LZ design LAK17A FES User manual
FES Maintenance manual, v1.16 May 2020
Page 2 of 24
Table of Contents
1. Important notices..................................................................................................... 3
1.1 Limited Warranty ................................................................................................. 3
2. Introduction............................................................................................................. 4
3. Description of the FES system ................................................................................... 4
3.1 General layout ..................................................................................................... 4
3.2 Description of main FES components .................................................................... 6
3.2.1 Electric motor ................................................................................................ 6
3.2.2 Propeller........................................................................................................ 7
3.2.3 FCU instrument.............................................................................................. 8
3.2.4 Battery packs................................................................................................. 9
3.2.6 Other components ....................................................................................... 10
3.3 General FES wiring scheme ................................................................................ 12
4. FES maintenance.................................................................................................... 13
4.1 Maintenance of main FES components ................................................................ 13
4.1.1 Motor maintenance ...................................................................................... 13
4.2 Normal procedures and inspections..................................................................... 14
4.2.1 Rigging and de-rigging of an FES equipped sailplane...................................... 14
4.2.2 Daily inspection............................................................................................ 14
4.2.3 Pre-flight inspection................................................................................... 14
4.2.4 FES test run on the ground ........................................................................ 14
4.2.3 After flight inspection ................................................................................... 15
4.2.4 Ground handling .......................................................................................... 15
4.2.5 Tie-down and ground-towing ........................................................................ 15
4.2.6 Storing and transportation ............................................................................ 16
4.2.7 Cleaning ...................................................................................................... 16
4.2.8 Inspection at the end of flight season............................................................ 16
4.3 Adjustments ...................................................................................................... 17
4.4 De-rigging and rigging of FES components .......................................................... 17
4.4.1 Removing battery packs from the sailplane:................................................... 17
4.4.2 Removing and installing the motor ................................................................ 18
4.4.3 Mounting and removal of the propeller .......................................................... 19
4.5 Lubrication instructions ...................................................................................... 19
5. Periodical inspections.............................................................................................. 20
5.1 Introduction ...................................................................................................... 20
5.2 Sailplane inspection periods................................................................................ 20
5.3 Inspection after every 100 flight hours................................................................ 20
5.4 Annual inspection .............................................................................................. 21
5.5 Inspection after a rough landing or ground loop .................................................. 21
5.6 Inspection at the end of flight season ................................................................. 21
6. Parts with limited service life ................................................................................... 21
7. Placards................................................................................................................. 21
8. Balancing of rotating parts ...................................................................................... 21
9. Repairs .................................................................................................................. 22
9.1 List of potential problems ................................................................................... 22
9.2 List of spare parts.............................................................................................. 23
9.3 Soldering........................................................................................................... 23
9.4 Materials necessary for small repairs................................................................... 23
10. Revision History.................................................................................................... 24
FES Maintenance manual, v1.16 May 2020
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1. Important notices
Please read this manual thoroughly. It contains important information about the FES
system and its maintenance, having vital importance to flight safety.
Information in this document is subject to change without notice. LZ design reserves
the right to change or improve their products and to make changes in the content of this
material without obligation to notify any person or organization of such changes or
improvements.
The following definitions apply to warnings, cautions, and notes used in this manual.
WARNING: Notes with a red triangle describe procedures that are critical
and may result in reduced safety or may lead to a critical situation.
CAUTION: A Yellow triangle is shown for parts of the manual, which should
be read carefully and are important.
NOTE: A bulb icon is shown when a useful hint is provided to the reader.
1.1 Limited Warranty
This FES system is warranted to be free from defects in materials or workmanship for
two years from the date of purchase when installed by LZ design. Within this period, LZ
design will, at its sole option, repair or replace any components that fail in normal use.
Such repairs or replacement will be made at no charge to the customer for parts and
labor; however, the customer shall be responsible for any transportation cost. This
warranty does not cover failures due to abuse, misuse, accident, or unauthorized
alterations or repairs.
If the FES system is installed into the sailplane by authorized company, warranty for
installation and failure of components (as a result of improper installation) is this
company’s responsibility. LZ design will not cover failures due to unauthorized installation,
alterations or repairs, abuse, misuse, or accidents.
