Air Creation BioniX2 13 User manual

GDMMBi²13-1G Version 0010 1
Maintenance Manual
Wing Type :
B
Bi io on ni iX X² ² 1 13 3
615 Route de l’Aérodrome, 07200 Lanas, France
Telephone: [phone] • Fax: [phone]
[email protected] • http://www.aircreation.fr

GDMMBi²13-1G Version 0010 2
1 Table of Contents
1Table of Contents................................................................... 2
2Amendment Record Sheet .................................................... 4
2.1 Table of Amendments.......................................................................... 4
2.2 Amendments........................................................................................ 4
3Introduction............................................................................ 5
3.1 Skills..................................................................................................... 5
3.2 Tools .................................................................................................... 5
3.3 Air Creation Directives ......................................................................... 6
3.4 Units..................................................................................................... 6
3.4.1 Use of Metric/Imperial Units...................................................................................6
3.5 Main Airframe Description.................................................................... 6
3.5.1 Keel ........................................................................................................................6
3.5.2 Nose Plates............................................................................................................7
3.5.3 U-Bracket................................................................................................................7
3.5.4 King Post................................................................................................................7
3.5.5 Tensioning U-channel ............................................................................................7
3.5.6 Control Frame.........................................................................................................7
3.5.7 Leading Edge .........................................................................................................8
3.5.8 Cross Bars..............................................................................................................8
3.5.9 Battens ...................................................................................................................8
3.5.10 Top and Bottom Side Wires ...................................................................................8
3.5.11 Top and Bottom Front-Back Wires.........................................................................8
3.5.12 Reflex Bridles .........................................................................................................8
3.5.13 CORSET.................................................................................................................9
3.5.14 Sail..........................................................................................................................9
3.5.15 Tip Fins...................................................................................................................9
3.5.16 Special purpose equipment....................................................................................9
3.6 Assembling from Shipping Crate........................................................ 10
3.6.1Reassembly Guide...............................................................................................10
3.7 Ground Handling................................................................................ 12
3.8 Transportation & Storage................................................................... 12
4Maintenance Checks............................................................ 13
4.1 General .............................................................................................. 13
4.2 Time Limits......................................................................................... 13
4.3 Scheduled Maintenance..................................................................... 14
4.3.1 Wing Maintenance Schedule................................................................................14

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4.4 Unscheduled Maintenance................................................................. 15
4.4.1 General.................................................................................................................15
4.4.2 Inspection after Heavy Landing............................................................................15
4.4.3 Inspection after Heavy Turbulence.......................................................................15
5Standard Practices –Airframe............................................ 16
5.1 Torque and Safety procedures........................................................... 16
5.1.1 Torque Procedures...............................................................................................16
5.1.2 Safety Procedures................................................................................................16
5.2 Sail Removal...................................................................................... 17
5.2.1 Wing Dismantling Procedure................................................................................18
5.2.2 Wing Reassembly Procedure...............................................................................19
5.2.3 Sail Reinstallation.................................................................................................23
5.3 Inspection Notes ................................................................................ 34
5.3.1 Tubing...................................................................................................................34
5.3.2 Bolts......................................................................................................................35
5.3.3 Cables & Terminals..............................................................................................35
5.3.4 CORSET...............................................................................................................36
5.3.5 Composites...........................................................................................................37
5.3.6 Sail........................................................................................................................37
5.3.7 Special Purpose Equipment.................................................................................38
6Adjustments ......................................................................... 39
6.1 General .............................................................................................. 39
6.2 Adjustments ....................................................................................... 39
7Appendix............................................................................... 43
7.1 Wing Inspection Forms ...................................................................... 43
7.1.1 BioniX² 13 Wing Frame Stage Inspection (1).......................................................43
7.1.2 BioniX² 13 Wing Final Assembly Stage Inspection (2).........................................45
7.2 Method for Folding the Sail ................................................................ 47
7.3 Maintenance Operation Board ........................................................... 49

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2 Amendment Record Sheet
2.1 Table of Amendments
Amendment date
Affected sections
Affected pages
Date inserted
Signature
2.2 Amendments
The information in this manual is based on the data that was available at the time of its
publication. The latest amendments to this manual will be issued on the Air Création
website (http://www.aircreation.fr) in PDF format. This should be printed out and added
to the manual. The amendment table should at that time be updated with the appropriate
details and date. Therefore it is important for operators to check the website regularly for
any amendments that have been made. If any errors or omissions are found in this manual
please advise the factory.

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3 Introduction
This manual contains factory recommended procedures and instructions for servicing,
inspecting and maintaining the BioniX² wing. The procedures described are to be used in
addition to the particular governing body regulations for each country where the aircraft
is flown.
The operator is directed to reference the trike maintenance manual for any issues related
to the trike component of the aircraft.
3.1 Skills
It is assumed that only people with an adequate skill level will perform maintenance on
this aircraft. A sound understanding of mechanical systems, experience with the
necessary tools and procedures and knowledge of the specific flight mechanics of weight-
shift controlled aircraft is required –as the continuing airworthiness of the aircraft
depends on the competence of the person performing the maintenance. If there are any
doubts regarding the required and appropriate maintenance then an Air Creation technical
station should be contacted for the correct procedures and/or servicing.
All maintenance and repairs should be carried out in accordance with good aeronautical
practices.
3.2 Tools
There are no specialized tools needed for the maintenance described in this manual. The
following is a list of the type of tools that may be required.
Loctite® will be required in certain locations and should always be replaced after
disassembly.
Loctite® 243 for the frame
Open ended metric spanner set (6, 10, 13, 17mm)
Dry lubricant –lubricant that doesn’t attract dust after application, like Teflon lubricant.
Hex key set up to 8mm
#2 Phillips screwdriver
Various general care items, specified where needed
This list may not be exhaustive.

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3.3 Air Creation Directives
The information in this manual needs to be followed, and it is not acceptable to make
changes to the materials and or physical features of this aircraft.
Air Creation will from time to time issue airworthiness directives, which detail any
changes to the maintenance manuals, pilot’s operating handbook, or any other
details that air creation deems necessary for owners to be notified of.
The web address for Air Creation directives is:
http://www.aircreation.fr
3.4 Units
3.4.1 Use of Metric/Imperial Units
This service manual uses the metric unit system as the basic system of measurement.
Where common usage or available instrumentation refer to the Imperial system, both
units are quoted. The following conversion factors are presented as a ready reference to
the conversion factors that have been used in this manual.
1 Pound (lb) = 0.4536 Kilogram (kg)
1 Pound per sq in (psi) = 6.895 Kilopascal (kPa)
1 Inch (in) = 25.4 Millimeters (mm)
1 Foot (ft) = 0.3048 Meter (m)
1 Statute mile = 1.609 Kilometers (km)
1 Nautical mile (NM) = 1.852 Kilometers (km)
1 Millibar (mb) = 1 Hectopascal (hPa)
1 Millibar (mb) = 0.1 Kilopascal (kPa)
1 Imperial gallon = 4.546 Liters (L)
1 US gallon = 3.785 Liters (L)
1 US quart = 0.946 Liter (L)
1 Cubic foot (ft3) = 28.317 Liters (L)
1 Degree Fahrenheit (F) = (1.8 X C)+32
1 Inch Pound (in lb) = 0.113 Newton Meters (Nm)
1 Foot Pound (ft lb) = 1.356 Newton Meters (Nm)
3.5 Main Airframe Description
The wing is a very specific part of the aircraft.
This section allows the user to understand the main function of each of the components of
the wing, which should help the operator, or maintenance personnel to properly inspect
the wing.
3.5.1 Keel
The keel of the wing is mainly constructed from 2017A aluminum. Each of the major
components of the wing is attached to the keel.

