DUC HELICES FLASH-2, FLASH Flash Manual

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Chemin de la Madone - 69210 LENTILLY - FRANCE Phone: + 33 (0)4 74 72 12 69 - Fax: +33 (0)4 74 72 10 01 E-mail: [email protected] - www.duc-helices.com

ISO 9001:2008 Certified Company for its Quality System Management

DH_FSH_BE_01_F Made in France 09/10/2013

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This instruction manual is to be maintained throughout the life of the propeller.

He may have to evolve. The owner must check with the DUC Hélices company

the latest version being valid applicable to the propeller.

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Identification

Date

Delivery note n°

Owner

Engine/Gearbox ratio

Aircraft

1st recommended pitch blade angle

Notes: ..............................................................................................................................................................................

..........................................................................................................................................................................................

Performances

PITCH (°) at

25cm from the

tip of the

blade

TAKE-OFF DISTANCE

(m)

CLIMB RATE

(ft/min or m/s)

SLOW

CRUISE

(km/h & rpm)

VARIOUS

CRUISE

(km/h & rpm)

FAST

CRUISE

(km/h & rpm)

FULL

THROTTLE

VARIO 0

(km/h & rpm)

Notes (Date, Number of people, Weight, Weather, …): ...............................................................................................

...........................................................................................................................................................................................

Notes (Date, Number of people, Weight, Weather, …): ...............................................................................................

...........................................................................................................................................................................................

Notes (Date, Number of people, Weight, Weather, …): ...............................................................................................

...........................................................................................................................................................................................

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Summary

1. Presentation of the FLASH propeller ......................................................................................................................... 5

1.1. Description ........................................................................................................................................................ 5

1.2. Characteristics ................................................................................................................................................... 5

1.1. Shielding leading edge in Inconel ..................................................................................................................... 6

1.2. Accessories ...................................................................................................................................................... 6

1.1. Sales reference ................................................................................................................................................. 6

2. Applications ................................................................................................................................................................ 7

3. Installation precautions .............................................................................................................................................. 7

4. Components of the FLASH propeller ......................................................................................................................... 8

4.1. Mounting configuration of the FLASH propeller ................................................................................................ 8

4.2. Mounting screws ............................................................................................................................................... 8

4.3. Exploded view for propeller ............................................................................................................................... 9

4.4. List of required tools .......................................................................................................................................... 9

5. Assembly instruction of the propeller ....................................................................................................................... 10

5.1. Assembly of the propeller ................................................................................................................................ 10

5.2. Installation on the aircraft ................................................................................................................................ 11

5.3. Setting of the propeller & Finalization of the installation ................................................................................. 14

6. Precautions .............................................................................................................................................................. 17

7. Indications for testing ............................................................................................................................................... 17

8. Installation without spinner or with spinner other than DUC .................................................................................... 18

9. Potential use & Propeller maintenance.................................................................................................................... 18

9.1. Potential use of the propeller: Unlimited ......................................................................................................... 18

9.2. Propeller maintenance schedule ..................................................................................................................... 18

9.1. Regular maintenance (by the user) ................................................................................................................. 19

9.2. General maintenance (by the user or an aeronautics workshop) ................................................................... 19

9.3. Complete maintenance (by DUC Hélices) ...................................................................................................... 20

10. General terms of sale............................................................................................................................................... 20

10.1. Ordering procedure ......................................................................................................................................... 20

10.2. Delivery ........................................................................................................................................................... 20

10.3. Price ................................................................................................................................................................ 20

10.4. Right of withdrawal .......................................................................................................................................... 20

10.5. Warranties ....................................................................................................................................................... 20

10.6. Privacy Policy .................................................................................................................................................. 20

10.7. Litigation .......................................................................................................................................................... 20

11. Annexes ................................................................................................................................................................... 21

11.1. Dimension of the engine propeller-shaft ......................................................................................................... 21

11.2. Airfoil ............................................................................................................................................................... 22

11.3. Moment of inertia of the FLASH propeller ....................................................................................................... 22

11.4. Operating limitation of the FLASH propeller ................................................................................................... 22

11.5. Identification marking of the propeller ............................................................................................................. 23

11.6. Calculation of the centrifugal force of the FLASH Inconel blade .................................................................... 24

11.7. Centrifugal force test under EASA CS-P350 specification ............................................................................. 24

11.8. Breaking test of the two-blade Inconel FLASH propeller ................................................................................ 25

11.9. Declaration of conformance of the FLASH propeller ...................................................................................... 27

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1. Presentation of the FLASH propeller

rpm

efficiency ƞ

1.1. Description

The FLASH propeller range is has a new innovative design, specific about its twisting axis and center of pressure.

Its aerodynamic design allows a "constant speed" effect, limiting variations in engine speed between on ground and in flight.

These propellers allow for high efficiency throughout the flight envelope i.e.:

 Improved takeoff and climb rate due to higher engine speed, then higher engine efficiency  Many cruise extension  A high user comfort

The blades and the hub of the FLASH propeller range are manufactured according the DUC Hélices company technologies, from unidirectional layers of carbon fibers prepreg epoxy resin.

Their composite structures are defined to obtain the maximum stresses in torsion and bending. Therefore "constant speed" effect is not related to deformation of the blade but its geometry and specific profile.

Due to its specific geometric definition, excellent performance is obtained in

both aerodynamic and acoustic, but also in consumption.

1.2. Characteristics

The FLASH propeller range is available:

 Tractor or pusher configuration (available in right & left rotation)  Diameters Ø1520, Ø1620, Ø1660, Ø1730, Ø1850mm and others tailor made

Ø59.8 Ø63.8 Ø65.4 Ø68.1 Ø72.8"

 Two-blade & Three-blade – FLASH 3.35 & 4.40 kg (7.39 & 9.70 lb.)