The warranties and remedies contained herein are exclusive and in lieu of all other
warranties expressed or implied or statutory, including any liability arising under any
warranty of merchantability or fitness for a particular purpose, statutory or otherwise. This
warranty gives you specific legal rights, which may vary from state to state.
In no event shall LZ design be liable for any incidental, special, indirect, or
consequential damages, whether resulting from the use, misuse, or inability to use this
product or from defects in the product. Some states do not allow the exclusion of
incidental or consequential damages, so the above limitations may not apply to you.
LZ design retains the exclusive right to repair or replace the unit or software, or to
offer a full refund of the purchase price, at its sole discretion. Such remedy shall be your
sole and exclusive remedy for any breach of warranty.
To obtain warranty service, contact your local LZ design dealer or LZ design directly.
© LZ design. All rights reserved.
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2. Introduction
The FES Maintenance manual contains information for pilots, technicians, and
mechanics about safe and proper maintenance of the sailplanes equipped with FES (Front
Electric Selflaunch/Sustainer) system. This information is given following the requirements
of EASA CS 22.1529 for sailplane maintenance.
3. Description of the FES system
We developed the FES system to be reliable and straightforward to use. It requires
minimal maintenance. You must familiarize yourself with the position of all the FES
components and their function to conduct maintenance on an FES system.
3.1 General layout
The general layout of the FES system.
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Connection of the instruments to the FES 12V power supply circuit.
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3.2 Description of main FES components
3.2.1 Electric motor
The FES system uses an outrunner type motor with brushless synchronous
permanent magnet and an electronically controlled 3 phase commutation system. The
rotor position is measured using three hall sensors, with an additional fourth hall sensor
used for automatic propeller positioning.
This motor can work only in combination with a suitable electronic motor controller.
It transforms the direct current supplied by the battery packs into a 3phase current
required by the motor.
The following table contains the electrical motor power ratings (type: FES-LAK-M100)
with 116 V on the motor controller and loaded with a propeller (type: FES-LAK-P10-100):
FES MOTOR
Maximum torque
75 Nm
Maximum current
200 A
Maximum Voltage
180 V
Motor velocity constant
45 RPM/V
RPM without load (116V DC on the controller)
5300 RPM
Motor current without load at 5300 RPM
16 -18 A
Max. RPM with FES-LAK-P10-100 propeller (1m diameter)
4500 –4700 RPM
Battery current loaded (4500 rpm, 116V) with FES-LAK-P10-100
up to 200 A
Rotor rink diameter
177 mm
Motor length
100 mm
Motor weight
cca. 7,3 kg
Motor efficiency
82 –95 %
Maximum allowed temperature
90 °C
Minimum allowed starting temperature
-20 °C
Please refer to the FES Motor manual for a detailed description.
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3.2.2 Propeller
The FES system uses a foldable fixed-pitch carbon fibre composite propeller. It is
designed and tested according to EASA CS 22 Subpart J.
The propeller blades are made from glass and carbon fibre composite in metal
moulds, which are CNC machined. This manufacturing technique improves the geometrical
accuracy of the moulds and enables us to manufacture blades with the best geometry
tolerance currently possible.
A quality acrylic white paint is used to protect the solid composite body against the
moisture and erosion. Each pair of propeller blades is sanded and polished to reduce the
mass difference between them to less than 0,2 g. The paint is resistant to fuel, oil, and
other chemical products and has excellent flexibility.
Propeller technical data and limitations:
FES Propeller
Number of propeller blades
2
Maximum power on a propeller shaft
23 kW
Maximum rotational speed
4500 RPM + 5 %
Propeller blade mass excluding attachment
bolts
Approx. 260 g
Propeller diameter
1000 mm
Service time between inspections
50 hours or 12 months
Service time between detailed inspections
200 hours
Type of propeller
Tractor
Direction of rotation
Clockwise looking at the direction of flight.
Operating conditions
Any normal environmental conditions.
Please see the FES Propeller manual for a detailed description.
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3.2.3 FCU instrument
FCU instrument was developed for the FES system by LXNAV –known in the gliding
community for their excellent flight computers (LX8000, LX9000) and electronic
variometers. LXNAV manufactures FCU instruments exclusively for the FES system.