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3.5.2 Nose Plates
The nose plates are bolted to the keel and provide attachment points from the leading
edges to the keel. They are attached to the keel with bolts. The nose plate bolts also fasten
the U-channel to the keel. The gooseneck catch fastens the front wires to the U-channel.
3.5.3 U-Bracket
The U-bracket is the major junction for the three main components of the aircraft, the
wing (keel attachment), trike (mast attachment) and control frame (top knuckle
attachment). The U-bracket has two components, a U-shaped channel, and an internal
Delrin sleeve.
The U-bracket is allowed to rotate around the keel, and is held in position longitudinally
by rings that are bolted to the keel.
The U-bracket should be checked thoroughly after any unusual loads, especially torsional
ones.
3.5.4 King Post
The king post assembly is a vertical post in aluminum 6082 that supports the reflex
bridles, the top front wire, and the top side wires. The king post works in compression,
and is secured to the keel by means of an aluminum locating foot.
3.5.5 Tensioning U-channel
The cross bars tensioning U-channel is bolted to the keel with two bolts. These bolts are
used to attach the rear wires.
3.5.6 Control Frame
The control frame is constructed mainly from 6005 AT5 and 2017 A aluminum. The
control frames down tubes work mainly in compression due to the positive loading of the
wing, which is reacted through the side wires and base bar sections. The base bar works
mainly in tension through the side wire loads from the crossbar and leading edges.
The control frame is bolted to the keel through the U-bracket. The fittings at the top of
the control frame allow relative movement between the U-bracket and the control frame.
This is necessary because of the movement between the base and the wing during the
weight shift control actions.
The control bar is not symmetrical. The central portion is offset from the ends to
compensate for lateral displacement of the trike due to the torque of the engine. For
an engine whose propeller rotates counterclockwise (Rotax 912), the center part
must be shifted to the Left. For a propeller rotating clockwise (Rotax 582), the center
part must be offset to the Right. If necessary, reverse the direction of the control bar
if it does not correspond to the engine used, by removing the connecting screws with
the A-frame uprights.

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3.5.7 Leading Edge
The leading edges are mainly constructed from 7075, 2017 and 6082 aluminum. The
leading edges are mainly loaded in bending and compression. They share loading with
the cross bars during positive and negative flight loads.
The leading edges are attached to the keel through the two nose plates at the front of the
wing, and via a bolt assembly to the cross bars and the outboard wires. The rear leading
edges fit inside the leading edge tubes, which locate onto a horizontal bolt in the leading
edge assembly. The rear leading edges are a part of the leading edge, but are made in
order that they may be removed for ease of shipping.
3.5.8 Cross Bars
The cross bars are mainly constructed from 7075 aluminum .the cross bars serve the
purpose of holding the leading edges forwards and spread against the sail, they share the
loading with the leading edges during positive and negative flight loads.
The cross bars are attached to each other at the keel using a ball joint that allows relative
movement.
They are also tethered to the keel via a webbing loop. The cross bars are attached to the
leading edges using a bolt assembly. The top and bottom side wires are a part of the
bolting arrangement.
3.5.9 Battens
The battens are mainly constructed from 7075 aluminum, with the exception of those at
the extremities of the wing which are in a carbon composite. The battens are secured by
batten pockets sewn into the sail. “Easyfit” tighteners on the trailing edge allow for the
quick installation and tension setting of the battens in their pockets.
The battens help to maintain the profile of the wing during flight, and are important to the
correct and stable operation of the wing.
Do not fly the wing with any other batten profile than that supplied by Air Creation, as
variation may have serious effects on flight performance and stall characteristics of
the wing.
3.5.10 Top and Bottom Side Wires
The bottom side wires are stainless steel braided wires that are attached to the cross bars
and the knuckle at the bottom of the control frame by stainless steel plates, thimbles and
swaged Nicopress sleeves. The top side wires are attached to the kingpost head.
3.5.11 Top and Bottom Front-Back Wires
The bottom front-back wires are stainless steel braided wires, equipped with stainless
steel plates, thimbles and swaged Nicopress sleeves that are attached to the nose catch,
control frame and keel. The top front wire is attached to the kingpost head.
3.5.12 Reflex Bridles
The reflex bridles are stainless steel wires, equipped with thimbles and swaged Nicopress
sleeves, and attached to the top rear wire via a pulley, and to the sail using shackles. The
external reflex bridle acts upon a lateral batten in carbon composite reinforced by an
internal tube of Zicral to hold up 3 upper surface battens.

