Baron Oxygen STC Installation Instructions (Front Baggage Installation)

NOTE: Picture P14 is a picture of the Adel clamp and standoff used for item 5. Install Adel clamp on center of frame flange in location that allows best routing of O2 tube without binding or interference with existing systems. Clearance size hole for #10 fastener is .193/.200 inch diameter (#10 drill). 5 P14 50 52 33 17 & 18 Interior Oxygen Installation (cont) 5. From step #2, continue installing aluminum tubes toward the front, in order as shown. Red lines parallel to tubing to help show setup. Use existing holes on mounting brackets forward of station 82.96 to install 3 Adel clamps. IO-2 Rev NC 3.8 P16 P17 P15 Picture: Under Pilot’s Seat Picture: Below Emergency Exit Window (L/H) Picture: L/H side of Pilot’s Seat 7 5 5 4 5 Interior Oxygen Installation (cont) IO-2 Rev F 3.9 P19 P18 6. P18 shows the aluminum tube crossing from left to right, in front of station 82.96, add Adel clamps (shown in blue circles below) to existing holes on mounting brackets. Add Adel clamp to station 58.00 as seen in P19, the hole will need to be drilled (.193/.200 diameter). At the forward end of P19, station 39.00, there will be a bulkhead fitting. (not shown) 12 8 Picture: Under Co- Pilot’s Seat Picture: Co-Pilot’s Seat Interior Oxygen Installation (cont) IO-2 Rev NC 3.10 NOTE: Here are pictures of the Adel clamp on the front spar 8 12 7 P20 Picture: Under Pilot’s Seat Picture: Under Co- Pilot’s Seat Picture: Front Door 12 Note: Adel clamp P21 P22 Interior Oxygen Installation (cont) 7. Add Adel clamp at existing Adel clamp location on former at station 124.75, then route aluminum tube (item 13) through it. The holes for the end of the tube are existing, use these to add fittings. 8. There are two bulkhead fittings in P23, shown in yellow circles. Both of these fittings use 90° fitting on one end and a straight fitting on the other, as shown in P23. Reference slide 3.5. 3.11 Rev F IO-3 P23 11 13 Picture: Rear of Emergency Exit(L/H) 33 Interior Oxygen Installation (cont) IO-3 Rev NC 3.12 P24 NOTE: Picture P24 shows the bulkhead fittings. Ensure proper build up when installing, leakage may occur if not properly installed. Picture: Rear of Emergency Exit(L/H) Interior Oxygen Installation (cont) 9. After aluminum tubing is installed, flexible tubing installation can be started. The routing is in a closed loop setup, to allow each user to receive equal amounts of oxygen. 10. The installation tries to make use of the maximum amount of existing holes in the airframe structure, IO-4 Rev F 3.13 but the flexible tubing crosses an airframe brace twice that will need reinforcements (item 54). Reference slide 3.15 P25 See Note #10 Interior Oxygen Installation (cont) IO-4 Rev NC 3.14 P26 P27 Note: Low Pressure T NOTE: Make sure when connecting low pressure tubing to fittings that the tube is completely pushed in, then tugged to make sure the tubing is seated and will not leak. NOTE: Ensure all flexible tubing is routed and protected from any possible chafe or compression that may cause failure. Interior Oxygen Installation (cont) IO-5 Rev F 3.15 54 P28 Picture: Above Passenger Seats Behind Pilot Seats Install flex tube protectors (Item 54) using two part epoxy adhesive supplied in kit (Item 74). Mix and apply adhesive in accordance with manufacturer’s instructions. 