Integrated Back-up Battery System

PS50120‑1‑2 OR EQUIVALENT (5A RATING). MARK CIRCUIT BREAKER WITH SAME SIZE IDENTIFIERS AS USED ON EXISTING CIRCUIT BREAKER PANEL. 7. ALL WIRE MARKING ACCORDING TO PIPER CHEROKEE SIX SERVICE MANUAL, OEM PNR 753- 690, TABLE X-IV. MARKING FORMAT: CNS-GG, WHERE C=CIRCUIT TYPE (P=POWER, RP=RADIO POWER) N=WIRE NUMBER (1 THRU 9) S=WIRE SEGMENT (A THRU Z) GG=WIRE GAUGE (18 THRU 22) 8. WIRE SPLICE TO BE WITHIN 3 INCHES OF GNS 430W CONNECTOR. 4 6 GARMIN GNS 430W P4002 11 12 P4001 19 20 8 RP9B-22 RP9C-22 RP9A-18 RP2D-18 TCW TECHNOLOGIES, LLC WIRING DIAGRAM, IBBS INSTALLATION WITH GARMIN GNS 430W STC PROJECT ST08596NY-A DRAWING 725.0006, REVISION 1.8 8 FEB 2019 5 6 8 4 11 13 RP2E-18 RP2F-18 Low Voltage BACK-UP ENABLE IBBS unit mounted to the back side of the spare panel IBBS control switch and warning LED indicator Existing cb including spare utilized in IBBS install avionics avionics Garmin GNS-430W avionics Typical Instrument Panel Installation view looking forward PA-32 install of IBBS-12v-3(6)ah-CRT TCW Technologies, LLC. 11 April 2019 725.0007 Rev 1.5 Mounting location Sheet 1 of 2 0.000 Existing instrument panel blank mounting plate from Co-pilot side. View from the front 1.75 1.50 0.25 7.25 Ø 0.34 4.50 5.50 1.28 Back up Master ON/OFF Switch LV LED Mount IBBS unit with the following hardware: 4x MS35207-263 10x32 Machine screw 4x AN960-10L Thin Washer 4x AN365-1032a Lock nut PA-32 install of IBBS-12v-3(6)ah-CRT TCW Technologies, LLC. 11 April 2019 725.0007 Rev 1.5 Mounting plate detail Sheet 2 of 2 Ø 0.49 0.37 Ø 0.13 7.00 8.50 Note: Aluminum mounting plate from 6061-T6 or 2024-T3 or equivalent 0.060" thick, exterior dimensions approximate for fit to exiting airframe instrument panel. Corrosion protection via paint or plating as required. Existing mounting locations, 4 places, MS35206-245 (8x32) machine screws, approx. 0.75" x 2" from each corner. Low Voltage BACK-UP ENABLE IBBS unit mounted to the back side of the spare panel IBBS control switch and warning LED indicator Existing cb including spare utilized in IBBS install avionics avionics Garmin GNS-430W avionics Typical Instrument Panel Installation view looking forward PA-32 install of IBBS-12v-3(6)ah-CRT TCW Technologies, LLC. 11 April 2019 725.0007 Rev 1.5 Mounting location Sheet 1 of 2 0.000 Existing instrument panel blank mounting plate from Co-pilot side. View from the front 1.75 1.50 0.25 7.25 Ø 0.34 4.50 5.50 1.28 Back up Master ON/OFF Switch LV LED Mount IBBS unit with the following hardware: 4x MS35207-263 10x32 Machine screw 4x AN960-10L Thin Washer 4x AN365-1032a Lock nut PA-32 install of IBBS-12v-3(6)ah-CRT TCW Technologies, LLC. 11 April 2019 725.0007 Rev 1.5 Mounting plate detail Sheet 2 of 2 Ø 0.49 0.37 Ø 0.13 7.00 8.50 Note: Aluminum mounting plate from 6061-T6 or 2024-T3 or equivalent 0.060" thick, exterior dimensions approximate for fit to exiting airframe instrument panel. Corrosion protection via paint or plating as required. Existing mounting locations, 4 places, MS35206-245 (8x32) machine screws, approx. 0.75" x 2" from each corner. Integrated Back-up Battery System (IBBS) Models IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT Instructions for Continued Airworthiness As Installed in Piper Aircraft PA-32 Series Aircraft Supplemental Type Certificate (STC) Project ST08596NY-A Document Number: 725.0008 Revision: 1.3 Instructions for Continued Airworthiness for IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT STC Project ST08596NY-A Revision History Revision Level Change Details Approval 1.0 Initial Release RCN / 18 Apr 2018 1.1 Rearranged sections and updated Airworthiness Limitations Section. RCN / 8 Jun 2018 1.2 Added section for revision notification EJK / 9 June 2018 1.3 Incorporated AEG comments. EJK / 26 Jun 2018 Table of Contents Section Section / Topic Page 1.0 General Introduction 3 2.0 Airworthiness Limitations 6 3.0 Required Test Equipment 8 4.0 Operational Performance Test Procedure 8 5.0 Ground-Based Charging 9 6.0 Service Contact Information 9 p/n 725.0008 Rev 1.3 Page 2 © 2018 TCW Technologies LLC Instructions for Continued Airworthiness for IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT STC Project ST08596NY-A 1 General Introduction 1.1 Scope This document identifies the Instructions for Continued Airworthiness for the modification of the PA-32 Series aircraft for the installation of the Integrated Back-up Battery System, IBBS, installed under the Supplemental Type Certificate ST08596NY-A. The installed IBBS provides back-up power to the Garmin GNS430(W) VHF Communication Transceiver / VOR/ILS Receiver / GPS Receiver, with or without WAAS Navigation, installed on the aircraft under a separate STC. 1.2 Integrated Back-up Battery System Description The IBBS is an electronic system that combines a Lithium-Iron-Phosphate (Li-Fe- PO4) battery pack, a charger and switching logic in one convenient package. The IBBS provides an engineered solution to enable an endurance bus for critical loads found in aircraft. It simplifies the wiring and installation of a source of back-up power by integrating all of the key elements in a single enclosure. Integral to the IBBS is a lithium-iron-phosphate battery pack and a matched charging system to ensure the battery is properly charged and maintained. The system also includes switching circuitry to provide a stable source of output power during normal and emergency operations. The IBBS is available in two models: • IBBS-12v-6ah-CRT – six (6) ampere-hour model • IBBS-12v-3ah-CRT - three (3) ampere-hour model Both models have identical case dimensions and electrical connections. They are mounted in an identical manner. The electrical voltage and current ratings are identical for both models. The only difference between the two models is the number of battery cells internal to the equipment, which determines the battery capacity and weight of the equipment. Either can be installed in the aircraft according to the STC, based on the operator’s need for back-up power. IBBS products are covered by US Patent 8,189,305 1.3 IBBS Installation Description The IBBS connects to the standard aircraft power bus and provides outputs to connected equipment identified in Section 1.1. Additionally, the IBBS provides surge and sag protection for connected equipment, allowing operation of connected equipment during engine starting. The IBBS output is controlled by a Back-up Power Master toggle switch on the instrument panel which directly commands the IBBS to enable or disable output power to connected equipment. The IBBS also provides a signal to a Low Voltage Warning LED on the instrument panel to communicate the operating state of the aircraft avionics bus as well as the state of the battery. Representations of these interfaces are shown in Figure 1 and Figure 2. p/n 725.0008 Rev 1.3 Page 3 © 2018 TCW Technologies LLC Instructions for Continued Airworthiness for IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT STC Project ST08596NY-A 1.4 IBBS Control and Operation The IBBS is designed to operate with minimal input from the aircraft crew. If aircraft power is available on the IBBS input, the IBBS will activate its battery charger as necessary to keep the internal batteries fully charged. The IBBS may also pass through aircraft power to the connected equipment. If aircraft power is not available on the IBBS input, the IBBS will deactivate its battery charger and may supply back- up power to the connected equipment. The Back-up Power Master toggle switch enables the crew to enable or disable the power output from the IBBS. The normal and emergency operating procedures for the IBBS are explained in Sections 3.0 and 4.0 of the document 725.0005, Pilot Operating Handbook Supplement. The basic operating procedures are as follows: IBBS Start-up 1. Set the Back-up Power Master Switch to ON (Up Position). Ideally, this should be done prior to turning on the Aircraft Master Switch or Avionics Master Switch to verify that the IBBS is able to power the connected equipment. 2. Power on the Garmin GNS 430(W) connected equipment. The connected equipment should operate normally. The Back-up Power Low Voltage Warning LED will indicate a low voltage condition exists on the aircraft avionics bus (LED Illuminated). 3. Set the Aircraft Master Switch and Avionics Master Switch to ON as directed by the existing POH/AFM. The connected equipment will continue to operate normally. The Back-Up Power Low Voltage Warning LED should indicate normal voltage condition (LED extinguished). 4. Start and operate the aircraft according to all other normal operating procedures. IBBS Shut-down 1. Shut down aircraft engine using normal procedures. 2. Set the Aircraft Master Switch and Avionics Master Switch to OFF as directed by the existing POH/AFM. The connected equipment will continue to operate normally. 3. Set the Back-up Power Master Switch to OFF (Down Position). The connected equipment will power down. If the installed equipment does not function as expected in the above procedures, it is possible that either the IBBS is not functioning properly, or there is a problem with the installation. Refer to Section 2.2 IBBS Troubleshooting. p/n 725.0008 Rev 1.3 Page 4 © 2018 TCW Technologies LLC Instructions for Continued Airworthiness for IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT STC Project ST08596NY-A Figure 1: IBBS Wiring Diagram p/n 725.0008 Rev 1.3 Page 5 © 2018 TCW Technologies LLC Instructions for Continued Airworthiness for IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT STC Project ST08596NY-A 2 Airworthiness Limitations This Airworthiness Limitations