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Reflex bridles produce longitudinal stability when the wing is at zero or negative angles
of attack. The reflex bridles work by preventing the trailing edge of the wing from
moving downward, as they are tethered to the king post assembly. When the wing has
any negative load on the top surface the rest of the lifting surface will move downward
relative to the trailing edge, effectively creating elevator type control surfaces that
produce a positive pitching moment, helping to restore level flight.
3.5.13 CORSET
The BioniX² wing is equipped with a configuration command that allows the setting of
cruise speed and the simultaneous adaptation of the shape of the sail in order to offer the
best maneuverability and the best performance depending on that speed. The command of
the CORSET is activated by a system of pulleys that tighten the two central battens,
acting on washout and reflex of the profile at the center of the sail. The CORSET is
activated by means of a control level located on the right A-frame strut. This lever
automatically locks in the selected position and activates a cone-shaped pulley on which
is wound the fine cord of the command.
3.5.14 Sail
The sail comprises the lifting surface of the wing. It is mainly constructed of UV
protected Trilam and Dacron polyester fabric, with some ABS and Mylar material
making up the leading edge areas. The sail is constructed from many individual panels,
which are sewn together using polyester thread to form the required shape. The sail has
attachment points sewn into it to attach to the frame at various points and to hold the
battens in place. The sail also provides zippers that facilitate easy preflight inspection of
all the members inside the double surface wing. The central part of the upper surface is
composed of a flexible fabric derived from neoprene which compensates for the
differences of tension due to the CORSET system. This part plays no mechanical role and
may easily be replaced thanks to the two zippers that hold it in place.
In as much as possible the wing must be stored away from sunlight, as UV rays cause
damage to the fabrics.
3.5.15 Tip Fins
The wing tip fins contribute to the stability of the wing in roll and yaw at high speeds.
They are made of a carbon composite material and attached to the wing by means of 3
quarter-turn screws. Flexibly mounted, they give way when the wing is placed on the
ground so that the end of the leading edge supports the force of any wind.
3.5.16 Special purpose equipment
Training Bars
The training bars are attached to the control bar and uprights in order to extend the
possibility to fly the aircraft from the back seat. They are supplied as an option for use by
qualified flight instructors.

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3.6 Assembling from Shipping Crate
This procedure is to be followed if the wing arrives in a short packed configuration. An
approved dealer is responsible for assembly from the short packed configuration. The
short packed wing has had the rear leading edges removed to reduce the packed size for
transport.
The correct reassembly of the wing is critical for safety and performance of the wing. If
there are any doubts about the correct procedure for assembly after shipping contact Air
Creation factory.
3.6.1 Reassembly Guide
1. Remove wing from box. Take care that no staple damages the bag or the sail during this operation.
2. Unzip bag
3. Remove all wing straps. Remove padding from control bar and rear leading edges.
4. Unfold the ends of the sail
5. Rotate the wing so that it is lying flat on the ground on the unfolded A-frame
6. Spread both leading edges approximately ½ meter.
7. Insert rear leading edges in the tip openings of the sail with the plastic lugs at the rear of the tubes
positioned horizontally and to the inside.
The two rear parts of the leading edges are not identical. A sticker on the tube indicates whether it is a
right (D) or left (G). An inversion can have serious consequences because it modifies the tip angle resulting in
negative twisting of the tips and strong longitudinal instability.
8. Finish sliding the rear leading edges in the front part. Turn slightly and push in order to line up the
half-hole and the horizontal bolt connecting the crossbar on the front part of the leading edge.
Make sure that the plastic lugs at the rear of the tubes are face-to-face. Once installed the rear
leading edge slot should be located on the channel horizontal bolt. it should be impossible to rotate
the leading edge, if correctly assembled.
9. Remove the self-tapping screws B 199010 (Refer to drawing OP10-23CA) which hold the sail on
the leading edge at the nose of the wing. This way, the sail will move back easily.
Figure 3-1
Figure 3-2
10. Attach the sail to the tip sleeves with 4 screws FHC 6-75-13 (B167510) (Refer to drawing OP10-
22VO).Note the indications “Right” & “Left” on the tubes. Make sure that the aluminum guide
that allows the setting of the sail’s tension is facing the slot in the sleeves, at the end of the leading
edge. To make things easier, use a screwdriver to line up the sail with the foremost drilling and
slide the screw in the back. Remove the screwdriver to insert the screw in the front. Figure 3-1 &
Figure 3-2. Apply the Threadlock glue to the nuts and tighten the Nylstop bolts.