FLASH-2 3.45 & 4.53 kg (7. 61 & 9.99 lb.)

 Shielded leading edge in Inconel®  Carbon composite hub with metallic inserts  Direct assembly on the propeller-shaft Ø101.6mm  Excellence version “FLASH-R”:

 Longitudinal reinforced carbon structure  Higher bending strength  Titanium color finishing  Advanced controls

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Designation

Reference

Part number

Two-blade Inconel FLASH propeller, Right

01-19-001

H-FSH_2-D-I

Two-blade Inconel FLASH propeller, Left

01-19-002

H-FSH_2-G-I

Two-blade Inconel FLASH-R propeller, Right

01-20-001

H-FSH_2-D-R_I

Two-blade Inconel FLASH-R propeller, Left

01-20-002

H-FSH_2-G-R_I

Three-blade Inconel FLASH propeller, Right

01-21-001

H-FSH_3-D-I

Three-blade Inconel FLASH propeller, Left

01-21-002

H-FSH_3-G-I

Three-blade Inconel FLASH-R propeller, Right

01-22-001

H-FSH_3-D-R_I

Three-blade Inconel FLASH-R propeller, Left

01-22-002

H-FSH_3-G-R_I

Three-blade Inconel FLASH-2 propeller, Left

01-23-002

H-FSH2_3-G-I

Inconel shielding

1.1. Shielding leading edge in Inconel

The leading edge of the FLASH blades is equipped with a metallic shielding in Inconel®. This material is refractory stainless with a very high hardness of surface.

1.2. Accessories

 Aluminum mounting spacer (Direct mounting on P.C.D Ø101.6mm/Ø4”)

Moves the plane of the propeller to adjust the position according the engine hood

 Aluminum adaptor spacer (Other mounting as SAE1, SAE2, …)  Move the propeller plane and adaptor the P.C.D fixation of the propeller

 Spinner available in diameter Ø250mm (Ø9.8") & Ø340mm (Ø14.4”)  Adjusting tool for the setting of the pitch angle of the blades  Neoprene cover protection of the blade  Cleaning treatment for composite propellers

Save money! A clean propeller is more efficient and decreases the fuel consumption.

1.1. Sales reference

Note:

Specify the flight regulation aircraft (E.g.: Ultra-light, LSA…) and diameter when ordering (E.g.: ref. 01-21-001/1730). For more information about the propeller marking, see section 11.5.

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2. Applications

Engine

Type

Gear

box

Recommended propeller

Propeller

diameter

(inch)

Blade angle

(°)

Blade

angle allowed range(°)

TBO

(hour)

3 AXIS – TRACTOR

ROTAX 912

4 strokes

2.273

2.43

Two-blade Inconel FLASH, Tractor Right

Ø1730

22°

20° → 28°

2000

ROTAX 912S/912iS/914

4 strokes

2.43

Three-blade Inconel FLASH, Tractor Right

Ø1730

24°

22° → 32°

Ø1750

JABIRU 2200

4 strokes

Two-blade Inconel FLASH, Tractor Right

Ø1520

18°

15° → 23°

JABIRU 3300

4 strokes

Two-blade Inconel FLASH, Tractor Right

Ø1620

19°

16° → 24°

UL Power 260i

4 strokes

Two-blade Inconel FLASH, Tractor Right

Ø1520

18°

15° → 23°

UL Power 350iS

4 strokes

Two-blade Inconel FLASH, Tractor Right

Ø1620

20°

17° → 25°

Continental O-200

4 strokes

Three-blade Inconel FLASH, Tractor Right

Ø1660

19°

17° → 25°

Lycoming O-235

Lycoming O-320

4 strokes

Three-blade Inconel FLASH-R, Tractor Right

Ø1850

20°

18° → 26°

Lycoming O-360

4 strokes

Three-blade Inconel FLASH-R, Tractor Right

Ø1900

20°

18° → 26°

3 AXIS – PUSHER

ROTAX 912

4 strokes

2.273

2.43

Three-blade Inconel FLASH, Pusher Left

Ø1730

22°

20° → 28°

2000

Three-blade Inconel FLASH-2, Pusher Left

Ø1730

21°

19° → 27°

ROTAX 912S/912iS/914

4 strokes

2.43

Three-blade Inconel FLASH, Pusher Left

Ø1700 Ø1730 Ø1750

22°

20° → 28°

Three-blade Inconel FLASH-2, Pusher Left

21°

19° → 29°

AUTOGYRO & TRIKES

ROTAX 912S/912iS/914

4 strokes

2.43

Three-blade Inconel FLASH, Pusher Left

Ø1700 Ø1730 Ø1750

22°

20° → 28°

2000

Three-blade Inconel FLASH-2, Pusher Left

21°

19° → 29°

BMW R12000 GF de SECOP

4 strokes

2.7

Three-blade Inconel FLASH, Pusher Right

Ø1750

22°

20° → 28°

OTHER APPLICATIONS

For all other applications, thank you to contact the DUC Hélices company to study the possibility of adapting the FLASH propeller.

The DUC propellers have an unlimited flight potential in normal operation. To keep the unlimited potential, DUC Hélices defined a TBO (Time Between Overhaul) for a propeller depending on its engine. Refer to section 9. Potential use & Propeller maintenance for more information.