Technical specification:
−ON/OFF switch
−Sunlight readable QVGA LCD (320*240 display)
−Consumption ca. 100 mA
−Audio signal
−1* rotary encoder with pushbutton
−1* RPM input
−2* LED inputs
−1* digital output for BRAKE
−1* analogue output for POWER (adjustable with rotary knob)
−4* temperature inputs (Controller, Motor, and two battery packs)
−1* analogue input for measuring current
−1* analogue input for measuring voltage
−1* RS232 input for firmware update
−1* input for open canopy switch
−1* CAN bus
−1* RS485
−1* additional analogue input
Please see the FES FCU Instrument manual for a detailed description.
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3.2.4 Battery packs
The battery packs have been developed specifically for the FES system. There are 14
cells, all wired in serial (14S) in each battery pack. A standard FES system requires a pair
of battery packs. The first pack is marked with the letter A and second pack as B. Battery
packs provide power to the whole FES system.
We are using high power SLPB (Superior Lithium Polymer Battery) cells produced by
the global leader of the Lithium polymer battery industry - Kokam Co. Please see the cell
technical specifications for detailed information about the cells.
Each battery pack is equipped with a Battery Management System (BMS):
−GEN1 battery packs have an external Battery Management System
−GEN2 battery packs have an internal Battery Management System. The system is
placed above the cells and is equipped with 14+2 LEDs to monitor its operation.
For the + and - terminals, we chose to use Amphenol Radsok hyperbolic high-power
contact technology. High current sockets are hidden inside of the pack. Different sizes of
the terminals are used to prevent incorrect polarity connections. The minus pole (-) uses
an 8mm and the plus pole (+) a 10,3mm socket.
Technical data of FES GEN2 14S 40Ah Battery packs
Battery pack type
FES GEN2 14S 40Ah
Weight per pack
15,7 kg
Box dimensions (W x L x H), without terminals and ventilators
154 x 220 x 260 mm
Cells producer
Kokam, South Korea
Electrochemical system
NMC (LiMnNiCoO2)
Cells type
SLPB100216216H
Cell average capacity
40 Ah
Number of cells
14
Energy storage capacity
2,1 kWh
Maximum allowed total voltage
58,3 V
Minimum allowed total voltage
42 V
Maximum allowed current
250 A
Max balancing current per cell
1 A
Internal BMS type
FES-BMS-9R
Standard 1200 W charger
FES KOP1001
Standard 600 W charger
FES KOP602
Optional 2000 W charger
FES KOP2300
Optional 2000 W charger
FES R2300
For a detailed description of the battery packs, please refer to the following manuals:
-FES GEN1 Battery pack manual
-FES GEN2 Battery pack manual
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3.2.5 Wiring
FES wiring consists of:
1. POWER CABLES
−For power cables, we use high-quality Betatherm 155 wires with a cross-section of
35 sqmm.
−On the end of power wires, suitable cable shoes and Radsok power connectors are
pressed and soldered.
2. SIGNAL CABLES
−We use high quality tinned and shielded wires in signal cables.
−Signal wires are soldered to multipole DB9 or DB15 connectors on one side and
directly to the circuit board inside the FCC box on the other.
3. 12 V WIRES
−We use aviation grade Spec 55 wires for all 12V circuits.
−12 V circuits are equipped with cable shoes.
4. DIFFERENT TYPES OF CONNECTORS
3.2.6 Other components
DC/DC converter converts high voltage from FES battery packs to 12 V, which supplies
the instruments and the main contactor. It also charges 12 V battery if installed.
The main contactor connects and disconnects the FES battery packs to the motor
controller. A pre-charge resistor is also installed.
The motor controller converts high voltage DC to three-phase AC voltage, which it
feeds to the motor. It also sends RPM and controller temperature by the CAN bus to the
Flight Control Unit (FCU) instrument.
Ventilators provide cooling to the motor controller.
The power switch provides 12V power to the main contactor and the motor controller
electronic circuit board.
The BMS in each battery pack controls charging and cell balancing. It can be connected
to a PC with a special cable to monitor the charging process with the BMS Control
software. During the flight, BMS sends temperature and individual cell voltage data to the
FCU instrument.
A shunt measures current from Battery packs.
The LXUI box converts analogue current and voltage measurement signals to a digital
signal, which is sent over the CAN bus to the FCU instrument.
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FCC box is where all signal and 12V wires meet and are distributed to the right
consumers. It houses a microprocessor for automatic propeller positioning, a 2A fuse, a
potentiometer for adjusting the electronic brake, and a female DB9 connector used when
updating the FCU.
