DUC Hélices FLASH-R User manual

Aérodrome de Villefranche-Tarare (LFHV)
289 Avenue Odette & Edouard DURAND
69620 FRONTENAS - FRANCE
Phone: + 33 (0)4 74 72 12 69
E-mail: [e-mail]
ISO 9001:2015
TC EASA: EASA P.038
Part 21G EASA: FR.21G.0273
DH_FSH-R_BE_04_A Made in France 06/05/2019
Instruction manual
3-blade propeller
Certified FLASH-R

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.
Revision update
Date
Index
Object of modification
09/05/2019
A
Creation
Every amendment in this document made for the latest revision will appear in dark red.
Identification form
Date
Delivery note n°
Owner
Engine/Gearbox
ratio
Aircraft
1st recommended
pitch blade angle
Notes: ..............................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................

ISO 9001: 2015
TCDS EASA: EASA P.038
Part 21G EASA: FR.21G.0273
Certified FLASH-R
3/27
Summary
1. Presentation of the Certified FLASH-R propeller.......................................................................................................4
Description ........................................................................................................................................................41.1.
Characteristics..................................................................................................................................................41.2.
Shielding leading edge in Inconel®....................................................................................................................51.3.
Accessories.......................................................................................................................................................51.4.
Sales references ...............................................................................................................................................51.5.
2. Applications................................................................................................................................................................6
3. Installation precautions..............................................................................................................................................6
4. Components of the Certified FLASH-R......................................................................................................................7
Mounting configuration of the FLASH-R propeller............................................................................................74.1.
Exploded view for propeller...............................................................................................................................74.2.
List of components............................................................................................................................................84.3.
List of required tools........................................................................................................................................104.4.
5. Assembly instruction of the propeller.......................................................................................................................10
Assembly of the propeller................................................................................................................................105.1.
Installation on the aircraft................................................................................................................................125.2.
Setting of the propeller & Finalization of the installation.................................................................................155.3.
6. Precautions..............................................................................................................................................................18
7. Continuing airworthiness .........................................................................................................................................19
Airworthiness limitations..................................................................................................................................197.1.
Schedule of propeller check............................................................................................................................197.2.
Regular maintenance (by the user).................................................................................................................207.3.
Maintenance of 100 hours or yearly maintenance..........................................................................................217.4.
Impact location on the blade carbon surface ..................................................................................................227.5.
8. General terms of sale...............................................................................................................................................23
Ordering procedure.........................................................................................................................................238.1.
Delivery ...........................................................................................................................................................238.2.
Price ................................................................................................................................................................238.3.
Right of withdrawal..........................................................................................................................................238.4.
Warranties.......................................................................................................................................................23
8.5.
Privacy Policy..................................................................................................................................................238.6.
Litigation..........................................................................................................................................................238.7.
9. Annexes...................................................................................................................................................................24
Dimension of the engine propeller-shaft .........................................................................................................249.1.
912H spacer –Table screw length vs. Spacer thickness .......................................Erreur ! Signet non défini.9.2.
Airfoil ...............................................................................................................................................................259.3.

Certified FLASH-R
4/27
1. Presentation of the Certified FLASH-R propeller
Description1.1.
The certified FLASH-R propeller 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.
This propeller allows 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 comforts
The blades and the hub of the FLASH-R propeller are manufactured according the DUC Hélices company
technologies, from unidirectional layers of carbon fibers prepreg epoxy resin.
The blade composite structure is defined to obtain the maximum strength 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.
Characteristics1.2.
The Certified FLASH-R propeller range is available:
Ground adjustable propeller
Tractor configuration available in right rotation
Diameters Ø1520 to Ø1900mm (Ø59.8 to Ø74.7")
Shielded leading edge in Inconel®
Carbon composite hub with metallic inserts
Protected again lightning strike
Direct assembly on the propeller-shaft Ø101.6mm
Safety marking on the tip of the propeller

ISO 9001: 2015
TCDS EASA: EASA P.038
Part 21G EASA: FR.21G.0273
Certified FLASH-R
5/27
Shielding leading edge in Inconel®1.3.
The leading edge of the Certified FLASH-R blades is equipped with a metallic shielding in Inconel®. This material is a
superalloy containing mainly nickel, with a very high hardness of surface.
Accessories1.4.
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") to 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.
Sales references1.5.
Designation
Reference
Part number
Three-blade Inconel FLASH-R Right (ROTAX mounting)
01-40-001
H-FSH_3-D-R_I_RX_C
Three-blade Inconel FLASH-R Right (AN6 mounting)
01-40-011
H-FSH_3-D-R_I_AN6_C
Three-blade Inconel FLASH-R Right (AN8 mounting)
01-40-021
H-FSH_3-D-R_I_AN8_C
Note:
Specify the flight regulation aircraft (E.g.: Ultra-light, LSA…) and diameter when ordering (E.g.: ref. 01-21-001/1730).
Inconel shielding

Certified FLASH-R
6/27
2. Applications
DUC propellers are given for a flight potential under normal operating conditions. To maintain this potential, DUC
Propellers has determined a TBO (time between revisions) for a propeller based on the engine it equips. See the
section 7.1 Airworthiness Limitations for Information Benefit.
Engine
Gearbox
Propellers limits
Propeller diameter
(mm)
Blade angle
(°)
Blade angle
allowed
range (°)
TBO- Time Between
Overhaul*
(hour)
ROTAX 912S
ROTAX 912iS
ROTAX 914
2.43
160 HP
2 700 RPM
Ø1730
24°± 2°
22° → 30°
2 000 hours
or
6 years
Ø1750
24°± 2°
22° → 30°
Ø1800
19°± 2°
17°→25°
Ø1850
19°± 2°
17°→25°
Ø1900
18°± 2°
16°→24°
CONTINENTAL O-200
-
Ø1660
20°± 2°
18°→ 26°
LYCOMING O-235
-
Ø1660
20°± 2°
18°→ 26°
LYCOMING O-320
-
Ø1900
20°± 2°
18° → 26°
* It is the maximum period of propeller use allowed by propeller type certificate.
Compliance with CS-P, Subpart D has not been demonstrated as part of the propeller certification.
Remark
The values of the pitch angle are defined by flight test on each engine. If necessary, this setting should be adjusted
according to the aircraft.
For proper use of the propeller, refer to section 7.Continuing airworthiness
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.8.General terms of sale).

ISO 9001: 2015
TCDS EASA: EASA P.038
Part 21G EASA: FR.21G.0273
Certified FLASH-R
7/27
4. Components of the Certified FLASH-R
Mounting configuration of the FLASH-R propeller4.1.
Here is a configuration table of the three-blade certified FLASH-R propeller mounting according the propeller-shaft of
the engine.
If needed, see annex 9.1 Dimension of the engine propeller-shaft
MOUNTING
ENGINE PROPELLER-SHAFT
Ø4" / Ø101.6mm
(Rotax)
Type SAE1
Ø4-3/8" / Ø111.125mm
(Ex: Continental O-200)
Type SAE2
Ø4-3/4" / Ø120.65mm
(Ex: Lycoming O-320)
direct on propeller-
shaft (without spacer)
X
with spacer
X
with adaptor spacer
X
X
Exploded view for propeller4.2.
Remark
This exploded view shows the principle of the certified FLASH-R 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…).
Inconel FLASH-R
blade right(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)
According to mounting
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)
According to mounting

Certified FLASH-R
8/27
List of components4.3.
Designation
Optional
(According to
the recommend
mounting)
Part Number
Quan
tity
Spacer (optional)
912H spacer - 3mm
X
EI-912H-3
01
912H spacer - 6mm
X
EI-912H-6
912H spacer - 10mm
X
EI-912H-10
912H spacer –15mm
X
EI-912H-15
912H spacer - 20mm
X
EI-912H-20
912H spacer - 45mm
X
EI-912H-30
912H spacer - 30mm
X
EI-912H-45
912H spacer - 60mm
X
EI-912H-50
912H spacer - 30mm
X
EI-912H-60
912H spacer - 70mm
X
EI-912H-70
912H spacer - 75mm
X
EI-912H-75
912H spacer - 80mm
X
EI-912H-80
912H spacer - 100mm
X
EI-912H-100
912H spacer - 120mm
X
EI-912H-120
Dowel spacer DUC Ø13 L20
X
PI-DUC13-20
06
Dowel spacer DUC Ø13 L30
X
PI-DUC13-30
Dowel spacer DUC Ø13 L40
X
PI-DUC13-40
Dowel spacer DUC/ROTAX Ø13 M8 L28
X
PI-RX-28
Dowel spacer DUC/ROTAX Ø13 M8 L30
X
PI-RX-30
Screws CHC M8x40mm
(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)
X
V-CHC8-40
06
Adaptor spacer (optional)
SAE1-AN6 adaptor spacer - 30mm
X
E-SAE1AN6-30
01
SAE1-AN6 adaptor spacer - 70mm
X
E-SAE1AN6-70
SAE1-AN6 adaptor spacer - 80mm
X
E-SAE1AN6-80
SAE1-AN6 adaptor spacer - 100mm
X
E-SAE1AN6-100
SAE2-AN6 adaptor spacer - 30mm
X
E-SAE2AN6-30
SAE2-AN7 adaptor spacer - 90mm
X
E-SAE2AN7-90
SAE2-AN7 adaptor spacer - 100mm
X
E-SAE2AN7-100
SAE2-AN8 adaptor spacer - 30mm
X
E-SAE2AN8-30
Dowel spacer DUC Ø17 AN6
X
PI-DUC17-AN6
06
Dowel spacer DUC Ø17 AN8
X
PI-DUC17-AN8
Safety washer DUC AN6
X
RS-AN6
Safety washer DUC AN8
X
RS-AN8
Screws 3/8" UNF 1-3/4"
X
V-3/8-1_3/4
06
Screws 1/2" UNF 1-1/2"
X
V-1/2-1_1/2
Screw 3/8" UNF 2-1/2"
X
V-3/8-2_1/2
Screw 3/8" UNF 3"
X
V-3/8-3
Hub
3-blade rear half-hub Certified FLASH-R ROTAX
-
DMFSH-3-AR_RX_C
01
3-blade rear half-hub Certified FLASH-R AN6
-
DMFSH-3-AR_AN6_C
3-blade rear half-hub Certified FLASH-R AN8
-
DMFSH-3-AR_AN8_C
Certified internal FLASH-R hub spacer
-
EMFSH_C
01
3-blade front half-hub Certified FLASH ROTAX
-
DMFSH-3-AV_RX_C
01
3-blade front half-hub Certified FLASH AN6
-
DMFSH-3-AV_AN6_C
3-blade front half-hub Certified FLASH AN8
-
DMFSH-3-AV_AN8_C
Screws CHC M8x30
(Included narrow plain washer Ø8mm and Nylstop self-locking nut M8)
-
V-CHC8-30
06
Certified hub clamping washer FLASH ROTAX
-
RS-FSH-RX_C
01
Certified hub clamping washer FLASH AN6
-
RS-FSH-AN6_C
Certified hub clamping washer FLASH AN8
-
RS-FSH-AN8_C

ISO 9001: 2015
TCDS EASA: EASA P.038
Part 21G EASA: FR.21G.0273
Certified FLASH-R
9/27
Designation
Optional
(According to
the recommend
mounting)
Part Number
Quan
tity
Blade FLASH-R
Certified Inconel FLASH-R blade, Right
-
FSH-D-R_I_C
03
Fixing screws
Screws CHC M8x130
(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)
-
V-CHC8-130
06
Screws CHC M8x140
(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)
-
V-CHC8-140
Screws CHC M8x150
(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)
-
V-CHC8-150
Screws CHC M8x160
(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)
-
V-CHC8-160
Screws CHC M8x180
(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)
-
V-CHC8-180
Screws CHC M8x200
(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)
-
V-CHC8-200
Screws DUC AN6-52
(included washer 960-616)
-
V-AN6-52
Screws DUC AN8-52
(included washer 960-816)
-
V-AN8-52
Accessories: Spinner & Mounting plate
3-blade spinner mounting plate Ø250mm ROTAX
X
P-250_3-RX
01
3-blade spinner mounting plate Ø250mm Ø17
X
P-250_3-17
3-blade spinner mounting plate Ø260mm ROTAX
X
P-260_3-RX
3-blade spinner mounting plate Ø260mm Ø17
X
P-260_3-17
3-blade spinner mounting plate Ø270mm ROTAX
X
P-270_3-RX
3-blade spinner mounting plate Ø270mm Ø17
X
P-270_3-17
3-blade spinner mounting plate Ø290mm ROTAX
X
P-290_3-RX
3-blade spinner mounting plate Ø290mm Ø17
X
P-290_3-17
3-blade spinner mounting plate Ø300mm ROTAX
X
P-300_3-RX
3-blade spinner mounting plate Ø300mm Ø17
X
P-300_3-17
3-blade spinner mounting plate Ø340mm ROTAX
X
P-340_3-RX
3-blade spinner mounting plate Ø340mm SAE1-AN6
X
P-340_3-SAE1AN6
3-blade spinner mounting plate Ø340mm SAE2-AN6
X
P-340_3-SAE2AN6
3-blade spinner mounting plate Ø340mm SAE2-AN7
X
P-340_3-SAE2AN7
3-blade spinner mounting plate Ø340mm SAE2-AN8
X
P-340_3-SAE2AN8
3-blade spinner Ø250mm
X
C-250_3
01
3-blade spinner Ø250mm L
X
C-250L_3
3-blade spinner Ø260mm
X
C-260_3
3-blade spinner Ø270mm
X
C-270_3
3-blade spinner Ø290mm
X
C-290_3
3-blade spinner Ø300mm
X
C-300_3
3-blade spinner Ø340mm
X
C-340_3
Spinner closure plate
X
CC-250_350
03
Spinner screws M5x16mm
X
V-P5-16
09
Spinner screws AN-525-10R8
X
AN-525-10R8

Certified FLASH-R
10/27
List of required tools4.4.
Rotax mounting
SAE1/SAE2 mounting (Lycoming, Continental, …)
6 Torque Allen Wrench (Torque: 25 Nm)
Flat key 13
Inclinometer (angle adjustment tools)
Nylon mallet
Torque screwdriver (Torque: 4 Nm)
6 Torque Allen Wrench (Torque: 25 Nm)
Flat key 13
3/8 or 1/2 Torque Wrench (Torque: 30 to 45 Nm)
Inclinometer (angle adjustment tools)
Nylon mallet
Torque screwdriver (Torque: 4 Nm)
5. Assembly instruction of the propeller
The assembly of the Three-blade Certified FLASH-R propellers is shown below. It is recommended to assemble the
propeller on a worktable before installing it on the plane.
For further information, contact the DUC Hélices Company.
Assembly of the propeller5.1.
A « Propeller Form » will be done to insure a propeller follow-up. Parts Number and component serial number of
propeller will be written on this form.
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 diameter of the bore of the metal inserts of
the rear half- hub is larger than the bore 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.
Positioning the blades in their hub slots by placing them
outwards.
The three blades of the propeller have been
balanced at DUC Helices before their dispatch.
Position the DUC Hélices logo facing you.
Note that the metal inserts of the half-hub allow a
locking of the blades in their axis within the hub.