* Ø1850mm = 72.83"; Ø1730mm = Ø68.12»; Ø1660mm = Ø65.4»; Ø1620mm = Ø63.8»; Ø1520mm = Ø59.8"

Remark

The values of the pitch angle are theoretical and associated with the engine. This setting should be adjusted according to the aircraft (see section 7. Indications for testing).

For proper use of the propeller, refer to section 9. Potential use & Propeller maintenance.

3. Installation precautions

WARNING Make sure the ignition is turned off before starting any type of operation on the propeller.

Do not run the engine without propeller, engine damage will result.

IMPORTANT The blades of a propeller are part of a whole. DO NOT INTERCHANGE with other similar blades from

propeller. The propeller blades are manufactured to their application. Their structure, weight and balance are different from a propeller to another.

The spinner is an important element for cooling the engine. The aircraft must not fly without a spinner.

Fitting a different spinner will be an addendum to this manual approved by the DUC to confirm its compatibility with the mounting of the propeller.

The propeller is delivered with the appropriate screws. The change of the screws is contrary to our recommendations unless

validated by the manufacturers.

WARRANTY CONDITIONS The user is still flying under its full responsibility (see 10. General terms of sale).

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MOUNTING

ENGINE PROPELLER-SHAFT

Ø4" / Ø101.6mm

(Ex: Rotax, Jabiru)

Type SAE 1

Ø4-3/8" / Ø111.125mm

(Ex: Continental O-200)

Type SAE2

Ø4-3/4" / Ø120.65mm

(Ex: Lycoming O-360)

Other

≠ Ø101.6mm

direct on propeller-

shaft (without spacer)

with spacer

with adaptor spacer

X X

Hub assembly:

Screws CHC M8, Nylstop locking nuts & pin contact washers Propeller fixation:

Screws CHC M8 (Screw length adapted according the mounting direct or with spacer)

Hub clamping washer:

Aluminum with holes Ø8mm on P.C.D. Ø101.6mm

Hub assembly: Screws AN5, locking nuts & standard washers

Propeller fixation: SAE1: Screws AN6 (3/8") SAE2: Screws AN8 (1/2") (Screw length adapted according the length of the spacer)

Hub clamping washer: Aluminum SAE1: Holes for screws AN6 (3/8") on P.C.D. Ø4-3/8" (Ø111.125mm) SAE2: Holes for screws AN8 (1/2") on P.C.D. Ø4-3/4" (Ø120.65mm)

4. Components of the FLASH propeller

The FLASH & FLASH-2 propellers are available in several versions and can be mounted on different model of engine.

4.1. Mounting configuration of the FLASH propeller

Here is a configuration table of the FLASH propeller mounting according the propeller-shaft of the engine. If needed, see annex 11.1. Dimension of the engine propeller-shaft.

4.2. Mounting screws

Rotax/Jabiru mounting 4.2.1.

SAE1/SAE2 mounting 4.2.2.

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4.3. Exploded view for propeller

Rotax/Jabiru mounting

SAE1/SAE2 mounting

M8 Torque Hex key (Tightening range: 22 to 30 Nm) M8 Torque Wrench (Tightening range: 22 to 30 Nm) Inclinometer (pitch adjusting tool) Plastic mallet Torque Screwdriver (Tightening: 4 Nm)

M8 Torque Hex key (Tightening range: 22 to 30 Nm) M8 Torque Wrench (Tightening range: 22 to 30 Nm) 3/8 or 1/2 Torque Wrench (Tightening range: 30 to 45 Nm) Inclinometer (pitch adjusting tool) Plastic mallet Torque Screwdriver (Tightening: 4 Nm)

FLASH blade (x2 or x3)

Screws & washers for hub assembly (x6)

Hub camping washer (x1)

Locking nuts & washers for hub assembly (x6)

Rear half-hub (x1) with rear metallic inserts (x6)

Fixing screws and washers of the propeller adapted according the mounting (x6)

Internal hub spacer (x1)

Caution when handling the blades CUTTING TRAILING EDGE

Front half-hub (x1) with front metallic inserts (x6)

Remark

This exploded view shows the principle of the FLASH propeller assembly. The size of all of these components changes depending on the configuration of the propeller (diameter hole of the metallic inserts of the half-hub, length of the screws…).

4.4. List of required tools

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5. Assembly instruction of the propeller

The assembly of the FLASH propellers is shown below. It is recommended to assemble the propeller on a worktable before installing it on the plane. The procedure is the same for two-blade and three-blade FLASH propellers.

For further information, contact the DUC Hélices Company.

5.1. Assembly of the propeller

STEP 1.

Place the rear half-hub on a worktable. Be careful not to invert with the front hub half.

Depending on your installation, the rear half-hub is one mounted on the propeller-shaft of the engine or on a spacer. The holes of the metal inserts of the rear halfhub are higher than the holes of the metal inserts of the front half-hub.

STEP 2.

Place the hub spacer in the center of the rear half-hub.

STEP 3.

STEP 4.

Place the front half-hub (metal insert with small hole) on the set to fit with the blade foots.

STEP 5.

From the front hub, set up the 6 screws and washers for hub assembly. At the rear, place washers and lock nuts.

Perform initial moderate tightening.

STEP 6.

Positioning the blades in their hub slots by placing them outwards.

Orient the logo facing you. DUC Hélices

Note that the metal inserts of the half-hub allow a locking of the blades in their axis within the hub.

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Place the hub clamping washer on the front of the propeller hub (side logo).

Be sure the direction of the clamping washer (rounded edge outwards).

Place the 6 fixing screws and their washer.

In the case of pin contact washers (Rotax/Jabiru mounting), the pins are oriented towards the screw head.

