is marked by a shaded area on the ammeter
face. Check the Aircraft Manual for the proper current range when a system ammeter is not used.
Use the de-icer heat test (Paragraph 4.2.1) and the ammeter test (Paragraph 4.2.2.5) to
determine which de-icer or de-icer element is not operating properly. Use the wiring schematic
in the Aircraft Manual to trace the circuits, and isolate the problem.
An excess current reading indicates a power lead shorted to ground. Locate the short circuit and
correct immediately.
Use a "Megger" (or other tester having a 500 VDC, 100 megohm capacity) for insulation
resistance tests.
When an ammeter reading is in the shaded area when the propellers are not rotating, and outside
the shaded area on the low side when the propellers are rotating at cruise RPM's, check for
defective wiring in the propeller mounted components.
De-leer Resistance Check
First Reading: To measure de-icer resistance or to locate a short or open circuit at the brush to slip ring
contact, disconnect the engine wire harness at the brush assembly, and use a low range ohmmeter or
Wheatstone bridge to read the resistance of each de-icer circuit lead to the brush assembly ground pin.
The correct de-icer resistance values are shown in BFG Report 59-728.
Second Reading: When actual values differ from the chart, disconnect the de-icer or wire harness leads
at the spinner bulkhead or starter ring gear and measure the resistance of each de-icer element. When
the first reading differs from the chart, and the second reading matches, look for trouble in the brush to
slip ring contact. When both the first and second readings differ from the chart, the de-icer or wire harness
is damaged and must be replaced.
4.3.3
Slip Ring Alignment Check
Refer to Paragraph 3.9.5.
4.3.4
Brush Assembly Resistance Check
To check for an open or short circuit or for high resistance in the brush assembly, use a low range
ohmmeter or Wheatstone bridge to measure the resistance from the brush face to the brush receptacle
pin. The probe contacting the brush should have at least a 1/16" square area. When the resistance value
is more than 0.013 ohms, locate and repair the cause of the excessive resistance or replace brush
assembly components as required.
For brush block assemblies only (does not apply to modular brush assemblies), measure the insulation
resistance between the three terminal studs or connector pins, and from the pins to the connector
housing. The value should be at least 0.50 megohms after one minute. When the value is lower, check
for a short circuit between the brush leads. To correct a short circuit, replace the insulating tubing.
I,
40
30-60-02 Page
Nov 15/92
..
~.
_. . _......... - .....
~.-.--
-_._-_._.-_.__.._-_._----_.
__ __._ ...__ ..._._._---_._---.._--_.
.
~~-
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Table 2 - Troubleshooting Chart
Trouble
Ammeter shows zero current all phases of the timer
cycle
,
0
.,
)
Probable Cause
Remedy
No power from aircraft
A. If no voltage into circuit breaker,
locate and correct open circuit.
Tripped circuit breaker caused by
short circuit
B. Locate and correct short, then reset
circuit breaker.
Circuit breaker or switch faulty
C. If voltage at circuit breaker input and
none at output, and circuit breaker does
not reset, replace circuit breaker.lf voltage is OK at output, check switch in same
manner. If voltage is OK at switch, see
"Ammeter faulty" under Probable Cause.
Ammeter faulty
D. Test Ammeter - Para. 4.2.2.5.
Open circuit - ammeter to timer
E. Disconnect wire harness at timer and
check for appropriate voltage from timer
power pin to ground. If none, locate and
correct open circuit.
Open circuit - timer to both brush
assemblies
F. Disconnect wire harness at brush
assembly and check voltage to ground
from appropriate pins or leads. If low.or
no voltage, locate and correct open circuit or high resistance in wire harness.
G. Check continuity from appropriate pin
or lead to ground. If high resistance is
indicated, check ground wire for breakage and ground connections for correctness and tightness. Correct as required.
o
Ammeter shows normal
current part of cycle, zero
current rest of cycle
)
o
Open circuit to de-icer, de-icer wire
harness or slip ring leads
H. Check de-icer wire harness leads for
continuity. Ohmmeter needle must not
flickerwhen leads are stretched or flexed.
Replace as required. For long lead strap
de-icers, disconnect de-icer leads and
check resistance per Report 59-728. If
OK, check for open circuit in slip ring
leads. Repair or replace parts as required.
Open circuit between timer and brush
assembly on one engine
I. See Remedy F above.
Open circuit in de-icer or slip ring
leads
J. See Remedy G above.
41
30-60-02 Page
Nov 15/92
BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Table 2 - Troubleshooting Chart
Trouble
Probable Cause
Remedy
Ammeter shows normal cur- Timer faulty
rent part of cycle, zero current rest of cycle (cont'd)
K. Test timer - Para. 4.2.2.4.
Ammeter shows normal cur- In system with dual element de-icers,
rent part of cycle, low current inboard and outboard de-icer elements are heating in same phase (in
rest of cycle
series)
L. Locate and repair incorrect lead
connections.
