LZ design LAK17A FES, LAK17B FES, AS 13, 5m FES, Silent 2 Electro FES Maintenance Manual
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FES MAINTENANCE MANUAL
Version 1.12
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
LZ design d.o.o.,
• Brod 3D, 1370 Logatec, Slovenia • tel +386 59 948 898
info@lzdesign.si • www.front-electric-sustainer.com
FES Maintenance manual Version 1.12 September 2016
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Table of Content
1. Important notices................................................................................................................................ 3
1.1 Limited Warranty ........................................................................................................................... 3
2. Introduction........................................................................................................................................ 4
2.1 Warnings, cautions and notes ......................................................................................................... 4
3. Description of FES system.................................................................................................................... 5
3.1 General layout ............................................................................................................................... 5
3.2 Description of main components ..................................................................................................... 6
3.2.1 Electric motor .......................................................................................................................... 6
3.2.2 Propeller.................................................................................................................................. 7
3.2.3 FCU instrument........................................................................................................................ 8
3.2.4 Battery packs and its chargers .................................................................................................. 9
3.2.5 Wirings.................................................................................................................................. 10
3.3 General FES wiring scheme........................................................................................................... 11
4. FES maintenance............................................................................................................................... 12
4.1 Maintenance of main FES components........................................................................................... 12
4.1.1 Motor maintenance ................................................................................................................ 12
4.1.2 Propeller maintenance............................................................................................................ 12
4.1.3 Battery packs maintenance..................................................................................................... 12
4.1.4 FCU instrument maintenance .................................................................................................. 12
4.2 Normal procedures and inspections ............................................................................................... 13
4.2.1 Rigging and de-rigging of a FES equipped sailplane.................................................................. 13
4.2.2 Daily inspection...................................................................................................................... 13
4.2.3 Pre-flight inspection ............................................................................................................... 13
4.2.4 FES test run on the ground..................................................................................................... 13
4.2.3 After flight inspection ............................................................................................................. 14
4.2.4 Ground handling .................................................................................................................... 14
4.2.5 Tie down and ground-towing .................................................................................................. 14
4.2.6 Storing and transportation...................................................................................................... 14
4.2.7 Cleaning and clean keeping .................................................................................................... 15
4.2.8 Inspection at the end of flight season...................................................................................... 15
4.3 Adjustments ................................................................................................................................ 16
4.4 De-rigging and rigging of sailplane FES parts ................................................................................. 16
4.4.1.1 Taking Battery packs out of sailplane ................................................................................ 16
4.4.1.2 Installation of Battery packs into sailplane ......................................................................... 16
4.4.2 Removing and installing the motor .......................................................................................... 17
4.4.3 Mounting and removal of the propeller .................................................................................... 18
4.5 Lubrication instructions................................................................................................................. 19
5. Periodical inspections......................................................................................................................... 20
5.1 Introducion.................................................................................................................................. 20
5.2 Sailplane inspection periods .......................................................................................................... 20
5.3 Inspection after every 100 flight hours .......................................................................................... 20
5.4 Annual inspection......................................................................................................................... 21
5.5 Inspection after rough landing, after ground loop........................................................................... 21
5.6 Inspection at the end of flight season............................................................................................ 21
6. Parts with limited service life.............................................................................................................. 22
7. Plackards .......................................................................................................................................... 22
8. Balancing of rotating parts ................................................................................................................. 22
9. Repair .............................................................................................................................................. 23
9.1 List of potential issues .................................................................................................................. 23
9.2 List of spare parts ........................................................................................................................ 24
10. Revision history ............................................................................................................................... 26
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1. Important notices
Please read this manual thoroughly. It contains important information about FES
system and its maintenance, having a vital importance to the flight safety.
Information’s in this document are subject to change without notice. LZ design
reserves the right to change or improve their products and to make changes in the content
of this material without obligation to notify any person or organization of such changes or
improvements.
1.1 Limited Warranty
This FES system is warranted to be free from defects in materials or workmanship for
two years from the date of purchase when installed by LZ design. Within this period, LZ
design will, at its sole option, repair or replace any components that fail in normal use.
Such repairs or replacement will be made at no charge to the customer for parts and
labor, however the customer shall be responsible for any transportation cost. This
warranty does not cover failures due to abuse, misuse, accident, or unauthorized
alterations or repairs.
I case that FES is installed to the sailplane by authorized Company, the Company
carries also responsibility and warranty for installation and failures of components, which
could be result of improper installation even if they occur later during normal use (if the
cause of a failure is with wrong installation). LZ design will not cover failures due to
unauthorized installation, alterations or repairs, abuse, misuse, or accidents.
THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE EXCLUSIVE AND IN
LIEU OF
ALL OTHER WARRANTIES EXPRESSED OR IMPLIED OR STATUTORY, INCLUDING ANY
LIABILITY ARISING UNDER ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, STATUTORY OR OTHERWISE. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, WHICH MAY VARY FROM STATE TO STATE.