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TIGHTENING TORQUE

3.0 Kg/m 30 N.m

5.2. Installation on the aircraft

Assembly of the two-blade or three-blade hub

Propeller fixing:

Screws CHC M8 & pin contact washer (length adapted according the indexing paws of the propeller-shaft)

Threaded paws (Ex: ROTAX): Screw CHC M8x130mm Ø8 hole paws (Ex: JABIRU): Screw CHC M8x140mm

14 mm

5 mm min.

TIGHTENING TORQUE TWO-BLADE HUB

2.5 Kg/m 25 N.m

As presented in section 4.1. Mounting configuration of the FLASH propeller, several mounting are possible:

1. Installing directly on propeller-shaft of the engine

2. Use a spacer for spacing propeller from the propeller-shaft

3. Use an adaptor spacer to adjust the diameter fixing of the propeller and for spacing the propeller from the propeller-shaft

Direct installation on the aircraft 5.2.1.

The direct installation of the FLASH propeller is possible only with the following conditions:

 Engine propeller-shaft type Rotax or Jabiru (6 indexing paws Ø13 or Ø14mm on P.C.D. Ø101.6mm/Ø4")  Engine propeller-shaft out of the engine hood of 14mm for the mounting of the DUC spinner

If needed, see in annex 11.1. Dimension of the engine propeller-shaft. Remark: All engines having a propeller-shaft with a P.C.D. Ø101.6mm/Ø4" can install the FLASH propeller directly.

The holes of the metal inserts of the rear half-hub must be adapted to suit with the indexing paws of the propeller-shaft. For further information, contact the DUC Propellers.

2.2 Kg/m 22 N.m

TIGHTENING TORQUE THREE-BLADE

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TIGHTENING TORQUE

3.0 Kg/m 30 N.m

Engine

Model

Length

ROTAX

912H spacer

6, 20, 30, 50, 60, 70, 80, 120mm

JABIRU

JABIRU spacer

6, 20, 30, 50, 60, 70, 80, 120mm

Assembly of the two-blade or three-blade hub

Propeller fixing:

Screw CHC M8 & pin contact washer (screw length adapted according the length of the spacer)

Consult the installation instructions of the spacer for more information.

Propeller-shaft not

outside the engine hood

14 mm min.

TIGHTENING TORQUE TWO-BLADE HUB

2.5 Kg/m 25 N.m

Use of an spacer 5.2.2.

A spacer is necessary in the following case:

 Engine propeller-shaft type Rotax or Jabiru (6 indexing paws Ø13 or Ø14mm on P.C.D. Ø101.6mm/Ø4")  Engine propeller-shaft placed inside the engine hood or not place at more than 14mm

Determination of the spacer length: Measure the distance X between the propeller-shaft and the engine hood limit, then add 14mm.

Available spacer:

Presentation of the installation

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2.2 Kg/m 22 N.m

TIGHTENING TORQUE THREE-BLADE

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TIGHTENING TORQUE 3.0 Kg/m 30 N.m

Consult the installation instructions of the adaptor spacer for more information.

Use of adaptor spacer 5.2.3.

Engine

Model

Length

Continental O-200 / Lycoming O-233

SAE1 adaptor spacer

30, 70, 100mm

Lycoming O-360

SAE2 adaptor spacer

30, 70, 100mm

Assembly of the two-blade or three-blade hub

Fixation of the adaptor spacer

SAE1: Screw AN6 / SAE2: Screw AN8 (screw length adapted according the adaptor spacer length and the starter flange on the propeller-shaft)

Propeller fixing: SAE1: Screw AN6-51 / SAE2: Screw AN8-51

Remark: It is imperative to use a spinner when using propeller FLASH. The mounting plate of the spinner can be placed before or after the spacer adaptation. It is necessary to adapt the mounting in function of its position.

Propeller-shaft not

outside the engine hood

14 mm min.

TIGHTENING TORQUE

ADAPTOR SPACER

AN6 (3/8"): 3.0 Kg/m 30 N.m AN8 (1/2"): 4.5 Kg/m 45 N.m

TIGHTENING TORQUE

PROPELLER FIXING

AN6 (3/8"): 3.0 Kg/m 30 N.m AN8 (1/2"): 4.5 Kg/m 45 N.m

An adaptor spacer is necessary in the following case:

 Engine propeller-shaft different than the type Rotax or Jabiru (other than P.C.D. Ø101.6mm/Ø4") If needed, see in annex 11.1 Dimension of the engine propeller-shaft. Determination of the adaptor spacer length:

Measure the distance X between the propeller-shaft and the limit of the engine hood, then add 14mm.

Available adpator spacer:

Presentation of the installation

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At this point, the propeller is installed on your aircraft with the spinner mounting plate.

If the propeller is already assembled and the blades angle set, pass directly STEP 7.

Otherwise, follow all the steps below to adjust the pitch angle before the final tightening of the screw.

A reminder of the definition of the airfoil and its vocabulary is presented in annex

11.2. Airfoil.

Side view

Front view

90°

Propellershaft plate

0°

90°

(90° - X)

25 cm

5.3. Setting of the propeller & Finalization of the installation

STEP 1.

For the setting, the concerned blade must be place in horizontal position. The setting is done with the adjusting tool flatten against the intrados (leading edge up) at 25 cm from the blade tip.

The attack angle is formed by the vertical and the intrados of the blade. To do this, place your aircraft horizontally, so that the propeller shaft is perfectly vertical. Check with the level of the adjustment tool (measured value = 90°). If unable to change the longitudinal axis of the

aircraft, raising the value of the X angle propeller shaft plate to subtract the value of the blade angle to be resolved.

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STEP 2.

Slightly untighten the propeller fixing screws and the hub assembly screw.