Section is FAA approved and specifies maintenance required under 14 CFR §§ 43.16 and 91.403 unless an alternative program has been FAA approved. FAA Approved By ___________________________Date Manager New York ACO Branch Federal Aviation Administration 2.1 IBBS Inspection Expected service life for the internal battery pack is greater than 500 discharge cycles. Operational performance must be checked at least annually. The IBBS is mounted on the backside of a panel installed on the instrument panel, as shown in Figure 2. To gain access to the IBBS, remove the (4) four 8-32 screws from the panel’s corners. Carefully remove the panel to reveal the IBBS. Operational performance shall be confirmed by successful completion of the endurance test procedure described in Section 4 Operational Performance Test Procedure. Figure 2: Access to IBBS Low Voltage BACK-UP ENABLE IBBS unit mounted to the back side of the spare panel IBBS control switch and warning LED indicator avionics avionics Garmin GNS-430W avionics 2.2 IBBS Troubleshooting If the functionality of the installed back-up power equipment cannot be confirmed using the normal procedures in Section 1.4 IBBS Control and Operation, the installation should be inspected for defects. Using Figure 1 and Figure 2 as guidance, inspect the wiring between the aircraft electrical bus and the IBBS, and between the IBBS and the Garmin GNS 430(W) and other installed equipment (e.g., Back-up Power Master Switch and Low Voltage Warning LED). Replace any worn or damaged wire and components per Advisory Circular 43.13-1B. Once the installation has been confirmed to be in proper order, repeat the normal operating procedures from Section 1.4. If the installed equipment is functioning properly, the aircraft can be returned to service. p/n 725.0008 Rev 1.3 Page 6 © 2018 TCW Technologies LLC Instructions for Continued Airworthiness for IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT STC Project ST08596NY-A If the installed equipment still appears to be not functioning, confirm that the IBBS itself is functioning properly by successful completion of the endurance test procedure described in Section 4 Operational Performance Test Procedure. If the installed IBBS does not pass the endurance performance test, the IBBS should be replaced. 2.3 IBBS Replacement At the end of 72 months of service the IBBS must be replaced. To replace the IBBS disconnect the wiring harness connector via the two thumb screws on the connector and remove the (4) four #10 mounting screws which secure the IBBS base plate to the mounting panel, as shown in Figure 3. Figure 3: Removal/Installation of IBBS 15 pin, female Dsub connector attachment location www.tcwtech.com Emmaus, PA USA MODEL: IBBS-12V-6AH-CRT Input: 10-15 volts DC Output: 12 volts, 8 amps INTEGRATED Back-up Battery SYSTEM Cells: 4S2P TSO-C179(a) 10x32 mounting screw 4 pls p/n 725.0008 Rev 1.3 Page 7 © 2018 TCW Technologies LLC Instructions for Continued Airworthiness for IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT STC Project ST08596NY-A 3 Required Test Equipment A DC voltmeter is connected to pin 2 of the IBBS unit under test to monitor the internal battery voltage during the test if pin 2 is not already connect to a ship mounted voltmeter. 4 Operational Performance Test Procedure On at least an annual basis the endurance capability of the IBBS shall be confirmed and compared against a minimum run time of 60 minutes for the operation of the connected equipment when operated in back-up mode. As an alternative to this test, the IBBS may be returned to the manufacturer for a loaded endurance test. See Section 6 Service Contact Information for return instructions. Prior to the start of test, ensure the IBBS is fully charged by operating the aircraft with the Aircraft Master Switch in the ON and the Back-up Master Switch in the ON position for a minimum of 120 minutes. See Section 5 Ground-Based Charging for details on recharging the IBBS prior to starting this test. 1. Remove access panel as shown in Figure 2 to access the IBBS. 2. Connect a DC volt meter to pin 2 of the IBBS to monitor the internal battery voltage if this voltage is not already available on a ship mounted voltage monitor (EFIS system or engine monitor or discrete volt meter). Verify the voltage on pin 2 is between 13.6 and 14.7 VDC. If this voltage is not achieved, the IBBS does not meet the minimum operational performance requirement, and must be replaced. 3. Turn OFF the Aircraft Master Switch. 