IN NO EVENT SHALL LZ DESIGN BE LIABLE FOR ANY INCIDENTAL, SPECIAL, INDIRECT
OR CONSEQUENTIAL DAMAGES, WHETHER RESULTING FROM THE USE, MISUSE, OR
INABILITY TO USE THIS PRODUCT OR FROM DEFECTS IN THE PRODUCT. Some states do
not allow the exclusion of incidental or consequential damages, so the above limitations
may not apply to you. LZ design retains the exclusive right to repair or replace the unit or
software, or to offer a full refund of the purchase price, at its sole discretion. SUCH
REMEDY SHALL BE YOUR SOLE AND EXCLUSIVE REMEDY FOR ANY BREACH OF
WARRANTY.
To obtain warranty service, contact your local LZ design dealer or contact LZ design
directly.
October 2013 © 2013 LZ design. All rights reserved
FES Maintenance manual Version 1.12 September 2016
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2. Introduction
This FES Maintenance manual is part of FES System manual, and it contains
information for pilots, technicians and mechanics about safe and proper maintenance of
the sailplanes equipped with FES (Front Electric Selflaunch / Sustainer) system. This
information is given in accordance with requirements of CS 22.1529 for sailplane
maintenance.
2.1 Warnings, cautions and notes
The following definitions apply to warnings, cautions and notes used in this manual.
Warning: Means that the non-observation of the corresponding procedure
leads to an immediate or important degradation of the flight safety.
Caution: Means that the non-observation of the corresponding procedure
leads to a minor or to a more or less long term degradation of the flight
safety.
Note: Draws the attention to any special item not directly related to safety
but which is important or unusual.
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3. Description of FES system
We spent a lot of effort to develop FES system to be simple and reliable, but also
that it would need as little as possible of maintenance. However some minimal
maintenance is still required. In order to be able to perform maintenance it is first required
to know locations of installed FES components and to understand how it works.
3.1 General layout
General layout of the FES system
Wiring of instruments to FES 12V power supply circuit
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3.2 Description of main FES components
3.2.1 Electric motor
Motor construction is outrunner brushless synchronous permanent magnet motor
with electronically controlled commutation system 3 phase. Rotor position is determined
by 3 hall sensors and additional 4th hall sensor for automatic propeller positioning.
This motor can work only in combination with suitable electronic motor Controller
which transform DC current from Battery packs to 3 phase current which supply motor.
Electrical motor power ratings (type FES-LAK-M100) at 116V on motor controller and
loaded with propeller (type FES-LAK-P10-100):
Maximum torque
75 Nm
Maximum current
200A
Maximum Voltage
180V
Rpm non loaded
45 rpm/V
Rpm non loaded (at 116V DC on Controller) 5300 rpm
Non loaded motor current (at 5300 rpm) 16-18 A
Rpm loaded with FES-LAK-P10-100 propeller (1m diameter)
4500 rpm
Battery current loaded (4500 rpm, 116V) with FES-LAK-P10-100
up to 200 A
Rotor rink diameter 177mm
Motor length 100mm
Motor weight cca. 7,3 kg
Motor efficiency 82-95 %
Maximum allowed temperature 90 °C
Minimum allowed starting temperature -20 °C
More detailed description of motor is provided in FES Motor manual.
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3.2.2 Propeller
The foldable fixed pitch carbon fibre composite propeller is high quality product.
Technical data and limitations of the propeller:
Number of propeller blades: 2
Maximum power on a propeller shaft: 23 kW;
Maximum rotational speed: 4500 RPM +5%;
Propeller blade mass excluding attaching bolts: approximately 245 g each blade;
Diameter of the propeller: d = 1000 mm;
Service time between main overhauls: 50 hours;
Total service time: 200 hours;
Type of propeller: tractor;
Sense of rotation: clockwise looking at direction of
flight.
Operating conditions: the propeller can be operated in any
normal environment conditions
except hail, sand storm or similar
FES propellers as described herein is designed and tested according to CS 22
Subpart J. It is made of GFC and CFC from accurate metal molds, which were
manufactured using modern CNC technology. This made it possible to have very accurate
propeller geometry. Inside is solid and not hollow.
Quality acrylic white paint is used to protect the composite body against moisture
and erosion. Each blade pair is sanded and polished so that mass difference tolerance is
only 0,2g. Paint is resistant against fuel, oil and other chemical products. This type of paint
has also an excellent flexibility.
More detailed propeller description is provided at FES Propeller manual.
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3.2.3 FCU instrument
FCU instrument was developed for LZ design’s FES system by LXNAV company, who
is otherwise well known in gliding community by their excellent flight computers (LX8000,
LX9000) - electronic variometers.
LXNAV produce FCU instruments exclusively for FES system of LZ design.
Technical specification:
• 1* RPM input
• 2* LED INPUT
• 1* digital output for BRAKE
• 1* analog output for POWER (adjustable with rotary knob)
• 4* temperature (Controller/Motor/ 2* battery)
• Audio signal
• 1* analog input for measuring current
• 1* analog input for maesuring voltage
• 1* rs232 input for firmware update
• 1* input for canopy open switch
• 1* CAN bus
• 1* rotary and push button
• ON/OFF switch
Functions not supported by software, but supported in HW.
• 1* rs485
• 1* additional analog input
Sunlight readable QVGA LCD (320*240).
Consumption cca 100mA.
More detailed description is provided at FES FCU instrument manual.
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