1 Interior Oxygen Installation (cont) IO-6 Rev NC 3.16 P29 Picture P29 shows the transition from preformed aluminum tubing to the flexible tubing. Reference P29 when connecting flexible tubing to aluminum tubes to ensure proper connection. Picture: Above and Behind Emergency Exit Window (L/H) Interior Oxygen Installation (cont) 11. With the headliner removed, install items 44 and 45 which are the oxygen ports in the cabin. Drill or machine 7/16 inch diameter holes in headliner to accommodate the oxygen ports. In picture P30, the front of the aircraft is toward the right. Reference installation figure 58-4960002 (slide 6.6) for installation of oxygen ports. IO-7 Rev F 3.17 P30 45 P31 Interior Oxygen Installation (cont) 12. Install items 44 and 45 as shown. Items 44 and 45 need a 90° fitting or a straight fitting as seen in the pictures, items 30 and 31. Dimensions are on the next page. IO-7 Rev F 3.18 P32 P33 P34 Item 44 Item 44 Interior Oxygen Installation (cont) IO-7 Rev F 3.19 1” from edge (both sides) 2” from edge (both sides) 5” from outboard hole 1” from edge P36 P35 Note: Flexible Tubing Clamps (Item 72) with tie-wraps (Item 73) Interior Oxygen Installation (cont) IO-8 Rev NC 3.20 NOTE: When reinstalling headliner, ensure proper connection of flexible tubing and oxygen ports, as seen in P37 and P39. This may require the help of more than one installer. P38 P39 P37 Interior Oxygen Installation (cont) IO-8 Rev NC 3.21 P40 Interior Oxygen Installation (cont) 1. The gauge installation should be installed in the co-pilot’s side of the instrument panel (shown in P41) or in lower central portion of instrument panel (see Slide 6.8). Locate the gauge and switch such that they do not interfere with existing equipment on or behind the panel. The switch may be located to the right or left of the gauge based upon clearance with existing equipment and/or personal preference. 2. Install item 48 over oxygen switch, as shown in P41. IO-9 Rev F 3.22 P41 Interior Oxygen Installation (cont) 3. Route electrical wires from baggage compartment to cabin thru existing opening below the right engine alternator regulator, with existing wiring from voltage regulator. 4. Attach ground wire using existing hole on former by first removing paint in the area around the hole, reference slide 1.3. 5. Splice power in from aircraft to 28/14V IN (letter A on 58-4960005) aft of wall as shown on 58-4960005. 6. Run 5’ (item 43) wire from Item 65 to right hand side of instrument panel to attach to oxygen switch with existing wire bundle. 7. Instrument lighting positive and ground (letter B and C, respectively, on 58- 4960005) should be connected to copilot’s subpanel lighting wiring. NOTE: Ensure Item 65 is behind circuit panel and run 5’ wire to switch next to O2 pressure gage. 8. Reference 58-4960005 and 58-4960006 for wiring diagram.(In Reference section) 9. Install circuit breaker placards (Item 68) over circuit breakers. IO-9 Rev F 3.23 Oxygen Bottle Installation 1. Lift oxygen bottle with attached RCR/RCV valve (item 60 or 61 depending on 115 or 77 cu. in. bottle) to bottom of brackets then clamp straps finger tight and repeat for second set of straps as shown in pictures on next page. NOTE: If installing a 77 cu. in. bottle (item 61), ensure item 63 is installed between bottle and straps before tightening. 2. Tighten strap locknut to 60 in-lbs plus the run on value for the nut being installed. Rev E FI-1 4.1 Oxygen Bottle Installation FI-1 Rev NC 4.2 P42 P43 NOTE: Ensure bottle does not touch heater tube insulation, as this may cause chafing. 3. Final oxygen bottle installation should look like either P42 or P43. P42 shows a 115 cu. in. bottle (item 60) installation, while P43 shows a 77 cu. in. bottle (item 61) installation. Oxygen Bottle Cover Installation 1. Install item 2, add cover to bottle using existing floating nutplate bracket. 2. Thread strap behind bottle then attach cover to nutplates with screws. 3. Install item 62 on exposed bolts from the bottle strap. 