LZ design AS 13,5m FES Maintenance Manual Download

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FES MAINTENANCE MANUAL

Version 1.16

For sailplane types:

LAK17A FES, LAK17B FES, MiniLAK FES

Silent 2 Electro FES, AS 13,5m FES

HPH 304ES FES

Discus-2c FES, Ventus-2cxa FES, Ventus 3F

Diana 2 FES

LZ design d.o.o.,

•

Brod 3D, 1370 Logatec, Slovenia

•

tel +386 59 948 898

[email protected]

•

www.front-electric-sustainer.com

Summary of Contents for AS 13,5m FES

Page 1: ...ypes LAK17A FES LAK17B FES MiniLAK FES Silent 2 Electro FES AS 13 5m FES HPH 304ES FES Discus 2c FES Ventus 2cxa FES Ventus 3F Diana 2 FES LZ design d o o Brod 3D 1370 Logatec Slovenia tel 386 59 948 898 info lzdesign si www front electric sustainer com ...

Page 2: ... Ground handling 15 4 2 5 Tie down and ground towing 15 4 2 6 Storing and transportation 16 4 2 7 Cleaning 16 4 2 8 Inspection at the end of flight season 16 4 3 Adjustments 17 4 4 De rigging and rigging of FES components 17 4 4 1 Removing battery packs from the sailplane 17 4 4 2 Removing and installing the motor 18 4 4 3 Mounting and removal of the propeller 19 4 5 Lubrication instructions 19 5 ...

Page 3: ...stomer shall be responsible for any transportation cost This warranty does not cover failures due to abuse misuse accident or unauthorized alterations or repairs If the FES system is installed into the sailplane by authorized company warranty for installation and failure of components as a result of improper installation is this company s responsibility LZ design will not cover failures due to una...

Page 4: ...aunch Sustainer system This information is given following the requirements of EASA CS 22 1529 for sailplane maintenance 3 Description of the FES system We developed the FES system to be reliable and straightforward to use It requires minimal maintenance You must familiarize yourself with the position of all the FES components and their function to conduct maintenance on an FES system 3 1 General ...

Page 5: ...FES Maintenance manual v1 16 May 2020 Page 5 of 24 Connection of the instruments to the FES 12V power supply circuit ...

Page 6: ... required by the motor The following table contains the electrical motor power ratings type FES LAK M100 with 116 V on the motor controller and loaded with a propeller type FES LAK P10 100 FES MOTOR Maximum torque 75 Nm Maximum current 200 A Maximum Voltage 180 V Motor velocity constant 45 RPM V RPM without load 116V DC on the controller 5300 RPM Motor current without load at 5300 RPM 16 18 A Max ...

Page 7: ...ion Each pair of propeller blades is sanded and polished to reduce the mass difference between them to less than 0 2 g The paint is resistant to fuel oil and other chemical products and has excellent flexibility Propeller technical data and limitations FES Propeller Number of propeller blades 2 Maximum power on a propeller shaft 23 kW Maximum rotational speed 4500 RPM 5 Propeller blade mass exclud...

Page 8: ...tch Sunlight readable QVGA LCD 320 240 display Consumption ca 100 mA Audio signal 1 rotary encoder with pushbutton 1 RPM input 2 LED inputs 1 digital output for BRAKE 1 analogue output for POWER adjustable with rotary knob 4 temperature inputs Controller Motor and two battery packs 1 analogue input for measuring current 1 analogue input for measuring voltage 1 RS232 input for firmware update 1 inp...

Page 9: ...he and terminals we chose to use Amphenol Radsok hyperbolic high power contact technology High current sockets are hidden inside of the pack Different sizes of the terminals are used to prevent incorrect polarity connections The minus pole uses an 8mm and the plus pole a 10 3mm socket Technical data of FES GEN2 14S 40Ah Battery packs Battery pack type FES GEN2 14S 40Ah Weight per pack 15 7 kg Box ...

Page 10: ...actor It also charges 12 V battery if installed The main contactor connects and disconnects the FES battery packs to the motor controller A pre charge resistor is also installed The motor controller converts high voltage DC to three phase AC voltage which it feeds to the motor It also sends RPM and controller temperature by the CAN bus to the Flight Control Unit FCU instrument Ventilators provide ...

Page 11: ... brake and a female DB9 connector used when updating the FCU A 12V battery acts as a redundant power supply for the instruments when the main battery packs are not installed The battery must be equipped with a 3A fuse A 325A power fuse protects the entire system in case of a high power short circuit FCU instrument displays battery and propulsion system information to the pilot via the screen and t...