Ammeter shows low current
over entire cycle
Open circuit or high resistance in deicer or slip ring leads
M. See Remedy G above.
High resistance in circuit with low
current
N. Check contact between brushes
and slip rings per Para. 3.11.1 and
correct as indicated. Check wiring
from timerto de-icers for loose or corroded connections or partially broken
wiring. Correct as required.
Aircraft voltage low under normal
operating conditions
O. Check voltage into switch.
Ammeter, switch or circuit breaker
faulty
P. Check voltage to and from ammeter, switch and circuit breaker. See
Remedy D. If output is low and input
OK, replace defective component.
High contact resistance in timer
See Remedy K above.
In system with dual element de-icers,
one de-icer element (or wiring connection to de-icer element) in each
cycle is open
R. Perform heat test on each de-icer
per Para. 4.2.1. Replace defective
de-icers.
Ammeter shows excess cur- Power lead shorted to ground
rent over entire cycle
Ammeter faulty
S. Check power leads from ammeter
to timer and then to de-icers for evidence of damage or arcing. With
system OFF and timer wire harness
disconnected, check insulation resistance to ground from harness pin B.
Disconnect harness at brush assembly and repeat check for applicable
pins. If ground is indicated, locate
and correct it.
See Remedy D.
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Table 2 - Troubleshooting Chart
Trouble
)
o
)
o
Probable Cause
Remedy
Ammeter shows normal cur- Short to ground or between adjacent
rent part of cycle, excess circuits, or between timer to brush ascurrent rest of cycle
sembly
T. Disconnect leads at brush assembly
and timer. Check insulation resistance
from power leads to ground and between adjacent circuits. If ground or
short circuit is indicated, locate and
correct.
Short circuit to propeller or between
two adjacent slip ring to de-icer circuits
U. Isolate brush assembly and check
insulation resistance from one slip ring
to bare prop. Reading should be at least
.5 megohms after 1 minute. If not,
disconnect slip ring leads one set at a
time to trace the short circuit. If reading
OK, disconnect slip ring leads and check
insulation resistance between slip rings.
Reading should be as shown above. If
not, clean slip ring thoroughly and retest. Replace as required.
Timer faulty
See Remedy K.
Ammeter does not "flicker"
Timer ground open; timer not cycling
between output inteNals. (See
Table 1 for applicability.)
V. Disconnect timer harness and check
ground connection with ohmmeter from
appropriate pin shown in Table 2.
Timer contacts welded together
(caused by short circuit in electrical
system)
See Remedy K. Repair or replace faulty
timer, insuring that short circuit causing
original failure has been located and
correded.
Ammeter flickers between
Loose connection between aircraft
output intervals. (See Table power supply and timer input
1 for applicability.)
W. Trace wiring from power source to
timer input. Insure all electrical contacts
are sound at each connection in .the
circuit.
Loose or poor timer to de-icer connection
X. If trouble occurs during only part of
the cycle, determine which de-icers are
affected and check for rough or dirty slip
rings causing brush to skip. Also, check
circuits for loose or poor connections. If
all de-icers on one propeller assembly
are affected, check ground circuit.
Timer cycles erratically
See Remedy K.
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
Table 2 - Troubleshooting Chart
Trouble
Probable Cause
Remedy
Brushes arcing
Y. Check brush alignment - Para.
3.11.1. Check for dirty or rough slip
rings. If found, clean, machine or
replace as required. Check slip ring
alignment per Para. 3.9.5.
Loose connection
See Remedies Wand X.
Switch or circuit breaker faulty
Z. Place jumper wire across switch
or circuit breaker. If radio noise disappears replace switch or circuit
breaker.
Wiring too close to radio equipment
or associated wiring
AA. Relocate de-icing system wiring at least 8" from radio equipment
and wiring.
Cycling sequence not correct Crossed connections between timer
and de-icers
BB. Check system wiring against
circuit diagram.
Radio noise or interference
with de-icing system ON
Rapid brush wear or
frequent breakage
Defective timer
CC. Replace timer.
Brush assembly out of alignment
DO. Check brush alignment per
Para. 3.11.1.
Slip ring wobbles
EE. Check slip ring alignment per
Para. 3.9.5.
Rough slip rings
FF. Refinish per Figure 44.
i
I,
,
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
4.3.5
Ammeter (Optional) Check
Determine whether the ammeter is externally or internally shunted. For externally shunted ammeters,
check that the ammeter and shunt are correctly matched by checking the notation on the shunt. Shunts
with the notation "30 Amps = 50 MV" are used with 0-30 amp range ammeters; those with "50 Amps =
50 MV" are used with 0-50 amp range ammeters.
For internally shunted ammeters, connect a properly calibrated test ammeter in series with the system
ammeter. Make sure the test ammeter is calibrated to +/- 2% full range accuracy or better. Activate the
de-icing system and check the readings on both ammeters. When the readings do not match, replace
the system ammeter.