4. Turn ON the Back-up Power Master Switch. Record the start time for the test. 5. Turn ON all equipment connected to and supplied with back-up power from the IBBS. 6. Monitor the connected equipment and the voltage on pin 2. When the first piece of connected equipment no longer functions, or the voltage on pin 2 drops below 9.5 VDC (which comes first), record the stop time for the test and the voltage on pin 2. Note: The voltage on pin 2 should not be allowed to go below 9 VDC at any time during this test. 7. If the recorded time for this test is at least 60 minutes, the IBBS meets the minimum operational performance requirement and may be returned to service. Allow the IBBS to be fully charged, using one of the methods described at the beginning of this section. 8. If the recorded time for this test is less than 60 minutes, the IBBS does not meet minimum operational performance, and must be replaced. 9. Record the results of the endurance test in the aircraft log book. p/n 725.0008 Rev 1.3 Page 8 © 2018 TCW Technologies LLC Instructions for Continued Airworthiness for IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT STC Project ST08596NY-A 5 Ground-Based Charging As an alternative to charging using aircraft power, the IBBS may be charged using a ground-based method. To accomplish this, connect an approved battery charger or DC power source (set to 14 volts) to the main aircraft battery and energize the main aircraft power bus by turning ON the aircraft master switch, set all other aircraft loads in their OFF state. Allow the ground-based power source to charge the IBBS for a minimum of 120 minutes. Note: The ground-base power source must be able to supply the load current of all devices that cannot be turned off in this nominal state, plus the 4 amps of IBBS charge current. TCW Technologies LLC offers a direct charger for the IBBS, under model number IBBS-12v-CHARGER-LI-FE. This charger may be used to charge the IBBS directly through its connector (not through main aircraft battery as above), in preparation of the endurance test procedure. It can also be used to keep the IBBS fully charged during long term product storage (9 months or longer) 6 Service Contact Information To receive future updates of these Instructions for Continued Airworthiness (ICA), please contact TCW Technologies, LLC at the following address: TCW Technologies, LLC Attn: Service Department 2955 Main Rd. E. Emmaus, PA 18049 USA The service department may also be contacted via email (support@tcwtech.com), telephone (610-928-3420), or website (www.tcwtech.com). The above information may also be used to contact TCW Technologies about IBBS product returns and factory endurance testing. 6.1 Revisions Revisions to this document shall be coordinated through the New York Aircraft Certification Office, the Kansas City AEG, and the STC holder. If you would like to be notified of future revisions to this manual please furnish the information listed below: Name Address City, State, and ZIP Code Part Number of Manual Current Revision Status of the Manual E-mail address Phone Number Please submit this information to the service contact in Section 6 above. p/n 725.0008 Rev 1.3 Page 9 © 2018 TCW Technologies LLC Integrated Back-up Battery System Models: IBBS-12v-3ah-CRT IBBS-12v-6ah-CRT Installation Instructions for PA-32(x)-xxx 26 August 2019 Rev 1.2 1 725.0011 rev 1.2 Revision History Rev level Details Approval 1.0 Initial release RCN 17 July 2019 1.1 Added document table RCN 12 August 2019 1.2 Removed project number EJK 26 August 2019 Table of Contents Section Topic Page Section 1 General Information 3 Section 2 Mounting Details 4 Section 3 Electrical Details 4 Section 4 Labeling 5 Section 5 Post-Install Test 5 Section 6 Weight and Balance 6 2 725.0011 rev 1.2 Section 1 General Information Applicable aircraft: PA-32(x)-xxx The Integrated Back-up Battery System, IBBS, is an electronic system that combines a Lithium-Iron-Phosphate (Li-Fe-PO4) battery pack, a charger and switching logic in one convenient package. The IBBS provides backup electrical power to operate the connected electrical load in the event of main power failure in the aircraft. In this application the IBBS is utilized to provide back-up power to a Garmin GNS-430W Navigator/Communication unit. IBBS must be installed in accordance with this document. In this installation the IBBS is mounted to the back of the instrument panel and wired into the existing aircraft electrical system to provide power to the installed Garmin GNS-430W Navigator/Communication unit. This installation is to be accomplished utilizing the install kit p/n 500.0027 available from TCW Technologies. This kit includes mounting hardware, a wiring harness, a panel mount switch and LED and supporting documentation. Description TCW Technologies Part Number PA-32 install kit 500.0027 PA-32 install mounting drawing 725.0007 PA-32 wiring harness 500.0028 PA-32 wiring details 725.0006 For additional information regarding the IBBS product refer to the specific equipment documentation: IBBS-12v-3ah-CRT P/N 725.0002 IBBS-12v-6ah-CRT P/N 725.0001 3 725.0011 rev 1.2 Section 2 Mounting