Page 12: ...FES Maintenance manual v1 16 May 2020 Page 12 of 24 3 3 General FES wiring scheme ...

Page 13: ...g leads to secondary damage Note Strong magnetic field of the magnets in the rotor can erase the data on magnetic memory cards or electronic devices and interfere with sensitive medical devices e g pacemakers Keep them away from the rotor s close up range The gap between the stator and the rotor magnet s function boundary is only a few tenths of a millimeter thick The danger of foreign objects acc...

Page 14: ...fore a flight Perform FES test run on the ground as described below 4 2 4 FES test run on the ground 1 Remove propeller covers and a tail dolly 2 Open the battery compartment cover 3 Check that the Power switch is OFF 4 Insert the connecting cable between the battery packs 5 Seal the battery compartment cover with glider tape 6 Take a seat in the glider and close the canopy 7 Check that the propel...

Page 15: ...before the flight Caution Make sure that the propeller is in a horizontal position when lifting the tail of the fuselage i e when attaching the tail dolly Warning Do not push on the propeller or spinner for pushing or pulling the glider or lifting the tail When opening and closing the canopy propeller blades must always be positioned horizontally 4 2 5 Tie down and ground towing Do not leave a FES...

Page 16: ...of propeller blades If you are not using a canopy cover use FES propeller blade covers to prevent the propeller blades from opening when pulling the fuselage out of the trailer The fuselage dolly should be positioned just forward of the main landing gear opening Forward stop or a belt must be provided for the fuselage dolly to prevent the fuselage from slipping forward and leaving it without suppo...

Page 17: ...r instruments are OFF i e Flight computer Flarm Radio Transponder PDA etc 3 Open cover of the battery compartment 4 Unplug the connecting cable between the packs 5 Unplug the RED and BLACK power connectors 6 Secure the power supply cables to the side of the battery compartment box 7 Remove both temperature sensor connectors DATA from each battery pack 8 Secure the temperature sensor cable to the s...

Page 18: ... front pack 11 Insert the BLACK contact pin into the rear pack 12 Close the battery compartment cover 4 4 2 Removing and installing the motor Note Removal of the motor from the sailplane is only allowed with written permission by the manufacturer Unauthorized removal voids the warranty Warning Flights without the motor are not allowed due to a significant change in the centre of gravity C G To rem...

Page 19: ...ling the motor check the following Spinner is in the centre of the fuselage The gap between spinner and fuselage is 0 5 1 mm All bolted connections are assembled correctly and secured properly Do a test run of the motor on the ground and check o Motor rotating direction o Motor running smoothly o Propeller brake works OK o FCU instrument is functioning correctly 4 4 3 Mounting and removal of the p...

Page 20: ...season or before the aircraft is stored for an extended period in a hangar or trailer 5 3 Inspection after every 100 flight hours It is mandatory to check the FES system thoroughly according to the following checklist Inspection after every 100 flight hours Date of inspection No Checking Conformity Yes No Signature 1 FCU instrument wiring and functioning 2 Inspect ventilation opening closing 3 Ins...

Page 21: ...V total voltage displayed in the FCU instrument 6 Parts with limited service life The following FES system parts have a limited service life 12 V Pb battery should be replaced every 5 years if installed in a glider Replace other components of the FES system based on their condition 7 Placards Sailplanes equipped with the FES system require additional placards in the cockpit Ventilation open and ve...

Page 22: ...briefly and then stops unexpectedly Check power switch flip it OFF an ON a few times Please use the following template when you are reporting a problem with the FES system FCU serial number FCU software version With power switch OFF Are battery pack temperatures available Is the motor temperature available With power switch ON and the motor stopped Does the OK LED on the FCU light up Does the FCU ...

Page 23: ...here is plenty of information available on the web about proper soldering techniques here are just a few key tips Use quality soldering iron or soldering station http en wikipedia org wiki Soldering_iron Keep the iron tip clean A clean iron tip means better heat conduction and a better bond Use a wet sponge to clean the iron tip between the soldering of joints Keep the iron tip well tinned Make su...

Page 24: ... The initial release of Maintenance manual Version 1 0 November 2013 Minor updates Version 1 1 June 2015 Minor updates Version 1 11 September 2016 Minor updates Version 1 12 October 2017 Minor updates Version 1 13 March 2018 Minor updates Version 1 14 May 2020 Proofreading Version 1 16 ...

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