Jonker Sailplanes JS3 RES User manual

JS-MD 3 RES Maintenance Manual
Supplement
MD11-AMM-00-002
Issue: 00
Rev. 00
Rev. Date: 23-May-22
Page i
JS-MD 3 RES MAINTENANCE MANUAL SUPPLEMENT
Type:
JS-MD Single
Model:
JS-MD 3 RES
Serial number:
Registration Number:
Document Number:
MD11-AMM-00-002
Title:
JS-MD 3 RES Maintenance Manual Supplement
Issue:
00
Date of issue:
23 May 2022
Created by
Responsible for
content
The technical content of this document is approved under the authority of the DOA ref.
EASA.21J.603.
Copyright ©:
M&D Flugzeugbau GmbH & Co.KG
Streeker Straße 5b 
D-26446 Friedeburg
-All rights reserved-
Uys Jonker
Digitally signed by Uys Jonker
Date: 2023.03.29 14:51:57 +02'00'
Michael Schwarz
2023.03.30 15:02:11
+02'00'

JS-MD 3 RES Maintenance Manual
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Issue: 00
Rev. 00
Rev. Date: 23-May-22
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JS-MD 3 RES Maintenance Manual
Supplement
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Issue: 00
Rev. 00
Rev. Date: 23-May-22
Page 0–1
0 GENERAL
This Maintenance Manual has been prepared to provide maintenance personnel with the
necessary information to maintain the JS-MD 3 RES System. All the data required to be
furnished to the pilot and the maintenance personnel, by the Airworthiness Requirement CS-
22, is contained in this manual. Supplementary data is also provided by the sailplane
manufacturer.
Record of Revisions
Issue
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Reason for Change
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Initial Issue

JS-MD 3 RES Maintenance Manual
Supplement
MD11-AMM-00-002
Issue: 00
Rev. 00
Rev. Date: 23-May-22
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JS-MD 3 RES Maintenance Manual
Supplement
MD11-AMM-00-002
Issue: 00
Rev. 00
Rev. Date: 23-May-22
Page 0–3
Record of Amendments
Date of Issue/ Revision
Date of
Insertion
Signature

JS-MD 3 RES Maintenance Manual
Supplement
MD11-AMM-00-002
Issue: 00
Rev. 00
Rev. Date: 23-May-22
Page 0–4
Table of Contents
0General ..................................................................................................................... 0–1
Record of Revisions............................................................................................ 0–1
List of effective sections ...................................................................................... 0–2
Record of Amendments....................................................................................... 0–3
Table of Contents................................................................................................ 0–4
List of Figures...................................................................................................... 0–7
List of Tables....................................................................................................... 0–9
List of Abbreviations............................................................................................ 0–9
1General ......................................................................................................................1-1
Descriptive data....................................................................................................1-1
Technical data......................................................................................................1-1
2Description of systems and components................................................................2-1
Introduction and overview.....................................................................................2-1
RES kinematics overview.....................................................................................2-2
Electrical system overview ...................................................................................2-3
3Airworthiness limitations and inspections..............................................................3-1
Airworthiness limitations.......................................................................................3-1
4Maintenance schedule..............................................................................................4-1
Annual inspection................................................................................................. 4-1
RES actuator assembly........................................................................................4-2
RES Pylon..........................................................................................................4-11
Propeller.............................................................................................................4-14
Electrical motor ..................................................................................................4-18
RES doors..........................................................................................................4-21
Front doors.........................................................................................................4-27
Battery latches ...................................................................................................4-29
Display and Control Unit (DCU)..........................................................................4-31
LXNAV Bridge....................................................................................................4-34
Motor controller assembly ..................................................................................4-35
DC-DC converter................................................................................................4-68
Retraction and Fuses Unit (RFU) .......................................................................4-72
Insulation Monitoring Device (IMD).....................................................................4-73
HV Connectors...................................................................................................4-74
Avionic Batteries.................................................................................................4-78

