HPH Glasflugel 304 eS User manual

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TE EC CH HN NI IC CA AL L D DE ES SC CR RI IP PT TI IO ON N, ,
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Mo od de el l: :
Glasflügel 304 eS
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Document No.: 304eS/MMSupp
Date of Issue: 11/17
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28 84 4 0 01 1 K Ku ut tn ná á H Ho or ra a
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CZ ZE EC CH H R RE EP PU UB BL LI IC C
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fa ax x: : + [phone] 13 34 44 41 1
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HPHLtd.

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Te ec ch hn ni ic ca al l D De es sc cr ri ip pt ti io on n, , O Op pe er ra at ti in ng g, , M Ma ai in nt te en na an nc ce e a an nd d R Re ep pa ai ir r M Ma an nu ua al l S Su up pp pl le em me en nt t
Document No.: 304eS/MMSupp
Date of Issue: 11/17
ii
HPHLtd.
Table of contents Page
0.1 LIST OF EFFECTIVE PAGES ................................................................................ IV
0.2 RECORD OF REVISIONS ......................................................................................V
1. BASIC TECHNICAL DATA ............................................................................1-0
1.1 BASIC TECHNICAL DATA ..................................................................................1-1
1.2 TECHNICAL DESCRIPTION................................................................................1-1
1.2.1 Fuselage ...................................................................................................1-1
1.2.2 Wing..........................................................................................................1-1
1.2.3 Horizontal Tail Unit....................................................................................1-2
1.2.4 Vertical Tail Unit........................................................................................1-2
1.2.5 Water ballast system.................................................................................1-2
1.2.6 Power-plant...............................................................................................1-2
1.3 SAILPLANE SYSTEMS.....................................................................................1-10
1.3.1 Control systems in the fuselage ..............................................................1-10
1.3.2 Control systems in the wing ....................................................................1-10
1.3.3 Rudder control system ............................................................................1-10
1.3.4 Main landing gear system .......................................................................1-10
1.3.5 Control surface deflections and dimensions............................................1-10
1.3.6 Electric system........................................................................................1-10
2. HANGARING, TRANSPORT, RIGGING ........................................................2-0
2.1.1 Hangaring, Parking, and Ground Handling ...............................................2-1
2.2 RIGGING ........................................................................................................2-2
2.3 DE-RIGGING ...................................................................................................2-3
3. MAINTENANCE .............................................................................................3-0
3.1 MANDATORY MAINTENANCE ............................................................................3-1
3.1.1 Inspections periods ...................................................................................3-1
3.1.2 Inspection after every 100 flight hours ......................................................3-1
3.1.3 Propeller....................................................................................................3-1
3.1.4 Motor –Propeller ......................................................................................3-2
3.2 REGULAR MAINTENANCE.................................................................................3-2
3.2.1 Annual inspection ......................................................................................3-2
3.2.2 Inspection at the end of flight season........................................................3-2
3.2.3 Adjustments ..............................................................................................3-2
3.2.4 Motor maintenance ...................................................................................3-3
3.2.5 Propeller maintenance ..............................................................................3-4
3.2.6 Battery packs maintenance.......................................................................3-4
3.3 SPECIAL INSPECTION PROCEDURE...................................................................3-6
3.3.1 After hard landing, ground loops and battery pack impact ........................3-6
3.4 FREE PLAY IN THE CONTROL CIRCUITS ............................................................3-7
3.5 FREE PLAY IN WING AND TAIL PLANE ATTACHMENTS .........................................3-7
3.6 PRIMARY AND SECONDARY STRUCTURES ..........................................................3-7
3.7 DAMAGE ........................................................................................................3-7
3.8 REPAIRS ........................................................................................................3-7
3.9 REMOVAL AND RE-INSTALLATION OF RELEASES ................................................3-8
3.10 CONTROL SURFACE MOMENTS ........................................................................3-8
3.11 PLACARDS AND MARKINGS IN THE COCKPIT.......................................................3-8
3.12 CLEANING AND CARE ......................................................................................3-8

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Date of Issue: 11/17
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3.13 LUBRICATION SCHEME.....................................................................................3-9
3.14 TIGHTENING TORQUE MOMENTS TABLE............................................................3-9
3.15 SAFETY HARNESS ..........................................................................................3-9
3.16 PITOT AND STATIC LINES AND INSTRUMENT CONNECTIONS ................................3-9
3.17 LIST OF INSTRUMENTS.....................................................................................3-9
3.17.1 Airspeed Indicators ...................................................................................3-9
3.17.2 Altimeters ..................................................................................................3-9
3.17.3 Variometers...............................................................................................3-9
3.17.4 Magnetic Compasses ...............................................................................3-9
3.17.5 Turn and Bank Indicators..........................................................................3-9
3.17.6 COMM.....................................................................................................3-10
3.17.7 Transponders..........................................................................................3-10
3.17.8 FCU Instrument.......................................................................................3-10
3.18 OXYGEN SYSTEM..........................................................................................3-10
3.19 SERVICE INSTRUCTIONS ................................................................................3-10
3.20 LIST OF SPECIAL TOOLS.................................................................................3-10
3.21 MOTOR REMOVING AND INSTALLATION ............................................................3-11
3.22 INSTALLATION OF PROPELLER ........................................................................3-12
3.23 BALANCING OF ROTATING PARTS....................................................................3-12
3.24 CONTROLLER ALARM CODES..........................................................................3-13
4. AIRWORTHINESS LIMITATIONS..................................................................4-0
4.1 GENERAL.......................................................................................................4-1
4.2 SERVICE TIME ................................................................................................4-1
4.3 INSPECTION ...................................................................................................4-1
4.4 CHECK OUT PROGRAM ....................................................................................4-1
4.5 INSPECTION RESULTS......................................................................................4-1
4.6 OBLIGATORY INSPECTIONS ..............................................................................4-1
4.7 LIFE LIMITED COMPONENT SECTION.................................................................4-1
5. CENTER OF GRAVITY ..................................................................................5-0
5.1 CENTER OF GRAVITY POSITION ........................................................................5-1
5.2 PAYLOAD RANGE............................................................................................5-1
6. INSTRUCTIONS FOR REPAIRS....................................................................6-0
6.1 CHECKLIST.................................................................................................6-1
6.1.1 General .....................................................................................................6-1
6.1.2 Wing..........................................................................................................6-1
6.1.3 Fuselage ...................................................................................................6-1
6.1.4 Propeller....................................................................................................6-1
6.1.5 Motor.........................................................................................................6-1
6.1.6 Batteries....................................................................................................6-1
6.1.7 List of potential problems ..........................................................................6-2
6.2 STRUCTURE OF COMPONENTS.........................................................................6-3
6.3 MATERIALS ....................................................................................................6-3
6.3.1 List of FES spare parts..............................................................................6-3
6.4 TYPE OF WAVES .............................................................................................6-3
6.5 BASIC TECHNIQUES AND TOOLS.......................................................................6-3
6.5.1 Soldering...................................................................................................6-3