See drawing p/n 725.0007 for details of mounting location. Remove the existing instrument panel blank-out panel, OEM p/n 68851-00, as shown in the drawing and modify by drilling holes as indicated for the IBBS mounting locations, the switch and LED. After completion of the wiring modifications install the IBBS unit, switch and LED into the panel and reinstall the blank-out panel. Utilize practices and techniques found in FAA Advisory Circular (AC) 43.13-1B for electrical and mechanical installations. Mount the IBBS unit to the blank-out panel with the 4 supplied machine screws, washers and nuts included in the 500.0027 install kit. The supplied hardware is required for compliance with the bonding requirements of AC 43.13-1B, Sections 11-187 & 11-188. Additionally, a bond test in accordance with Section 11-188 is recommended. Section 3 Electrical The existing aircraft electrical harness has to be modified to add the IBBS. See drawing p/n 725.0006 for details. The two existing aircraft circuit breakers utilized for the Garmin GNS-430W are repurposed for this installation. A 10-ampere circuit breaker utilized for the Comm function of the GNS-430W is to be relabeled as, “GNS COMM/NAV.” This breaker is re-wired to feed pins 6&7 of the IBBS unit. The 5-ampere circuit breaker previously utilized to power the GNS-430W Navigation and Display functions is repurposed to power pins 4&5 of the IBBS unit. This breaker is to be relabeled as, “IBBS CHARGE.” The wire(s) utilized to provide power to the Garmin GNS-430W on connector P4002, pins 11 and 12, are moved from the previously installed circuit breaker to pin 14 of the IBBS unit. The wire(s) utilized to provide power to the Garmin GNS-430W on connector P4001, pins 19 and 20, are moved from the previously installed circuit breaker to pin 13 of the IBBS unit. The new wiring harness provided in the install kit, p/n 500.0028, accommodates these changes. Additionally, the wiring of the back-up master switch and low voltage warning lamp are directly connected to the IBBS unit via the new wiring harness. Complete all electrical connections and secure wires per AC 43.13-1B. 4 725.0011 rev 1.2 Section 4 Labeling Apply indelible marking to each of the following items to ensure the identification of the function of each item is understood. The following must be labeled at the completion of the installation, see below for recommended indicia: Device Label The 10 amp circuit breaker re-purposed to drive pins 6,7 of the IBBS GNS COMM/NAV The 5 amp circuit breaker re-purposed to drive pins 4,5 of the IBBS IBBS CHARGE Back-up Master Switch BACK-UP ENABLE LED indicator LOW VOLT WARN Section 5 Post Install Test Start-up Procedure 1) Prior to turning on the Aircraft Master Switch or Avionics Master Switch, turn ON the IBBS Back-up Enable switch. 2) Turn on any equipment that derives back-up power from the IBBS product. 3) Ensure the connected equipment successfully boots-up and is operating properly. (During this period of time the equipment is running off of the back- up battery within the IBBS product. This test ensures the transfer circuit and back-up battery are working properly.) 4) Verify the low voltage warning light is indicating a low voltage condition. 5) Turn on the Aircraft Master Switch and Avionics Master Switch as directed by the existing POH; ensure the connected equipment remains energized. The low voltage warning light should go out. 6) Start and operate the aircraft according to all other normal operating procedures. Shut-down Procedure 1) Shut down aircraft engine using normal procedures. 2) Shut down the Aircraft Master Switch and Avionics Master Switch. 3) Verify that equipment that derives back-up power from the IBBS product remains ON. 4) Turn-off Back-up Enable switch, ensure that equipment powers down. (This procedure further ensures the operation of the transfer circuit in the IBBS product.) 5 725.0011 rev 1.2 Section 5 Weight & Balance IBBS-12v-3ah-CRT Weight 18 oz IBBS-12v-6ah-CRT Weight 34 oz Switch and LED Weight 1.5 oz Wiring harness weight 8 oz CG located at the center of the unit in all axes. 6 725.0011 rev 1.2 Master Data List for Supplemental Type Certificate (STC) Project ST08596NY-A Models: IBBS-12V-6ah-CRT and IBBS-12V-3ah-CRT Document Number: 760.0011 Revision: 1.2 Release Date: 19 September 2019 STC Project: ST08596NY-A Prepared by: Robert Newman Approved by: Master Data List for STC Project ST08596NY-A Revision History Revision Level Change Details Date Author/ Approver 1.0 Initial Release 08/16/2019 RCN 1.1 Replaced IBBS install documents with STC install guide. Updated document revisions. 