A 12V battery acts as a redundant power supply for the instruments when the main
battery packs are not installed. The battery must be equipped with a 3A fuse.
A 325A power fuse protects the entire system in case of a high power short-circuit.
FCU instrument displays battery and propulsion system information to the pilot via the
screen and three status LEDs and houses the throttle rotary control knob.
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3.3 General FES wiring scheme
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4. FES maintenance
4.1 Maintenance of main FES components
4.1.1 Motor maintenance
We designed the FES motor such that it does not require any special maintenance.
Warning:
Opening or disassembling the motor can void the warranty! It is
very dangerous due to powerful magnets installed on the rotor!
To ensure proper operation of the motor, please consider the following:
−Make sure the motor compartment is clean and completely free of all
foreign objects that could enter the interior of the drive.
−It is necessary to protect the motor from humidity, dirt, paint, glue, etc.
Proper functioning of the motor cannot be guaranteed, and irreparable damage is
possible if you ignore this.
−In case of damage, ship the motor back to the manufacturer for repair.
Unintended handling leads to secondary damage.
Note: Strong magnetic field of the magnets in the rotor can erase the data on
magnetic memory cards or electronic devices and interfere with sensitive
medical devices (e.g., pacemakers).
Keep them away from the rotor’s close-up
range!
The gap between the stator and the rotor magnet's function-boundary is only a few
tenths of a millimeter thick. The danger of foreign objects accumulating in this gap exists
and makes itself noticeable by scratching-sounds. In this case, remove the spinner, and
blow out the motor with compressed air. Stop using the system and prevent the motor
from running until you have cleaned it. Be especially aware of metal shavings, which can
firmly stick to the magnets. If this is the case, the drive needs to be disassembled by the
manufacturer.
4.1.2 Propeller maintenance
Please refer to the FES Propeller manual.
4.1.3 Battery packs maintenance
Please refer to the FES Battery pack manual.
4.1.4 FCU instrument maintenance
Please refer to the FES FCU Instrument manual.
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4.2 Normal procedures and inspections
4.2.1 Rigging and de-rigging of an FES equipped sailplane
Please refer to the sailplane’s manual.
Warning:
Remove the cable connecting the battery packs during rigging and
de-rigging if the batteries are installed in the fuselage.
4.2.2 Daily inspection
It is essential to inspect the glider after rigging. As a minimum, check the following:
−Check the sailplane as required for the specific type of sailplane.
−Check the FES system visually, especially the condition of the propeller blades.
If you find any issues, repair them before the flight!
4.2.3 Pre-flight inspection
Perform a pre-flight inspection each day before the first take off.
−Check the sailplane itself as required before a flight
−Perform FES test run on the ground as described below
4.2.4 FES test run on the ground
1. Remove propeller covers and a tail dolly.
2. Open the battery compartment cover.
3. Check that the Power switch is OFF.
4. Insert the connecting cable between the battery packs.
5. Seal the battery compartment cover with glider tape.
6. Take a seat in the glider and close the canopy.
7. Check that the propeller area and the space in front of the glider are free of people
and obstacles.
8. Switch on the FCU.
9. Switch on the Power switch and rotate a throttle knob gently clockwise.
10. Wait about 8 seconds, for FCU to show all battery symbols.
11. Start the motor but use only low power to check the proper operation.
Caution:
If you want to test the system at its maximum power, a helper
must press the fuselage down and prevent the glider from moving.
12. Check if propeller braking and automatic positioning are working fine.
13. Switch OFF the power switch.
14. Switch OFF the FCU.
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4.2.3 After flight inspection
Caution:
Always remove the connecting cable between the battery packs
after landing. (Older packs with external BMS: Always remove the Power
fuse after landing and put safety covers on the exposed terminals.)
Warning:
Make sure that the Power switch is OFF before removing the
connecting cable (or the Power fuse).
If you used the system during flight, remove both batteries from the glider and
recharge them according to the charging instructions in the FES Battery pack manual.
4.2.4 Ground handling
Use the protective propeller covers on the ground that prevent propeller blades
from opening. Do not forget to remove the covers before the flight!
Caution:
Make sure that the propeller is in a horizontal position when lifting
the tail of the fuselage, i.e., when attaching the tail dolly.