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Date of Issue: 11/17
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0.1 List of Effective Pages
Section
Page
Date
Section
Page
Date
Section
Page
Date
Cover page
3-11
11/17
3-12
11/17
i
11/17
3-13
11/17
ii
11/17
3-14
11/17
iii
11/17
iv
11/17
v
11/17
4
4-0
09/16
4-1
09/16
1
1-0
09/16
1-1
11/17
1-2
11/17
5
5-0
09/16
1-3
11/17
5-1
09/16
1-4
09/16
1-5
09/16
1-6
09/16
1-7
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6
6-0
09/16
1-8
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6-1
09/16
1-9
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6-2
09/16
1-10
11/17
6-3
09/16
1-11
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1-12
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1-13
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2
2-0
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2-1
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2-2
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2-3
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3
3-0
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3-1
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3-2
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3-3
09/16
3-4
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3-5
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3-6
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3-7
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3-8
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3-9
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3-10
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Document No.: 304eS/MMSupp
Date of Issue: 11/17
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0.2 Record of revisions
Any revision of this Manual must be recorded in the following table and in case
of approved Sections endorsed by the responsible airworthiness authority.
The new or amended text in the revised page will be indicated by a black
vertical line in the left hand margin, and the Revision No. and the date will be
shown on the bottom left hand of the page.
Rev.
No.:
Affected
Section
Affected
Page
Date of
Issue
Approval
Date of
approval
Date
Inserted
Signature
R00
all
all
09/16
R01
1,
3
1-1, 1-2,
1-3, 1-8,
1-10, 1-11
1-13,
3-4, 3-5,
3-6, 3-7,
3-8, 3-9,
3-10, 3-11,
3-12, 3-13,
3-14
11/17

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Document No.: 304eS/MMSupp
Date of Issue: 09/16
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1. . B BA AS SI IC C T TE EC CH HN NI IC CA AL L D DA AT TA A

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Document No.: 304eS/MMSupp R01
Date of Issue: 11/17
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1.1 Basic Technical data
Power-plant
Sailplane is equipped with a high-tech powerful FES front electric propulsion system
developed for high performance sailplanes. Main parts of the FES system are:
Brushless electric motor
Controller for motor
Foldable propeller
Battery packs (FES-BP-14S) with internal BMS (Battery Management System)
Charger (1200W or 600W)
FCU (FES control unit) instrument
LXUI box with Shunt (for current and voltage measurements)
FCC box (FES connecting circuit)
Power switch
DC/DC converter (converts high voltage to 12V)
1.2 Technical Description
The GLASFLÜGEL 304 eS is single seat 18m flapped sailplane of 18m FAI class,
constructed from fiber-reinforced plastics (FRP), featuring camber-changing flaps
and a T-tail (with fixed horizontal stabilizer and elevator). The sailplane is equipped
with FES (front electric propulsion system) which enables self-sustaining flight.
1.2.1 Fuselage
Front part of the fuselage is equipped with electric permanent magnet motor. The
motor is directly connected with spinner and foldable propeller. The system enables
restarting of the motor in flight and precise positioning of the spinner after motor turn
off to achieve good aerodynamic qualities of the fuselage.
Motor controller and other electronic devices there are located in the central part of
the fuselage in place of original baggage compartment.
Battery packs there are located aft the wing in battery compartment accessible
through a covered opening in the upper side of the fuselage.
1.2.1.1 Battery compartment cover and venting valve
Battery compartment cover is equipped with venting valve. The valve consist of hole
with diameter 40mm covered by special foil. The foil is hold in place by circular ring
made of adhesive tape (inner diameter 30mm, outer diameter 50mm). The valve
must be attached only the way described above. Other attachment options are
prohibited.
1.2.2 Wing
Not affected.

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Document No.: 304eS/MMSupp R01
Date of Issue: 11/17
1-2
HPHLtd.
1.2.3 Horizontal Tail Unit
Not affected.
1.2.4 Vertical Tail Unit
Not affected.
1.2.5 Water ballast system
Not affected.
1.2.6 Power-plant
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.

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Document No.: 304eS/MMSupp R01
Date of Issue: 11/17
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HPHLtd.
Genera layout of the FES system
1.2.6.1 Electric motor
Motor construction is out-runner 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-HPH-M100) at 116V on motor controller
and loaded with propeller (type FES-HPH-P1-102):
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-HPH-P1-102 propeller
4500 rpm
Battery current loaded (4500 rpm, 116V) with FES-HPH-P1-102
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.