JS-MD 3 RES Maintenance Manual
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Issue: 00
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Rev. Date: 23-May-22
Page 0–5
Fire warning system...........................................................................................4-79
5Calibration & setup...................................................................................................5-1
Actuator system setup..........................................................................................5-1
Actuator calibration...............................................................................................5-4
Main door setup....................................................................................................5-4
Motor resolver calibration.....................................................................................5-5
Propeller alignment ..............................................................................................5-6
6Wiring loom............................................................................................................... 6-1
Display And Control Unit (DCU) ...........................................................................6-1
RES Control Board (RCB)....................................................................................6-2
Retraction And Fuses Unit (RFU).........................................................................6-4
Actuator................................................................................................................6-5
Left battery connector...........................................................................................6-6
Charger connector................................................................................................6-7
DC-DC converter..................................................................................................6-8
Right battery connector ........................................................................................6-9
Motor, motor controller and resolvers.................................................................6-10
Cooling fans....................................................................................................... 6-11
Insulation Monitoring Device (IMD).....................................................................6-12
Avionic batteries................................................................................................. 6-13
Ground bus ........................................................................................................6-14
Supplementary fire warning system....................................................................6-15
LXNAV bridge ....................................................................................................6-16
Complete schematic...........................................................................................6-17
Supplementary information and pictures ............................................................6-18
7Lubrication ................................................................................................................7-1
Introduction ..........................................................................................................7-1
Lubricants.............................................................................................................7-1
Lubrication plan....................................................................................................7-1
8System operation...................................................................................................... 8-1
Guarded RES master switch ................................................................................8-1
Display and control unit interface..........................................................................8-2
Battery selection switch........................................................................................8-2
Operational mode................................................................................................. 8-3
Other Information screens....................................................................................8-8
Warning Caution and Information messages......................................................8-10

JS-MD 3 RES Maintenance Manual
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Issue: 00
Rev. 00
Rev. Date: 23-May-22
Page 0–6
Maintenance mode.............................................................................................8-11
Setup menu........................................................................................................8-11
Charge mode ..................................................................................................... 8-12
Fire warning system...........................................................................................8-12
9Software/ Firmware update ......................................................................................9-1
Requirements for firmware updated......................................................................9-1
DCU firmware update...........................................................................................9-1
RFU firmware update ...........................................................................................9-2
Accessing the motor controller parameters...........................................................9-3
10 High Voltage batteries ............................................................................................ 10-1
Overview............................................................................................................10-1
Inspections.........................................................................................................10-2
Trailer considerations.........................................................................................10-2
Battery status indicators.....................................................................................10-3
Battery handling .................................................................................................10-4
Installing the HV batteries................................................................................... 10-4
Battery care........................................................................................................10-5
Long term storage..............................................................................................10-5
Charging ............................................................................................................10-7
11 Placard Booklet....................................................................................................... 11-1
12 Service Bulletins..................................................................................................... 12-1
13 Contact ....................................................................................................................14-1
Type Certificate Holder & Approved Manufacturing Organisation.......................14-1
Warranty and technical support................................ Error! Bookmark not defined.
APPENDIX A –Annual inspection checklist ..................................................................... 1
APPENDIX B –General torque specifications .................................................................. 1
APPENDIX C –STCs and Minor Change Approvals......................................................... 1
APPENDIX D –LIST OF WARNINGS/CAUTIONS .............................................................. 1