For externally shunted ammeters, first check the shunt by disconnecting the ammeter leads at the shunt
and connecting a millivoltmeter across the shunt. Activate the de-icing system and check the
millivoltmeter reading. When the ammeter scale is 0-50, the millivoltmeter reading should be equivalent
to the amperage reading in the shaded area of the ammeter. When the scale is 0-30, the reading should.
be 1- 2/3times (167%) the shaded area. Then check the ammeter by connecting a test shunt of the proper
value, or by using an adjustable 0-50 millivolt source. Check for a correct reading with the de-icing system
activated. When readings from the ammeter and the shunt do not agree, replace whichever is
determined to be defective.
4.4
4.4.1
Repair Procedures
Electrical Repairs
For soldering, use Kester "Resin Five" core solder, 0.062 strand, No. 66 or equivalent. Do not allow solder
flow (wicking) to extend onto any portion of the wire which is flexed.
Use a manufacturer recommended crimping tool that crimps both sides of the terminal, to avoid loosening
the insulation when attaching terminals to wire. Make sure the terminal is crimped to bare wire. When
the wire is too short to repair, replace it with same gauge and quality.
Straighten bent receptacle pins with long needle nose pliers. When work hardening leaves a pin brittle,
replace the receptacle. Minor damage to receptacle threads can be repaired; major damage requires replacement. Check the insulation resistance with a Megger between the pins to make sure the receptacle
has not been damaged. The resistance should be at least 0.5 megohm after one minute at 500 VDC.
Redress wiring when it is chafed or worn. When the damage is minor, wrap the wiring well with insulating
tape and cover the area with vinyl tubing. When the damage is major, replace the wiring with the same
gauge and quality.
4.4.2
Mechanical Repairs
Use safety wire at the timer, wire harnesses, brush assembly, slip ring, de-icer lead clip and in such other
locations as specified in the Aircraft Manual. Tighten the mounting hardware and electrical connections
firmly or according to the torque value given for each. Avoid stripping the threads with excess force.
Always use new locknuts during reassembly.
4.4.3
Switch, Circuit Breaker, Ammeter (Optional), Timer Repairs
The switch, circuit breaker, ammeter, shunt and timer are not field repairable.
If a BFGoodrich
component is suspected of malfunction, return to a BFGoodrich authorized repair facility for evaluation,
or replace it with an identical part as listed in the BFGoodrich Replacement Parts List or the Aircraft Manual
Parts List. Use the same (or equivalent to original) mounting and electrical connection hardware to install
the replacement component.
NOTE: When the component is not manufactured by BFGoodrich, check with the
component or aircraft manufacturer for repair procedures and replacemen~ parts.
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BFGoodrich De-Icing Systems
Electrothermal Propeller De-Icing Systems
Installation and Maintenance Manual
4.4.4
Brush Assembly Repairs
See BFGoodrich Report 68-04-714 for brush assembly repair procedures.
4.4.5
Slip Ring Repairs
A structurally sound slip ring with roughened or damaged surfaces can be machined to restore serviceability. Check the slip ring before machining to determine if sufficient slip ring surface remains to allow for
resurfacing. See BFGoodrich Slip Ring Reference Chart for minimum dimensions and Figure 42 for
machining instructions. Do not use a slip ring worn at or below minimum dimensions.
4.4.5.1 Slip Ring Stud Repairs
Some slip rings have studs which are brazed or welded to the assembly, and serve as the electrical
connection. Avoid side loading these studs while working on the assembly. Broken studs can be repaired
only at the BFGoodrich manufacturing facility.
4.4.5.2 Non-concentricity of Slip Rings
When the brush alignment cannot be adjusted sufficiently per Figures 39-41 to ride fully on the copper
rings, then the spinner bulkhead, the slip ring mounting holes, or the slip ring is not concentric. The nonconcentric item must be replaced; there is no remedy.
4.4.5.3 Slip Ring Lead Wire Repairs
/
When a slip ring wire is frayed or broken, repair or replace it with wire of equivalent length, gauge and
quality. When a wire is broken inside the slip ring, there is no remedy. The slip ring must be replaced.
When a wire breaks at a stud, replace it as follows: Place the assembly on a heat sink; the temperature
of the assembly should not rise above 1750 F anywhere except at the stud. Clean out the hole in the stud;
remove the broken wire and solder in a new wire of equivalent length, gauge and quality. Check continuity
with an ohmmeter after wire replacement.
4.4.5.4 Slip Ring Replacement
A slip ring which is open electrically, cracked or damaged structurally, or with a badly damaged surface
must be replaced. Align the new assembly per Paragraph 3.9.5.
4.4.6
De-Icer Replacement
When testing shows the need to replace a de-icer, replace the de-icer per BFGoodrich Report 59-728,
paying particular attention to the weight and balance instructions.
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