08/27/2019 RCN 1.2 Corrected table references in Sections 2.1.1 and 2.1.2. Removed “or later FAA-approved revisions” from Sections 2.1.1, 2.1.2, 2.2, and 2.3. See Cover See Cover p/n 760.0011 Rev 1.2 Page 2 © 2019 TCW Technologies LLC Master Data List for STC Project ST08596NY-A Table of Contents Revision History......................................................................................................................................... 2 1 Introduction........................................................................................................................................... 4 1.1 Purpose......................................................................................................................................... 4 1.2 Compliance Summary................................................................................................................... 4 1.3 Abbreviations and Acronyms.........................................................................................................4 2 Data and Equipment List Required for Installation................................................................................5 2.1 Data Required for Installation........................................................................................................5 2.2 Substantiating Data....................................................................................................................... 5 2.3 Equipment List.............................................................................................................................. 6 3 General Installation Requirements........................................................................................................7 3.1 Prerequisite................................................................................................................................... 7 3.2 Mechanical.................................................................................................................................... 7 3.3 Hardware....................................................................................................................................... 7 3.4 Wiring............................................................................................................................................ 7 3.5 Circuit Protection........................................................................................................................... 7 3.6 Electrical Load Analysis................................................................................................................. 8 4 Special Installation Instructions............................................................................................................. 8 5 Additional System Notes....................................................................................................................... 9 Table of Figures Figure 1: IBBS Mounting Diagram for PA-32 (from 725.0007, Revision 1.5)..............................................8 Figure 2: IBBS Wiring Diagram for PA-32 (from 725.0006, Revision 1.8)..................................................9 Table of Tables Table 1: Abbreviations and Acronyms........................................................................................................4 Table 2: STC Data, IBBS-12v-6ah-CRT.....................................................................................................5 Table 3: STC Data, IBBS-12v-3ah-CRT.....................................................................................................5 Table 4: STC Substantiating Data for ST08596NY-A.................................................................................6 Table 5: Equipment List for ST08596NY-A.................................................................................................6 Table 6: Installation Kit, Part Number 500.0027 (Revision A).....................................................................7 p/n 760.0011 Rev 1.2 Page 3 © 2019 TCW Technologies LLC Master Data List for STC Project ST08596NY-A 1 Introduction 1.1 Purpose The purpose of this document is to list the data required to support STC installation of the Integrated Back-Up Battery System (IBBS), Models IBBS-12v-6ah-CRT and IBBS-12v-3ah-CRT, in accordance with STC ST08596NY-A requirements, and to list other data associated with the STC which is not required for installation. This document applies to the installation of the IBBS units when installed IAW the data listed in this document on the Piper Aircraft Inc. Model PA-32 aircraft as defined for this STC. This document includes general installation requirements, special installation instructions, and it provides an index of STC data including both data required for installation and data associated with the STC, but not required for installation. 