Warning:
Do not push on the propeller or spinner for pushing or pulling the
glider or lifting the tail!
When opening and closing the canopy, propeller blades must always be positioned
horizontally.
4.2.5 Tie-down and ground-towing
Do not leave a FES equipped sailplane outside in the rain, unless it is fully covered
with high quality all weather covers.
Protect the motor and battery compartment from water. Remove the battery packs
from the glider and store them in a dry place, without direct sunlight, to prevent to be
overheating.
Towing on the ground should always be performed with the battery packs
appropriately secured with the propeller in a horizontal position. We recommend using tow
gear or at least a towing rope to tow the glider to the start.
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4.2.6 Storing and transportation
A FES sailplane should be transported and stored in a high-quality enclosed trailer
constructed of metal or fiberglass reinforced plastics with adequate insulation and
ventilation characteristics.
−Lighter fuselages can be secured against forward and jumping motions with a
nose cone support in the shape of the spinner with a recess for propeller blades in
the horizontal position, covered with a soft and thick material.
−We recommend securing heavier fuselages with the support that holds fuselage
behind the spinner. Otherwise, the loads on motor and propeller blades could be
too high and damage them during transportation on bad roads.
We recommend using soft cotton canopy cover, which covers the nose of
the sailplane and prevents the opening of propeller blades.
If you are not using a canopy cover, use FES propeller blade covers to prevent the
propeller blades from opening when pulling the fuselage out of the trailer.
The fuselage dolly should be positioned just forward of the main landing gear
opening. Forward stop or a belt must be provided for the fuselage dolly to prevent the
fuselage from slipping forward and leaving it without support.
4.2.7 Cleaning
Avoid cleaning with water around the FES motor and battery compartment area.
Clean the spinner and propeller blades with a wet sponge or soft cotton towel. Tape
adhesives are best removed using pure petroleum spirits or nitro thinner.
4.2.8 Inspection at the end of flight season
At the end of the flying season or before long storage of the glider in a hangar or a trailer,
store the FES Battery packs in a dry, warm place (room temperature). The battery pack is
best stored when cells have a voltage of 3.7 V per cell, which is equal to ca. 52 V per pack
or ca. 104 V total system voltage –displayed by the FCU instrument.
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4.3 Adjustments
The following FES system items have to be checked and adjusted if they are out of the
allowable range:
1. Early LAK FES aircraft only: The gap between spinner and fuselage should be
around 0,5 –1,0 mm. You can change the gap with tightening or un-tightening of 4
nuts on the backside of the mounting wall.
2. Closing and opening of the ventilation: When the ventilation knob is in the full
rearward position, the ventilation should be fully closed. If not, adjust it with two
M3 bolts that hold the wire inside of the instrument panel.
4.4 De-rigging and rigging of FES components
4.4.1 Removing battery packs from the sailplane:
1. Check power switch (key) is OFF
2. Check that FCU and all other instruments are OFF - i.e., Flight computer, Flarm, Radio,
Transponder, PDA, etc
3. Open cover of the battery compartment
4. Unplug the connecting cable between the packs
5. Unplug the RED + and BLACK - power connectors
6. Secure the power supply cables to the side of the battery compartment box
7. Remove both temperature sensor connectors (DATA) from each battery pack
8. Secure the temperature sensor cable to the side of the battery compartment box
9. Un-tighten battery pack fixation knobs
10. Remove the fixation plate
11. Tightly grip the front battery by a carrier strap
12. Lift it out of the fuselage and lay it down in a safe spot
13. Tightly grip the rear battery by a carrier strap and slide it forward along the bottom of
the battery compartment
14. Lift the battery pack out of the fuselage and lay it down in a safe spot
15. Close the cover of the compartment
Caution:
Make sure to store battery packs in a dry and safe place. Read the
FES Battery pack manual.
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Installing the battery packs into the sailplane:
Warning:
Make sure that you fully charge both battery packs before
installation into the sailplane. Both battery packs must have an
approximately equal voltage of cells (approx. 4.16 V per cell). The total
voltage difference of each battery pack must be less than 1 V!
1. Open the battery compartment cover.
2. Check that the power switch (key) is OFF.
3. Check that FCU and all other instruments are OFF –i.e., Flight computer, Flarm,
Radio, Transponder, PDA, etc.