The accuracy of the adjustment tool is 0.2°. This is defined by the tolerance of the visual position of the bubble between the two lines.

Adjustment roller of the leading edge

Reading blade angle

Intrados of the blade with the leading edge upwards

Horizontal blade

25 cm

STEP 3.

Horizontal blade, leading edge upward, place the adjustment tool at 25 cm from the tip of the blade, intrados side (flat), handle down.

STEP 4.

Set the desired value of the adjustment tool.

Caution to apply the value X if a correction of the aircraft plan was needed.

STEP 5.

Correct the position of the bubble on the adjustment tool by rotating the blade in the hub. To do this, using a mallet, lightly tap on the foot of the blade in the desired direction.

Do not apply pressure near the trailing edge, thinner area.

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Once the desired pitch angle obtained, slightly tighten the assembly screws of

the hub, those around the foot blade and then perform the same operation on

each of the other blades.

IMPORTANT

After a 1 hour operation following the installation or modification of the assembly, recheck the assembly of your propeller according the instructions

manual using appropriate tools (tightening torque, pitch angle…).



At this point, the FLASH propeller is ready for first tests.

TIGHTENING TORQUE

Screw assembly of the two and three-blade hubs = 30 Nm (3.0 kg/m)

Propeller fixing screws

Direct mounting/Spacer

Adaptor spacer mounting

Two-blade screw CHC M8 = 22 Nm (2,2 kg/m)

Three-blade screw CHC M8 = 25 Nm (2.5 kg/m)

Screw AN6 (3/8") = 30 Nm (3 kg/m)

Screw AN8 (1/2") = 45 Nm (4.5 kg/m)

STEP 6.

STEP 7. Remove the adjusting tool from the propeller then perform a first tightening of the bolts manually.

Then, carry out a progressive tightening of all the screws by applying the correct torque with a torque wrench:

STEP 8.

After a final verification (position and orientation of parts, tightening...), mount the spinner on the mounting plate by tightening the spinner screws to a torque of 4Nm (0.4kg/m) with the appropriate tools.

In the presence of a marking, please respect the indexing of the spinner from its plate.

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6. Precautions

IMPORTANT

After a 1 hour operation following the installation or modification of the assembly, recheck the assembly of your propeller according the instructions manual using appropriate tools (tightening torque, pitch angle…).

PRECAUTIONS

If you notice any abnormal installation or operation, do not undertake the flight and immediately contact the DUC Hélices company.

Being aware of potential risks during assembly and initial testing of the propeller. Stay focused, attentive and vigilant to your environment. Recheck several times points to be observed. Maintaining high safety clearance during the set operation.

The products of the DUC Hélices company must be installed and used according to the instruction manuals provided. No modification can be made without the agreement of DUC Hélices company. The non-compliance of these data assumes no responsibility for the DUC Hélices company and makes out the warranty of the considered products (See section 10. General terms of sale).

7. Indications for testing

INDICATIONS FOR TESTING

The tests are important. It is normal to make several adjustments successive alternating ground and flight tests.

PRELIMINARY TEST to secure the 1st flight (Ground Test)

- Immobilized your aircraft, brakes locked. Apply the manufacturer's recommendations for safety.

- Turn the engine on, warm it up.

- Full throttle, the engine must be at least 85% of maximum engine speed recommended by the manufacturer in flight. If this is not the case, adjust the blade pitch angle.

Increase pitch angle to reduce engine speed (and vice versa). 1° of pitch angle affects approximately 200 rpm engine speed.

VALIDATION TEST of the pitch angle setting (Flight Test)

- Check all tightening. Take off and place the aircraft in stabilized flight, vario zero.

- To take off, it is not recommended to throttle, brake applied and then releases the brakes. You must put the throttle gradually, brake released. The propeller has a constant speed effect, so this second way avoids cavitation takeoff. Furthermore, this method allows shorter takeoffs.

- Full throttle, the maximum engine speed recommended by the manufacturer must be reached but not exceeded. If this is not the case, adjust the blade pitch angle.

Increase pitch angle to reduce engine speed (and vice versa). 1° of pitch angle affects approximately 200 rpm engine speed.

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Page 18

In the case of installation of the propeller without spinner mounting plate or other spinner mounting plate, be careful to check the following points:

 Length of the fixing screws of the propeller: Must be adapted according

the thickness of the spinner mounting plate.

 Mechanical resistance of the plate when tightening: For a similar

assembly of the DUC spinner, the plate takes the tightening of the propeller fixing screws. It is therefore necessary to ensure that the used plate can withstand the clamping and resist of the propeller operate efforts (crushing of the plate).

Type

Actor

Frequency

Regular

User

Each pre-flight

General

user or an aeronautics workshop

Every 100 hours or annually

Complete

DUC Hélices company

Each TBO

8. Installation without spinner or with spinner other than DUC

IMPORTANT

The spinner is an important element for engine cooling.

The aircraft must not fly without propeller spinner. Mounting a different cone will be an amendment to this instruction manual approved by the DUC in order to confirm its compatibility mounting the propeller.

WARRANTY CONDITIONS

The user is still flying under its full responsibility (see section 10. General terms of sale).

9. Potential use & Propeller maintenance

9.1. Potential use of the propeller: Unlimited

The DUC propellers have an unlimited flight potential in normal operation.

To keep the unlimited potential, DUC Hélices has defined a TBO (Time Between Overhaul) for a propeller depending on its engine. This TBO according the engine is indicated in this manual (see 2. Applications). In all cases, it may not exceed 5 years.

When more intensive use (flight school...), the value of the TBO can be doubled maintaining control at least every 2 years.