1.2 Compliance Summary This document shows compliance per the Certification Plan, document 710.0008 Rev 1.0, to the following regulations/amendments: • 14 CFR 21.31(a), Amdt 21-92 1.3 Abbreviations and Acronyms Abbrev. Description Abbrev. Description AC Advisory Circular IP Issue Paper CFR Code of Federal Regulations LED Light Emitting Diode CIP Conformity Inspection Plan MDL Master Data List CP Certification Plan NYACO New York Aircraft Certification Office CR Compliance Report OEM Original Equipment Manufacturer ELA Electrical Load Analysis POHS Pilot’s Operating Handbook Supplement FAA Federal Aviation Administration SSA System Safety Analysis FHA Functional Hazard Assessment STC Supplemental Type Certificate GTP Ground Test Plan TC Type Certificate GTR Ground Test Report TCDS Type Certificate Data Sheets IBBS Integrated Back-Up Battery System TSO Technical Standard Order ICA Instructions for Continued Airworthiness TSOA Technical Standard Order Authorization INSTL Installation Table 1: Abbreviations and Acronyms p/n 760.0011 Rev 1.2 Page 4 © 2019 TCW Technologies LLC Master Data List for STC Project ST08596NY-A 2 Data and Equipment List Required for Installation 2.1 Data Required for Installation 2.1.1 IBBS-12v-6ah-CRT Installation Data All documents listed in Table 2 are required for installation purposes for installations of the IBBS- 12v-6ah-CRT equipment. All documents must be at the revision listed below. Manufacturer Document No. Revision Description TCW Technologies 760.0011 1.2 Master Data List for STC Project ST08596NY-A (This document) TCW Technologies 725.0011 1.2 Installation Instructions for PA-32(x)-xxx TCW Technologies 725.0005 1.5 Pilot’s Operating Handbook Supplement (POHS) TCW Technologies 725.0006 1.8 Wiring Diagram, IBBS Installation with Garmin GNS 430W TCW Technologies 725.0007 1.5 Mounting Location, PA-32 Install of IBBS-12v- 3(6)ah-CRT TCW Technologies 725.0008 1.3 Instructions for Continued Airworthiness Table 2: STC Data, IBBS-12v-6ah-CRT 2.1.2 IBBS-12v-3ah-CRT Installation Data All documents listed in Table 3 are required for installation purposes for installations of the IBBS- 12v-3ah-CRT equipment. All documents must be at the revision listed below. Manufacturer Document No. Revision Description TCW Technologies 760.0011 1.2 Master Data List for STC Project ST08596NY-A (This document) TCW Technologies 725.0011 1.2 Installation Instructions for PA-32(x)-xxx TCW Technologies 725.0005 1.5 Pilot’s Operating Handbook Supplement TCW Technologies 725.0006 1.8 Wiring Diagram, IBBS Installation with Garmin GNS 430W TCW Technologies 725.0007 1.5 Mounting Location, PA-32 Install of IBBS-12v- 3(6)ah-CRT TCW Technologies 725.0008 1.3 Instructions for Continued Airworthiness Table 3: STC Data, IBBS-12v-3ah-CRT 2.1.3 Continued Airworthiness Instructions for continued airworthiness are found in the IBBS Instructions for Continued Airworthiness, document number 725.0008. See Table 2 or Table 3 for document revision. 2.2 Substantiating Data The documents listed in Table 4 contain information related to this STC but are not required for follow-on installations. p/n 760.0011 Rev 1.2 Page 5 © 2019 TCW Technologies LLC Master Data List for STC Project ST08596NY-A Document No. Revision Description 710.0008 1.0 IBBS-12v-6(3)ah-CRT Installation in Piper PA-32 Series Aircraft STC Certification Plan (CP) 710.0009 1.8 IBBS-12v-6(3)ah-CRT Installation in Piper PA-32 Series Aircraft STC Functional Hazard Assessment (FHA) 710.0010 1.5 IBBS-12v-6(3)ah-CRT Installation in Piper PA-32 Series Aircraft STC System Safety Assessment (SSA) 720.0006 1.0 Electrical Load Analysis (ELA) for STC Project ST08596NY-A 720.0009 1.0 Ground Test Plan/Procedure (GTP) for Installation of an Integrated Back-up Battery System on Piper PA-32 Series Aircraft 720.0011 1.0 Conformity Inspection Plan (CIP) for Installation of an Integrated Back- up Battery System on Piper PA-32 Series Aircraft 760.0010 1.1 IBBS-12v-6(3)ah-CRT Integrated Backup Battery System Compliance Report (CR) 760.0012 1.0 Ground Test Report (GTR) for Installation of an Integrated Back-up Battery System on Piper PA-32 Series Aircraft 760.0021 1.0 Engineering Coordination Memo (ECM) – RTCA/DO-347 Qualification Test Data P2230-IBBS-Panel- Substantiation.pdf 11 Apr 2019 Structural Substantiation of the IBBS Support Panel in Support of ST08596NY-A Table 4: STC Substantiating Data for ST08596NY-A 2.3 Equipment List All equipment must have the Part Numbers contained in Table 5. Model Description Part Number Revision Manufacturer or IBBS, 3A-hr Integrated Back-Up Battery System, 3 ampere-hour IBBS-12v-3ah-CRT C TCW Technologies IBBS, 6A-hr Integrated Back-Up Battery System, 6 ampere-hour IBBS-12v-6ah-CRT C TCW Technologies 500.0027 Installation Kit for Installation of an Integrated Back-up Battery System on Piper PA-32 Series Aircraft, ST08596NY-A See Table 6 A See Table 6 Table 5: Equipment List for ST08596NY-A The STC installation kit, 500.0027, is available