JS-MD 3 RES Maintenance Manual
Supplement
MD11-AMM-00-002
Issue: 00
Rev. 00
Rev. Date: 23-May-22
Page 0–7
List of Figures
Figure 1-1 JS3 with RES pylon extended...........................................................................1-1
Figure 2-1 RES System overview.......................................................................................2-1
Figure 2-2 Kinematics layout overview...............................................................................2-2
Figure 2-3 Electrical system overview................................................................................2-3
Figure 2-4 Electrical interaction overview...........................................................................2-5
Figure 4-1 RES Actuator Assembly....................................................................................4-2
Figure 4-2 Actuator assembly ............................................................................................4-4
Figure 4-3 Pylon bell crank assembly.................................................................................4-5
Figure 4-4 Pylon bell crank bracket assembly....................................................................4-7
Figure 4-5 Pylon driver arm assembly................................................................................4-9
Figure 4-6 Pylon assembly...............................................................................................4-12
Figure 4-7 Motor wires routing .........................................................................................4-13
Figure 4-8 Propeller assembly .........................................................................................4-14
Figure 4-9 Electrical motor...............................................................................................4-18
Figure 4-10 Doors assembly............................................................................................4-21
Figure 4-11 Main door bell crank assembly......................................................................4-23
Figure 4-12 Main doors assembly....................................................................................4-25
Figure 4-13 Front doors assembly....................................................................................4-27
Figure 4-14 Battery latches..............................................................................................4-29
Figure 4-15 DCU..............................................................................................................4-31
Figure 4-16 Motor controller overview..............................................................................4-36
Figure 4-17 Motor controller assembly.............................................................................4-37
Figure 4-18 Motor controller assemblt top view................................................................4-37
Figure 4-19 Motor controller PCBs...................................................................................4-39
Figure 4-20 Cooling fans..................................................................................................4-41
Figure 4-21 Motor controller HV wire sequence ...............................................................4-43
Figure 4-22 HV wire.........................................................................................................4-44
Figure 4-23 DC-DC converter ..........................................................................................4-70
Figure 4-24 RFU..............................................................................................................4-72
Figure 4-25 Insulation monitoring device..........................................................................4-73
Figure 4-26 High Voltage Connectors..............................................................................4-74
Figure 4-27 Seatback specification ..................................................................................4-78
Figure 4-28 Fire warning system......................................................................................4-79
Figure 5-1 Fuselage clearance...........................................................................................5-2
Figure 5-2 Pylon driver arm extension................................................................................5-2
Figure 5-3 B9 Bulkhead .....................................................................................................5-3
Figure 5-4 Main door setup................................................................................................5-5
Figure 6-1 DCU wiring........................................................................................................6-1
Figure 6-2 RCB Wiring.......................................................................................................6-2
Figure 6-3 RFU Wiring.......................................................................................................6-5
Figure 6-4 Actuator Wiring .................................................................................................6-5
Figure 6-5 Left battery connector wiring.............................................................................6-6
Figure 6-6 Charger connector wiring..................................................................................6-7
Figure 6-7 DC-DC Converter..............................................................................................6-8
Figure 6-8 Right battery connector wiring...........................................................................6-9
Figure 6-9 Motor, motor controller, and resolvers wiring...................................................6-10
Figure 6-10 Cooling Fans wiring ......................................................................................6-11
Figure 6-11 IMD Wiring....................................................................................................6-12
Figure 6-12 Avionics battery wiring ..................................................................................6-13
Figure 6-13 Ground bus wiring.........................................................................................6-14
Figure 6-14 Supplementary fire warning system wiring....................................................6-15

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Issue: 00
Rev. 00
Rev. Date: 23-May-22
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Figure 6-15 LXNAV bridge...............................................................................................6-16
Figure 6-16 LXNAV bridge wiring.....................................................................................6-16
Figure 6-17 Interlock and HV wiring.................................................................................6-18
Figure 6-18 Charge connector termination plug ...............................................................6-18
Figure 6-19 Battery connector termination plug................................................................6-19
Figure 7-1 Lubrication points..............................................................................................7-2
Figure 8-1 Guarded RES master switch.............................................................................8-1
Figure 8-2 DCU Primary Controls.......................................................................................8-2
Figure 8-3 Standby screen.................................................................................................8-3
Figure 8-4 Extension/retraction screen...............................................................................8-4
Figure 8-5 Extended screen...............................................................................................8-5
Figure 8-6 Propulsion screen.............................................................................................8-6
Figure 8-7 Battery charging screen....................................................................................8-7
Figure 8-8 Other information screens.................................................................................8-8
Figure 8-9 Message screen................................................................................................8-8
Figure 8-10 System screen................................................................................................8-9
Figure 8-11 Warning screen.............................................................................................8-10
Figure 8-12 Service screen..............................................................................................8-11
Figure 8-13 Setup screen.................................................................................................8-11
Figure 8-14 Fire warning system......................................................................................8-12
Figure 9-1 Adapter installation ...........................................................................................9-3
Figure 10-1 Battery overview ...........................................................................................10-1
Figure 10-2 Battery status indicators................................................................................10-3
Figure 10-3 Dual battery operation...................................................................................10-5
Figure 10-4 Single battery operation................................................................................10-5
Figure 10-5 Dual battery in aircraft charging ....................................................................10-7
Figure 10-6 Single battery in aircraft charging..................................................................10-8
Figure 10-7 External dual battery charging.......................................................................10-8
Figure 10-8 External single battery charging....................................................................10-9
Figure 11-1 RES placard booklet.....................................................................................11-1