To achieve this, we propose to return the propeller to make a full control and ensure its proper use. If no critical anomaly is detected, it is again credited with the same TBO and is returned to you.

As a reminder, there is no imperative logbook. But know that this control is offered as a service to our customers for continuing airworthiness and there is no obligation. In fact, security will not be affected. The deliveries costs of sending and returning will be payable by the customer.

9.2. Propeller maintenance schedule

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9.1. Regular maintenance (by the user)

For a safety use of the FLASH propellers, it is necessary that the user performs regular maintenance to detect any abnormalities. This maintenance is usually just a simple check.

Frequency of checking: Each pre-flight Control methods: Visual inspection & Manual handling Checkpoints:

- Fixation of the propeller: Manually maintaining the tip of a blade of the propeller, shake it firmly to feel if a too much clearance appears in the setting of the propeller.

- Degradation of material: Check visually the entire propeller without dismantling (blade root, Inconel leading edge, surface of the blade, spinner, hub, etc.)

- Fixation of the spinner: Check visually the fixation screws of the spinner. A marking paint can be made between each screw and spinner to have a means of visual inspection of proper tightening the screws.

Possible problems:

- Too much clearance in the propeller fixation

- Surface degradation due to dirt or impact / Crack apparent

Corrective actions (depending on the importance):

1. Clean the propeller with the DUC cleaning treatment DUC (ref. 01-80-003)

2. Perform a repair with the DUC repair kit (ref. 01-80-004)

3. Tighten the screws to proper torque with wrench

4. Replace(s) damage component(s)

5. Contact DUC Hélices to define a solution

9.2. General maintenance (by the user or an aeronautics workshop)

A general maintenance by the user or an aeronautics workshop must be made at lower frequency.

Frequency of checking: Every 100 hours or annually Control methods: Visual inspection & Torque wrench Checkpoints:

- Fixation of the propeller: By removing the spinner of the propeller, check the proper tightening of the screws to the wrench. These screws of the hub should be tightened to proper torque, defined in the installation instructions attached. A marking paint of all the screw/washer/hub after tightening can be done to help make a visual check outside of the general maintenance.

- Degradation of material: Check visually the entire propeller (blade root, Inconel leading edge, surface of the blade, spinner, hub, etc.)

Possible problems:

- Too much clearance in the propeller fixation

- Surface degradation due to dirt or impact / Crack apparent Corrective actions (depending on the importance):

1. Clean the propeller with the DUC cleaning treatment DUC (ref. 01-80-003)

2. Perform a repair with the DUC repair kit (ref. 01-80-004)

3. Tighten the screws to proper torque with wrench

4. Replace(s) damage component(s)

5. Contact DUC Hélices to define a solution

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9.3. Complete maintenance (by DUC Hélices)

Upon reaching the TBO (potential flight time between overhaul) defined by DUC Hélices, the propeller must be returned to the corporation for a full inspection of all components of the propeller.

See section 2. Applications for the potential value of an hour's flight engine. The possible degradation of the propeller components may vary depending on the location of use.

10. General terms of sale

10.1. Ordering procedure

Orders placed by fax, by phone or mail server engage the customer upon receipt by our Customer Service Order and the Regulations.

10.2. Delivery

DUC Hélices Company agrees to make every effort to deliver the order within the shortest time, and the receipt of the order together with the Regulation. The delivery times indicated on the order are only indicative and the possible delays do not entitle the buyer to cancel the sale, to refuse the goods or claim damages. Any claim for non-compliance or failure will be sent within one week following the date of receipt of order. The DUC Hélices Company is released from its obligation to deliver for all fortuitous events or force majeure. As an indication, the total or partial strikes, floods, fires are cases of force majeure. The transfer of ownership of goods supplied or delivered is suspended until full payment of price by the customer and without affecting the transfer of risk.

10.3. Price

The DUC Hélices Company may change its prices at any time. The customer agrees to pay the purchase price in effect at the time of order entry. Regulation Order is payable in advance in one payment when sending the DUC Hélices Company purchase order.

10.4. Right of withdrawal

Under Article L121-16 of the Consumer Code, the customer shall have seven clear days after the delivery of his order to return the products to the DUC Hélices Company for exchange or refund, without penalties except for the return costs. Returned products must not have suffered modification, damage consequence of shock or improper use and be packaged in original packaging. Goods shipped with postage due will not be accepted.

10.5. Warranties

The DUC Hélices Company's products must be installed and used in accordance with instruction manuals provided. No changes can be made without the prior approval of the DUC Hélices Company. The failure of these data releases any liability of the DUC Hélices Company and makes non-warranty the considered products. The user is still flying under its sole responsibility. The legal guarantee of industrial products is six months or for the potential duration of the helix (depends on which engine it is installed) against defects and hidden defects. See the section 2. Applications to determine the potential value of an hour's flight engine. DUC Hélices Company guarantees its product defect under normal use in the manner described below: If the customer finds a defect, he must report it immediately to the DUC Hélices and features of one months after its purchase to return to society DUC Helices, all structural defects will snuff into account (except for damage result of incorrect operation, shock, injury, impairment or neglect, water or generally inappropriate use by the engine type, power, speed and gear). To qualify for this warranty, the customer must send at its expense within one month after its purchase to be returned to society with DUC Hélices delivery order attached to the product. In return, the DUC Hélices Company takes no responsibility for damage or loss during transit due to improper or inadequate packaging. The company DUC Propellers then returned at his expense to the customer at the address on the delivery note, an identical or equivalent. In addition to these guarantees, the company DUC Hélices provides no other warranties.