4. Attach item 66 or 67 (depending on bottle size) to bottle cover as shown in P44. CI-1 Rev A 5.1 P44 Item 66 or 67 (depending on bottle size) Bottle Charge & Leak Check SYSTEM LEAK CHECK (TROUBLESHOOTING) • Charge O2 system as detailed on next page. • Unplug all masks and/or cannulas from oxygen ports. • Turn Master Switch ON. • Turn Oxygen Switch ON. • Check Oxygen Pressure Gage for pressure reading. A pressure of approximately 1,800 psi (at 70 ˚F) should be indicated on the gage when the oxygen cylinder is full. (Cylinder pressure will vary considerably with radical temperature changes.) The gage near the fill port should indicate nearly the same pressure as the instrument panel mounted gage. • Check the complete system for leaks by monitoring the pressure for one hour. If there is less than a 100 psi drop in pressure in one hour the system is considered acceptable. • Shut oxygen OFF until inflight use is required. • Turn Master Switch OFF. FI-1 Rev E 5.2 Bottle Charge & Leak Check • When filling the oxygen system, use only 99.99% pure oxygen to be sure that it does not contain moisture which can cause the oxygen valve to freeze. • Do not service the oxygen system at the same time and in the same area that the fuel system is being serviced. To service the oxygen system, use the following procedures for initial charging as well as subsequent charging: • Gain access to the filler port for the oxygen system (see Descriptive Data for filler port location). • Check oxygen cylinder pressure gage. If the cylinder is completely empty or open, check to make sure it has not been internally contaminated with any combustible materials such as oils, fluids, or gases, before charging. If you are unsure, empty cylinder must be removed, inspected, and cleaned before charging. • Check the hydrostatic test date of the cylinder. Oxygen bottles installed in accordance with Engine Technologies, Inc. STC SA10960SC are Kevlar® wrapped aluminum specifically designed for aviation use. They must be hydrostatically tested every 5 years and must be retired from service after 15 years. If the periodic retest date is past, do not return the cylinder to service until the test has been accomplished. • Remove the cap from the filler valve and attach the recharging outlet. • Slowly open the valve of the cylinder on the oxygen filling manifold system having the lowest pressure and allow the pressure to equalize. • Close the cylinder valve on the manifold system and slowly open the valve of the cylinder having the next highest pressure. Continue this procedure until the cylinder has been charged to 1850 ± 50 psi at an ambient temperature of 70ºF. This pressure may be increased an additional 3.5 psi for each degree of increase in ambient temperature. Similarly, for each degree of drop in ambient temperature, reduce the cylinder pressure 3.5 psi. • Close all valves on the manifold system. • Remove the recharging outlet, and replace the filler valve cap. • Let the cylinder stabilize for a period of at least 1 hour, and then recheck the pressure. • Make any necessary adjustments in the pressure. • Reinstall components removed to gain access to the filler valve. FI-2 Rev E 5.3 Final Paperwork • Insert Airplane Flight Manual Supplement (Item 70) in airplane flight manual. • Perform Aircraft Weight and Balance change (see slides 7.1 thru 7.3). • Keep these instructions and Instructions for Continued Airworthiness (Item 71) with aircraft maintenance logs for future reference. 5.4 FP-1 Rev F Reference Rev NC 6.1 R-1 Reference (cont) Rev NC 6.2 R-2 Reference (cont) Rev NC 6.3 R-3 Reference (cont) Rev NC 6.4 R-4 Reference (cont) Rev NC R-5 6.5 Reference (cont) Rev F R-6 6.6 Reference (cont) Rev F R-7 6.7 Reference (cont) Rev F R-8 6.8 Reference (cont) Rev F R-9 6.9 10 Rev NC 6.10 Reference (cont) Reference (cont) Rev F R-11 6.11 55, 58 Baron O2 Parts List Item # Part Name Part Number Qty Item # Part Name Part Number Qty 1 Tube Protector 58-4900037 2 38 O2 Gage Electrical Connector ETI-B-5006P6-B 1 2 Bottle Cover Assembly 58-4950018 1 39 O2 Gage Switch ETI-B-5006P6-D 1 3 RCR Electrical Connector ETI-B-5006P6-C 1 40 Screw MS35214-30 4 4 Aluminum Oxygen Tube Assembly 58-4950007 1 41 Butt Splice AP323975 9 5 Aluminum Oxygen Tube Assembly 58-4950008 1 42 Ring Terminal (#6) AP36150 4 6 Aluminum Oxygen Tube Assembly 58-4950009 1 43 