4. Insert the first pack into the fuselage with contacts facing forward.
5. Slide it back against the rear bulkhead.
6. Insert the second pack into the fuselage with contacts facing rearward.
7. Place the fixation plates.
8. Tighten the battery pack fixation knobs.
9. Insert and secure the temperature sensor connectors (DATA) to each battery pack.
10. Insert the RED (+) contact pin into the front pack.
11. Insert the BLACK (–) contact pin into the rear pack.
12. Close the battery compartment cover.
4.4.2 Removing and installing the motor
Note:
Removal of the motor from the sailplane is only allowed with written
permission by the manufacturer. Unauthorized removal voids the warranty!
Warning:
Flights without the motor are not allowed due to a significant
change in the centre of gravity (C.G.)!
To remove the motor from the glider (with spinner and propeller attached):
1. Open the ventilation fully –push the ventilation lever forward.
2. Remove the round composite cover on the front motor mounting rib from inside the
cockpit.
3. Unlock the springs securing the DB15 cable connector. Carefully unplug the
connector from the motor.
4. Unscrew three self-locking nuts from the rear of the motor.
5. Label the three power cables as A, B, and C and note their respective connectors
and position on a piece of paper (required for installation).
6. Disconnect the three power cables.
7. Un-secure six M8 bolts and remove them. The M8 bolt below the power cables has
a thinner head. Hold the motor assembly and carefully remove it from the fuselage.
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Installing the motor into the glider
To install the motor back into the aircraft, follow the steps above in the reverse order with
the following additional steps:
1. Open ventilation fully –push the ventilation lever forward.
2. We recommend using new bolt locking plates to secure M8 motor fastening bolts.
3. Connect the power connectors in the same order A, B, C as before. Only use new
M6 self-locking nuts. Make sure there is no contact between the cable shoes and
aluminum mounting wall or the M8 fastening bolts. Install the M8 bolt with the
thinner head below the power cables.
4. Carefully plug-in the signal cable connector into the connector on the motor's rear
wall. Secure the connector with the lock springs.
After reinstalling the motor, check the following:
−Spinner is in the centre of the fuselage
−The gap between spinner and fuselage is 0,5-1 mm
−All bolted connections are assembled correctly and secured properly
−Do a test run of the motor on the ground and check:
oMotor rotating direction
oMotor running smoothly
oPropeller brake works OK
oFCU instrument is functioning correctly
4.4.3 Mounting and removal of the propeller
For mounting and removal of the propeller blades, refer to the FES propeller manual.
4.5 Lubrication instructions
There are only three parts in the FES system which require lubrication:
-Two pins that attach the propeller blades
-The ventilation valve pin, which goes through the shaft of the motor
Use a small amount of lubricant, creating a thin grease film. If there is an excess of
grease, the centrifugal force will spread it along the inside of the spinner and the bottom
surfaces of the propeller blades, making them dirty. The excess lubricant may appear like
a crack.
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5. Periodical inspections
5.1 Introduction
This section introduces a list of inspections designed to ensure the safe operation of
the FES system during its lifetime.
Qualified personnel, authorized to do sailplane inspections, should perform these
inspections at the time of regular sailplane inspections.
5.2 Sailplane inspection periods
The FES inspections are carried out in parallel to the regular aircraft maintenance
and inspections required for the specific type of the sailplane. These occur usually:
−After every 100 flight hours
−At annual inspection
−After rough landings or ground loops
−At the end of the flight season or before the aircraft is stored for an extended
period in a hangar or trailer
5.3 Inspection after every 100 flight hours
It is mandatory to check the FES system thoroughly, according to the following
checklist:
Inspection after every 100 flight hours
Date of inspection: ………………
No.
Checking
Conformity
Yes / No
Signature
1
FCU instrument wiring and functioning
2
Inspect ventilation opening - closing
3
Inspect propeller as per propeller manual
4
Inspect motor as per the motor manual
5
Check the motor mount on the motor frame
6
Check the gap between spinner and fuselage
7
Check all bolted connections
8
Check power cables for damage
9
Check battery packs
10
Check 12V battery condition - if installed
11
Inspect controller and main contactor
12
Perform a ground test run of the motor
13
Check operation of the propeller brake
14
Check operation of the propeller positioning
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