10.6. Privacy Policy

All the data you entrust to us are able to process your orders. Under Law No. 78-17 of January 6, 1978 relating to data, files and freedoms you have with the customer service company DUC Hélices right to access, review, correct, correct and delete data you

have provided.

10.7. Litigation

Any order placed convincing the customer, without any restriction, the General Conditions of sale of the DUC Hélices Company. Any dispute concerning the sale (price, GTS, product ...) will be subject to French law before the Tribunal de Commerce de Lyon.

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11. Annexes

ROTAX 912S engine propeller-shaft

JABIRU 2200 engine propeller-shaft

UL Power engine propeller-shaft

Lycoming O-235-H2C engine prop-shaft, type SAE 1

Lycoming O-320-A2A engine prop-shaft, type SAE 2

Lycoming O-360-A3A engine prop-shaft, type SAE 2

11.1. Dimension of the engine propeller-shaft

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Type of propeller

Diameter (mm)

Inertia (kg.cm²)

Three-blade Inconel FLASH

Left & Right

1620

3457

1660

3586

1700

3722

1730

3817

1750

3882

1850

4211

1900

4375

Designation

Maximum

engine power

Maximum

rotational speed

Two-blade Inconel FLASH propeller, Right & Left

140 hp

3400 rpm

Two-blade Inconel FLASH-R propeller, Right & Left

160 hp

3000 rpm

Three-blade Inconel FLASH propeller, Right & Left

160 hp

3400 rpm

Three-blade Inconel FLASH-R propeller, Right & Left

215 hp

3000 rpm

Three-blade Inconel FLASH-2 propeller, Left

160 hp

3400 rpm

Axis of propeller carrier plate completely vertical

Intrados

Extrados

Leading edge

Advancement of the aircraft

Trailing edge

Attack angle

Side view

11.2. Airfoil

11.3. Moment of inertia of the FLASH propeller

11.4. Operating limitation of the FLASH propeller

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11.5. Identification marking of the propeller

FLASH Left blade (All version)

FLASH Right blade (All version)

Half-hub (2 and 3-blade)

1st line: Part number of the propeller model

Two-blade (2) or Three-blade (3)

Left (G) or Right (D)

Reinforced structure (R) and/or Inconel leading edge (I)

Diameter in mm

2nd line : Propeller data

Serial number of the propeller (not only the component)

Value of the static balancing of each blade of the prop

Propeller version

Label Propeller version

Label

Two-blade Inconel FLASH propeller, Right

Three-blade Inconel FLASH propeller, Right

Two-blade Inconel FLASH propeller, Left

Three-blade Inconel FLASH propeller, Left

Two-blade Inconel FLASH-R propeller, Right

Three-blade Inconel FLASH-R propeller, Right

Two-blade Inconel FLASH-R propeller, Left

Three-blade Inconel FLASH-R propeller, Left

Three-blade Inconel FLASH-2 propeller, Left

P/N: H-FSH_3-D-R_I-1730

S/N: XXXX EQ-003: XX

Manufacturing label 11.5.1.

As the propeller is dismountable, each component (blade and half-hub) has a manufacturing traceability label which identifies the component and specifies its own serial number:

Propeller label (for LSA certified version) 11.5.2.

At the end of the manufacturing, a 2nd label - the propeller label - is placed on each components of the propeller (blade and half-hub) with the following information:

Here is an example for each versions of the FLASH propeller possible:

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ENGINE

PROPELLER

CENTRIFUGAL FORCE

Type

RPM

max

(rpm)

Red.

RPM

Red

(rpm)

hélice

(mm)

pale

(mm)

( m/s )

(kg) F (N)

FoS(2)

(N)

ROTAX 912

6000

2.273

2643

2-Ø1730

209

263.6

72.93

1.020

20 578

41 157

ROTAX 912S/914

6000

2.43

2469

3-Ø1730

209

263.6

68.12

1.020

17 958

35 916

FoS(2)

: Centrifugal force with factor of

safety 2 (RPM)

RPM

max

: Maximum engine speed (RPM)

hélice

: Propell er diameter (mm)

F : Centrifugal force (N)

pale

: Gravity center position on the blade (mm)

RPM

red

: Propell er rotation s peed (RPM)

RG : Radius of the gravity center of the blade (mm)

Red. : Gear box ratio

FoS(2)

: Centrifugal force with factor of

safety 2 (RPM)

F : Centrifugal force (N)

M : Weight of the blade (kg)

FoS(2)

: Centrifugal force with factor of

safety 2 (RPM)

hélice

: Propell er diameter (mm)

F : Centrifugal force (N)

pale

: Gravity center position on the blade (mm)

RG : Radius of the gravity center of the blade (mm)

V : Linear s peed in tip bl ade of the propeller (m/s)

Force sensor

Tested propeller

Traction hydraulic

actuator

11.6. Calculation of the centrifugal force of the FLASH Inconel blade

The centrifugal force undergoes by the FLASH blade was calculated for the most soliciting configuration, i.e. engine Rotax 912 (80hp).



Calculation of the centrifugal force:  







11.7. Centrifugal force test under EASA CS-P350 specification

Standard reference:

EASA Certification Specifications for Propeller CS-P

Test method: The test of centrifugal force propeller is defined by the certification specification of propeller CS-P 350. Its objective is to demonstrate its compliance with the certification specification of propeller (CS-P) defined by the European Aviation Safety Agency (EASA). After the test, the propeller must show no evidence of fatigue, failure or permanent deformation that would result in a major or hazardous effect on the propeller. It is considered that this test is used to validate the mechanical strength of the propeller, i.e. to confirm the manufacturing process thereof.