Electrical Wire, 5 ft WM22759\16-20-9 1 7 Aluminum Oxygen Tube Assembly 58-4950010 1 44 User Block 35-1100008 3 8 Aluminum Oxygen Tube Assembly 58-4950011 1 45 User Block Port 35-1100009 6 9 Aluminum Oxygen Tube Assembly 58-4950012 1 46 Washer NAS1149C0732R 6 10 Aluminum Oxygen Tube Assembly 58-4950013 1 47 Bolt AN3-11A 2 11 Aluminum Oxygen Tube Assembly 58-4950014 1 48 Oxygen Switch Placard 58-4900038 1 12 Aluminum Oxygen Tube Assembly 58-4950015 1 49 13 Aluminum Oxygen Tube Assembly 58-4950016 1 50 Screw AN525-10R12 1 14 High Pressure Copper Tubing, 4 ft 19605-0002-00 1 51 15 Ring Terminal (#10) AP36154 2 52 1/2" Spacer 58-4900039 1 16 Bolt AN3-3A 8 53 Flowmeter and Cannula 35-1100005 6 17 Washer NAS1149F0332P 18 54 Flex Tube Protector 58-4900015 2 18 Nut MS21045-3 11 55 Filler Port Placard 58-4900005 1 19 Adel Clamp MS21919WDG2 3 56 Alternator Regulator Patch 58-4900027 1 20 Filler Box w/Gage 58-4950022 1 57 Secure Baggage Placard 58-4900028 1 21 Screw AN525-832R6 4 58 Bracket Assembly - 115 Cu Ft Bottle 58-4950020 2** 22 59 Bracket Assembly - 77 Cu Ft Bottle 58-4950021 2* 23 Grommet MS35489-4 1 60 115 Cu Ft O2 Bottle 35-1100001 1** 24 Bulkhead Fitting AN833-4D 3 61 77 Cu Ft O2 Bottle 35-1100004 1* 25 B-Nut AN924-4D 3 62 Bolt Cover 58-4900036 2 26 Washer NAS1149F0763P 6 63 115 to 77 Bottle Adapter 58-4900026 2* 27 AN-to-pipe thread Fitting AN816-4D (alt. AS5194D0402) 2 64 RCR Valve 35-1100003 1 28 Brass Union 3300x2 2 65 Dual Isolated Power System 58-4950006 1 29 Low Pressure Tee 00-HDW-1328-00 2 66 77 Cu Ft Bottle Placard 58-4900034 1* 30 Low Pressure Straight Fitting 00-HDW-1350-00 4 67 115 Cu Ft Bottle Placard 58-4900035 1** 31 Low Pressure 90˚ Fitting 00-HDW-1353-00 4 68 Circuit Breaker Placard 58-4900041 2 32 AN Aluminum Union AS5174D0404 6 69 Baron O2 Installation Instructions 58-4960001 1 33 Adel Clamp MS21919WDG4 6 70 Airplane Flight Manual Supplement 35-4960005 1 34 Low Pressure O2 Tubing, 15, ft 00-HDW-0014-20 1 71 Instructions for Continued Airworthiness 35-4960006 1 35 Grommet MS35489-6 2 72 Flexible Tubing Clamp 7582K11 4 36 Circuit Breaker, 2 Amp 7277-5-2 2 73 Tiewrap TY5242M 12 37 O2 Electric Gage 00BLT-1072-00 1 74 Extra Thick Quick Setting Epoxy 7538A15 1 Note: Quantities with single asterisk (*) included in kit for 77 Cu Ft Bottle Quantities with double asterisk (**) are included in kit for 115 Cu Ft Bottle Weight and Balance Information Weight and balance change for 115 cubic foot O2 bottle mounted in fwd baggage compartment Baron 58 series Items Added Weight (lbs) Arm (in) Moment O2 valve/regulator 2.30 32.5 74.75 2 2 pl O2 ports 2.00 92 184 1 2 pl O2 port 1.00 175 175 O2 fill port & gage 1.30 21 27.3 O2 tubing - 25 ft. 1.00 140 140 O2 hard lines 2.00 80 160 Pressure gage & switch 0.50 58 29 O2 bottle support 2.00 32.5 65 115 cu ft O2 bottle (full) 27.65 32.5 898.625 Total 39.75 44.11761 1753.675 W-1 Rev D 7.1 Weight and Balance Information Weight and balance change for 77 cubic foot O2 bottle mounted in fwd baggage compartment Baron 58 series Items Added Weight (lbs) Arm (in) Moment O2 valve/regulator 2.30 32.5 74.75 2 2 pl O2 ports 2.00 92 184 1 2 pl O2 port 1.00 175 175 O2 fill port & gage 1.30 21 27.3 O2 tubing - 25 ft. 1.00 140 140 O2 hard lines 2.00 80 160 Pressure gage & switch 0.50 58 29 O2 bottle support 2.00 32.5 65 77 cu ft O2 bottle (full) 19.29 32.5 626.925 Total 31.39 47.21169 1481.975 W-2 Rev D 7.2 Weight and Balance Information Weight and balance change for 115 cubic foot O2 bottle mounted in fwd baggage compartment Baron 55 series Items Added Weight (lbs) Arm (in) Moment O2 valve/regulator 2.30 42.5 97.75 2 2 pl O2 ports 2.00 102 204 1 2 pl O2 port 1.00 175 175 O2 fill port & gage 1.30 11 14.3 O2 tubing - 25 ft. 1.00 140 140 O2 hard lines 2.00 80 160 Pressure gage & switch 0.50 68 34 O2 bottle support 2.00 42.5 85 115 cu ft O2 bottle (full) 27.65 42.5 1175.125 Total 39.75 52.45723 2085.175 W-3 Rev D 7.3