which contains the components shown in Table 6 required for installation of either the 6Ahr or 3Ahr IBBS into the PA-32 Series aircraft. p/n 760.0011 Rev 1.2 Page 6 © 2019 TCW Technologies LLC Master Data List for STC Project ST08596NY-A TCW Part Number Description Quantity Manufacturer Part Number Manufacturer 350.0015 Panel Mount Indicator, Blue LED 1 249-4167-3734-504F Dialight 370.0004 Toggle Switch, SPST 1 1NT1-2 Honeywell 500.0028 Wire Harness, IBBS for PA-32 Series Aircraft 1 500.0028 TCW Technologies 350.0016 Machine Screw, Cross Recessed, Cadmium-Plated, 10-32 x 1/2” 4 MS35207-263 Aircraft Spruce 350.0017 Flat Washer, Cadmium-Plated, #10 4 AN960-10L Aircraft Spruce 350.0018 Stop Nut, Cadmium-Plated, 10-32 4 AN365-1032A Aircraft Spruce Table 6: Installation Kit, Part Number 500.0027 (Revision A) 3 General Installation Requirements The installation must be done in accordance with all applicable FARs. The installation shall conform to the data listed in Section 2.1, Data Required for Installation, with exception of special instructions as defined in Section 4, Special Installation Instructions, which shall have precedence over the data listed in Section 2.1. 3.1 Prerequisite This STC installation of the IBBS requires that the Garmin GNS 430W equipment has already been installed into the PA-32 Series aircraft, in accordance with the STC SA01933LA requirements. This STC does not support mounting installation or operation of the Garmin equipment, except for operational checks to show the Garmin equipment receives electrical power through the IBBS. 3.2 Mechanical Mechanical installation, wiring, cable bundling and routing, and connections to existing aircraft systems must conform to those specific instructions or requirements found in the STC data. Those aspects of the STC where specific installation instructions or requirements are not provided in the STC data, the installer shall conform to the recommended practices and procedures found in Advisory Circular (AC) 43.13-1B, Chapter 11, Electrical Systems, Section 3, 4, and 7. 3.3 Hardware Hardware not supplied with the equipment, or otherwise specified in the appropriate installation manuals or other STC data (ie screws, nuts, tie wrap.... etc) shall be from standard aircraft hardware as described by AC 43.13-1B, Chapter 7, Aircraft Hardware, Control Cables and Turnbuckles. 3.4 Wiring All wire used in the installation shall be of appropriate standard aircraft quality grade and size as described in AC 43.13-1B, Chapter 11, Sections 5-20. 3.5 Circuit Protection All circuits modified by this STC shall be protected in accordance with AC 43.13-1B, Chapter 11, Section 4, Circuit Protection Devices. p/n 760.0011 Rev 1.2 Page 7 © 2019 TCW Technologies LLC Master Data List for STC Project ST08596NY-A 3.6 Electrical Load Analysis An electrical load analysis shall be performed on each aircraft, as described in AC 43.13-1B, Chapter 11 Section 3. The Electrical Load Analysis for STC Project ST08596NY-A, document 720.0006, provides specifications on the IBBS power requirements. 4 Special Installation Instructions The installation of the IBBS requires the modification of an existing cover assembly in the cockpit instrument panel. This cover assembly is not included in the STC installation kit, however the instructions for modifying the cover assembly, as well as all of the hardware required to complete the equipment installation is included in the kit. The location of the cover assembly is on the copilot’s instrument panel, to the right and above the copilot’s control yoke, as shown in Figure 1 below. The cover assembly, OEM part number 68851-00, is an aluminum plate, 6½ inches wide by 8.5 inches tall by 0.060” thick. The IBBS is installed on the back side of the cover assembly using the metal flanges located at either end of the IBBS. The backup power master switch and low-voltage warning light emitting diode (LED) are installed on the front side of the cover assembly. Figure 1: IBBS Mounting Diagram for PA-32 (from 725.0007, Revision 1.5) This installation of the IBBS requires the modification of existing wiring which provide electrical power to the Garmin GNS 430W equipment. The STC installation kit includes a pre-built wire harness which must be spliced into the existing wiring on the Garmin GNS 430W. Figure 2 p/n 760.0011 Rev 1.2 Page 8 © 2019 TCW Technologies LLC Master Data List for STC Project ST08596NY-A Figure 2: IBBS Wiring Diagram for PA-32 (from 725.0006, Revision 1.8) 5 Additional System Notes The IBBS has been authorized under Technical Standard Order (TSO) C179a, Permanently Installed Rechargeable Lithium Cells, Batteries, and Battery Systems. The TSO Authorization (TSOA) was completed under a separate certification project, FAA Project PT10025NE. p/n 760.0011 Rev 1.2 Page 9 © 2019 TCW Technologies LLC