JS-MD 3 RES Maintenance Manual
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Issue: 00
Rev. 00
Rev. Date: 23-May-22
Page 0–9
List of Tables
Table 1-1 RES Technical Data...........................................................................................1-1
Table 2-1 Electrical loads...................................................................................................2-5
Table 3-1 Life Limits Durations...........................................................................................3-1
Table 4-1 Maintenance Requirement Schedule..................................................................4-1
Table 4-2 Actuator specifications ......................................................................................4-4
Table 4-3 DC-DC converter specifications ......................................................................4-69
Table 4-4 Seatpan battery specification ...........................................................................4-78
List of Abbreviations
AMO
-
Approved Maintenance Organisation
CAN
-
Controller Area Network
DCU
-
Display and Control Unit
EGT
-
Exhaust Gas Temperature
HV
-
High Voltage (typically 400V in this configuration)
IMD
-
Insulation Monitoring Device
LE
-
Leading Edge
LiFePO
-
Lithium Ferrite Phosphate
M&D
-
M&D Flugzeugbau GmbH & Co. KG
MCP
-
Maximum continuous power
MOP
-
Means of Propulsion
MP
-
Maximum power
NAA
-
National Aviation Authority
OAT
-
Outside Air Temperature
OEM
-
Original Equipment Manufacturer
PRS
-
Power Rail Supply
RCB
-
RES control box
RFU
-
Retraction and Fuses Unit
RPM
-
Revolutions Per Minute
SOC
-
State of charge
TCDS
-
Type Certificate Data Sheet
TE
-
Trailing Edge
VFR
-
Visual flight rules
VMC
-
Visual meteorological conditions

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Rev. Date: 23-May-22
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1 GENERAL
Descriptive data
The JS-MD 3 RES System is an electric propulsion system used for self take-off or sustained
flight when soaring conditions become unfavorable. Propulsion is made possible using a 2-
bladed propeller powered by an electric motor mounted on a retractable pylon in the rear
section of the fuselage.
The normal performance of the sailplane continues when the pylon is retracted.
Technical data
System technical data
Propulsion system
SOLO Electric Propulsion System 80400
Propeller Type
Technoflug KS-1C-120-R-065-S
Battery type
EMECTRIC BM 384 (96S4P)
Maximum RPM
4350
Max power for take-off (2 batteries)
40 kW
Max continuous climb power (2 batteries)
25 kW
Max power (1 battery)
25 kW
Max continuous power (1 battery)
12.5 kW
Complete system mass –no batteries
~24 kg (53 lbs)
Maximum Motor temperature
120 °C
Maximum Controller temperature
85 °C
Maximum HV Batteries temperature
70 °C
Table 1-1 RES Technical Data
Figure 1-1 JS3 with RES pylon extended

JS-MD 3 RES Maintenance Manual
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Rev. Date: 23-May-22
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Rev. Date: 23-May-22
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2 DESCRIPTION OF SYSTEMS AND COMPONENTS
Introduction and overview
The RES system can be divided into two main systems, the kinematic system, and the
electrical system.
Figure 2-1 RES System overview

JS-MD 3 RES Maintenance Manual
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Rev. Date: 23-May-22
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RES kinematics overview
Kinematics layout overview
The pylon extension/retraction kinematic system is contained inside the fuselage bay and
controls the pylon position as well as the operation of the main doors.
Figure 2-2 Kinematics layout overview
This system is comprised of a single pylon, for the mounting of the motor, driven by an
electromechanical actuator. The doors open in sequence with the movement of the pylon and
are closed when the pylon is fully extended.
Kinematics components
The RES system consists of the following kinematic components:
•Actuator assembly
•Pylon Assembly
•Main Doors Assembly
•Battery latches

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Rev. Date: 23-May-22
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Electrical system overview
Electrical overview
The electrical system consists of various components as illustrated in Figure 2-3:
Figure 2-3 Electrical system overview

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Rev. Date: 23-May-22
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Electrical components
The electrical system consists of the following electrical components:
•HV Batteries (removable)
•Avionic Batteries (removable)
•Display and control unit (DCU)
•Motor Controller assembly
•Cooling system
•RES Control Board (RCB)
•DC-DC converter (400 V - 12 V)
•Retraction and Fuses Unit (RFU)
•Insulation monitoring device (IMD)
•Charging Port (Optional)
•HV Connectors
•Wiring Looms
The electrical components interact with each other as illustrated in Figure 2-4: