DUC Hélices SWIRL-2 User manual

Aérodrome de Villefranche Tarare (LFHV)
289 Avenue Odette & Edouard DURAND
69620 FRONTENAS - FRANCE
Phone : + 33 (0)4 74 72 12 69 - Fax : [phone]
E-mail : [e-mail] - www.duc-helices.com
ISO 9001:2008 Certified Company
for its Quality System Management
DH_SW2_BE_02_D Made in France 22/03/2017
Instruction manual
SWIRL-2 propeller range

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
23/12/2014
A
Creation in English
20/01/2015
A
Minor correction
02/04/2015
B
Update of the hub
01/06/2015
C
Update
22/03/2017
D
New address

Identification
Date
Delivery note n°
Owner
Engine/Gearbox
ratio
Aircraft
1st recommended
pitch blade angle
Notes: ..............................................................................................................................................................................
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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, …): ..............................................................................................
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Notes (Date, Number of people, Weight, Weather, …): ..............................................................................................
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Notes (Date, Number of people, Weight, Weather, …): ..............................................................................................
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Summary
1. Presentation of the SWIRL-2 propeller......................................................................................................................5
1.1. Description ........................................................................................................................................................5
1.2. Characteristics..................................................................................................................................................5
1.3. Shielding leading edge in Inconel .....................................................................................................................6
1.4. Accessories......................................................................................................................................................6
1.1. Sales reference.................................................................................................................................................6
2. Applications................................................................................................................................................................7
3. Installation precautions..............................................................................................................................................7
4. Components of the SWIRL-2 propellers....................................................................................................................8
4.1. Mounting configuration of the SWIRL-2 propellers...........................................................................................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 SWIRL-2 propeller....................................................................................................22
11.4. Operating limitation of the SWIRL-2 propeller ................................................................................................22
11.5. Identification marking of the propeller.............................................................................................................22
11.6. Declaration of conformance of the SWIRL-2 propellers..................................................................................23

SWIRL-2
5/24
1. Presentation of the SWIRL-2 propeller
1.1. Description
The SWIRL-2 propeller range 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 SWIRL-2 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 SWIRL-2 propeller range is available:
Tractor configuration (available in right rotation)
Diameters Ø1520, Ø1620, Ø1660, Ø1730, Ø1830mm and others tailor made
Ø59.8 Ø63.8 Ø65.4 Ø68.1 Ø72"
Two-blade & Three-blade –SWIRL-2 3.20 & 4.17 kg (7.05 & 9.19 lb.)
SWIRL-2-R 3.30 & 4.32 kg (7. 28 & 9.52 lb.)
Shielded leading edge in Inconel®
Carbon composite hub Ø101.6mm (Ø4”) with metallic inserts
or carbon composite hub Ø75mm
2-blade hub available in Compact version for Ø210mm spinner
Direct assembly on the propeller-shaft Ø101.6mm (Ø4”)
Excellence version “SWIRL-2-R”for direct drive engine from 100hp to 140hp:
Longitudinal reinforced carbon structure
Higher bending strength
Titanium color finishing
Advanced controls
rpm
efficiency ƞ
rpm
efficiency ƞ

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1.3. Shielding leading edge in Inconel
The leading edge of the SWIRL-2 blades is equipped with a metallic shielding in Inconel®. This material is a superalloy
containing mainly nickel, with a very high hardness of surface.
1.4. 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: Ø210 (Ø8.3"), Ø250mm (Ø9.8"), Ø260mm (Ø10.3"),
Ø300mm (11.8”) & 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
Preview
Designation
Reference
Part number
Ø101.6mm (4") Compact hub –Fixingwith 6 screws CHC M8 withØ13 or 14mm drive lug
Two-blade Inconel SWIRL-2 propeller, Right (Compact hub)
01-28-001
H-SW2_2-D-I_MFU
Two-blade Inconel SWIRL-2-R propeller, Right (Compact hub)
01-37-001
H-SW2_2-D-R_I_MFU
Ø101.6mm (4") hub –Fixing with 6 screws CHC M8 with Ø13 or 14mm drive lug
Two-blade Inconel SWIRL-2 propeller, Right
01-36-001
H-SW2_2-D-I_MF
Two-blade Inconel SWIRL-2-R propeller, Right
01-31-001
H-SW2_2-D-R_I_MF
Three-blade Inconel SWIRL-2 propeller, Right
01-33-001
H-SW2_3-D-I_MF
Three-blade Inconel SWIRL-2-R propeller, Right
01-32-001
H-SW2_3-D-R_I_MF
Note:
Specify the flight regulation aircraft (E.g.: Ultra-light, LSA…) and diameter when ordering (E.g.: ref. 01-28-001/1730).
For more information about the propeller marking, see section 11.5.
Inconel shielding

SWIRL-2
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2. Applications
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.
Engine
Type
Gear
box
Recommended propeller
Propeller
diameter
(inch)
Blade
angle
(°)
Blade
angle
allowed
range(°)
TBO
(hour)
3 AXIS –TRACTOR
JABIRU 2200
4 strokes
-
Two-blade Inconel SWIRL-2, right
Ø1620
18°
15° → 23°
2000h
JABIRU 3300
4 strokes
-
Two-blade Inconel SWIRL-2-R, right
Ø1660
19°
16° → 24°
UL Power 260i/iS
4 strokes
-
Two-blade Inconel SWIRL-2, right
Ø1620
18°
15° → 23°
UL Power 350i/iS
4 strokes
-
Two-blade Inconel SWIRL-2-R, right
Ø1660
20°
17° → 25°
Continental O-200
4 strokes
-
Three-blade Inconel SWIRL-2-R, right
Ø1660
19°
17° → 25°
Lycoming O-235
OTHER APPLICATIONS
For all other applications, thank you to contact the DUC Hélices company to study the possibility of adapting the
SWIRL-2 propeller.
* 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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4. Components of the SWIRL-2 propellers
The SWIRL-2 propellers are available in several versions and can be mounted on different model of engine.
4.1. Mounting configuration of the SWIRL-2 propellers
Here is a configuration table of the SWIRL-2 propeller mounting according the propeller-shaft of the engine.
If needed, see annex 11.1. Dimension of the engine propeller-shaft.
MOUNTING
ENGINE PROPELLER-SHAFT
Ø4" / Ø101.6mm
(Ex: 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)
X
with spacer
X
with adaptor
spacer
X
X
X
4.2. Mounting screws
Coming soon.

SWIRL-2
9/24
4.3. Exploded view for propeller
Remark
This exploded view shows the principle of the SWIRL-2 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
Jabiru mounting
SAE1/SAE2 mounting
M8 Torque Hex key (Tightening: 25 Nm)
M8 Torque Wrench (Tightening: 25 Nm)
Inclinometer (pitch adjusting tool)
Plastic mallet
Torque Screwdriver (Tightening: 4 Nm)
M8 Torque Hex key (Tightening: 25 Nm)
M8 Torque Wrench (Tightening: 25 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)
SWIRL-2
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)

10/24
5. Assembly instruction of the propeller
The assembly of the SWIRL-2 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 SWIRL-2 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 half-
hub 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.
Positioning the blades in their hub slots by placing them
outwards.
Orient 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.
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.
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 (Jabiru
mounting), the pins are oriented towards the screw
head.
Compact Hub version