Objective: This test is conducted with the Inconel FLASH propeller, Ø1730mm which is representative of its mounting on the engine Rotax 912 (80hp). This engine is the most penalizing for the propeller due to its rotation speed. Thus, the test is used to validate all configurations below that selected. In addition, all using the same propeller design and the same manufacturing technology will be considered consistent with values similar or lower than those of the test.

Tested sample: Two-blade Inconel FLASH propeller Ref. 01-19-001 P/N: H-FSH_2-D-I S/N: 003

Procedure:

Applying a charge for 1 hour = 2 x maximum centrifugal load = 41 157 N

Test bench:

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Test performing:

1 000

2 000

3 000

4 000

5 000

6 000

Force (dN)

Time

FLASH Centrifugal force test (CS-P350)

1 hour at 42 000 N

Results: Obtained by visual analysis, no damage or failure was observed during and after the centrifugal load test.

Declaration of conformance:

The centrifugal load test according to specification EASA CS-P 350 leads to the conclusion that the propeller is properly sized and is designed to operate on a similar installation (or less soliciting) of ROTAX 912 engine, soliciting the blade in a centrifugal force of 20 578 N.

11.8. Breaking test of the two-blade Inconel FLASH propeller

Reference: Extract from the SOPAVIB test report n° R6375973-002-1

Purpose of the test: Tensile test to rupture

Tested sample: Two-blade Inconel FLASH propeller Ref. 01-19-001 P/N: H-FSH_2-D-I S/N: 003

Testing method: The tested propeller is placed between the fixed part and the movable part of the lab bench traction. Applying of the following sequence:

 Progressive increase of the load of 42 000 N in 120s (350N/s)

 Hold 42 000 N during 60 minutes

 Progressive increase of load to reach the break

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100

110

120

130

0 500 1000 1500 2000 2500 3000 3500 4000

Force (kN)

Time (s)

FLASH breaking test

1 hour at 42 000 N

Breaking at 123 758 N

Results: At the end of the level at 42 000 N, no defect was found. The test was continued until failure. The curve below shows the traction load applied to the propeller according the time.

Analysis of the specimen

Conclusion The failure of the blade occurred at the foot, like expected, to an effort of 123.7 kN, i.e. more than 12 tons of load.

However, it was found in annex 11.6 Calculation of the centrifugal force of the FLASH Inconel blade that the maximum effort in centrifugal, with safety factor of 2 (the standard required under EASA CS-P350), does not exceed 41 157 N.

Therefore, we can confirm the correct size of the FLASH propeller for all applications with a safety factor of 6.

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11.9. Declaration of conformance of the FLASH propellers

Design and Construction 11.9.1.

The propellers FLASH were designed to be adapted to the applications described in section 0. Every design features are reliable and mastered by DUC Hélices company.

The materials used in the propeller were selected for their technical properties to be conforms to the definition of the propeller and durable during the propeller life.

About the ground adjustable system, the design allows a fine and careful setting of the propeller blade pitch. Also, the system is robust to not change during normal and emergency operation of the propeller and also after many settings.

Definition FLASH propeller conforms to withstand the stresses of operation on all its lifetime. Refer to the centrifugal force test (section 11.6 & 11.7), breaking test (section 11.8) and next section 11.9.2. Tests and Inspections.

Tests and Inspections 11.9.2.

The FLASH propeller completes the tests and inspections described below, without failure or malfunction. Strength Testing:

Proof of strength is presented in section 11.7. Centrifugal force test under EASA CS-P350 specification. The blade root and blade retention system were tested for 1 hour at a load level equal to two times the centrifugal load that would be generated by the blade weight at maximum rated rotational speed. This test was done in a static pull test.

Endurance Testing: The FLASH propeller conforms to endurance test of each application exposed in section 0.

Teardown Inspection: After completion of each test described above, the tested FLASH propeller was completely disassembled and each propeller parts were inspected. No failure or crack was found.

Propeller Adjustments and Parts Replacements: During the tests and inspections carried out, no parts have to be repaired or replaced. All propeller parts resisted the tests and were conform after inspections.

Design Control 11.9.3.

The FLASH propeller was design on CAD software. All the CAD files and 2D drawings are stored in the Design Office of DUC Hélices Company, as the definition of the FLASH configurations. All the technical data (dimensions, materials and processes) are saved in manufacturing procedure. Also, a copy all these data are archived out of the company.

Quality Assurance 11.9.4.

DUC Hélices Company is ISO 9001:2008 certified for its management of the quality system, which ensures manufactured propellers maintain conformity to the established design. Refer to page 2.

Certification of Conformity for ASTM F2506-10 11.9.5.

“ASTM F2506-10 is the standard specification for design and testing of fixed-pitch or ground adjustable for Light Sport Aircraft propellers.

DUC Hélices Company declares that the FLASH propeller complies with the ASTM F2506-10 standard and after verification, it responds every requirement.”

Mr. Vincent Duqueine

Manager

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Chemin de la Madone - 69210 LENTILLY - FRANCE Tél. : + 33 (0)4 74 72 12 69 - Fax : +33 (0)4 74 72 10 01 E-mail : [email protected] - www.duc-helices.com S.A.V. : [email protected]

Entreprise certifiée

ISO 9001:2008

Neoprene cover – Commercial reference: 01-80-002

Degrease your propeller

REDUCE CONSUMPTION

by improving performance

Commercial reference: 01-80-003

Data and pictures included in this instruction manual are exclusively property of DUC Hélices Company. Any part of this manual can be reproduced or transmitted in any form with any means, electronic or manual, for any reason, without written approval of DUC Hélices Company.