LZ design FES DG P1 102 User manual

FES PROPELLER MANUAL
Version 1.24
Type: FES DG P1 102
This manual is accepted by DG Flugzeugbau as manual for the
propeller FES-DG-P1-102, if used in the DG-1001E.
Issued
(DE/EI)
LZ Design
Checked
(CVE/MPI)
Wassenaar
Approved
(HoOA/LMPL)
Dirks
Date
Oct. 2022
Date
11 .Nov. 2022
Date
16. Nov. 2022
LZ design d.o.o. •Brod 3D, 1370 Logatec, Slovenia •tel [phone]
[email protected] •www.front-electric-sustainer.com

FES Propeller Manual Version 1.23 October 2022
Page 2 of 11
Table of Content
1. Important notices..................................................................................................... 3
1.1 Limited Warranty ................................................................................................. 3
2. Technical data.......................................................................................................... 5
3. Model designation .................................................................................................... 5
4. Construction ............................................................................................................ 6
4.1 Certification standards ......................................................................................... 6
4.2 Construction Material ........................................................................................... 6
4.3 Surface finish ...................................................................................................... 6
5. Removal of propeller blades ...................................................................................... 7
6. Installation of propeller blades .................................................................................. 8
7. Operating instructions............................................................................................. 10
8. Acceptable minor damages ..................................................................................... 10
9. Maintenance and repair .......................................................................................... 11
10. Shipping and storage ............................................................................................ 11
11. Revision history .................................................................................................... 11

FES Propeller Manual Version 1.23 October 2022
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1. Important notices
Owners and pilots who use FES system should read this manual thoroughly. It
contains important information about operation, maintenance, and service of FES propeller
blades, having a vital importance to the flight safety.
Caution: Yellow triangle is shown for parts of the manual which should be
read carefully and are important for proper operation.
Warning: Notes with a red triangle describe procedures that are critical and
may result in reduced safety or may lead to a critical situation.
Note: A bulb icon is shown when a useful hint is provided to the reader.
1.1 Limited Warranty
This product is warranted to be free from defects in materials or workmanship for
two years from the date of purchase. 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, but 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.
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 parts, 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 contact LZ design
directly.
© LZ design. All rights reserved

FES Propeller Manual Version 1.23 October 2022
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Warning!
Users of FES powered sailplanes should recognize that various types of risks are
involved, and they should take all precautions to minimize them, since they cannot be
eliminated entirely.
The propeller blades are one of the most critical parts of powered sailplane, having
vital importance to the flight safety. They are subject to constant torque loads from the
motor, airflow, and high centrifugal and bending loads. A mechanical failure could cause a
forced landing or create vibrations sufficiently severe to damage the glider. Unusual
vibrations should be investigated and fixed immediately, as it could be a warning that
something is wrong.
Please pay your attention, especially to the section dealing with inspections and
maintenance. It is essential that the propeller blades are properly maintained according to
the service procedures and intervals described in this manual.

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2. Technical data
FES propeller is assembly of foldable, fixed pitch composite propeller blades which
are mounted on special hub with attachment bolts at certain angle.
Number of propeller blades
2
Maximum power on a propeller shaft
30 kW
Maximum rotational speed
4800 RPM
Propeller blade mass (excluding attaching
bolts)
approximately 260 g each blade
Diameter of the propeller
1020 mm
Service time between periodic controls
50 hours or 12 months
Service time between special controls
200 hours
Type of propeller
Tractor
Sense of rotation
clockwise looking at direction of flight
Operating conditions
any normal environment condition
3. Model designation
Propeller model designation is the following:
FES DG P1 102
(1)
(2)
(3)
(4)
where:
- (1) designed for application
- (2) designed for specific sailplane type (DG1001-e)
- (3) model version
- (4) propeller diameter in cm
Propeller serial-number is identified as follows:
XXX (L and R) - YYYY
where:
- XXX (L and R) - serial number of the propeller
left blade is marked as L
right blade is marked as R
- YYYY - year of manufacture.
Propeller identification placard is located on the propeller sticker (transparent sticker glued
on lower center part of the propeller).
Note: Propeller type FES DG P1 102 is identical like FES VEN P1 102. It is
marked differently due to different type and manufacturer of the sailplane.

FES Propeller Manual Version 1.23 October 2022
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4. Construction
4.1 Certification standards
Propeller type FES DG P1 102 described here is designed and tested according to
CS 22 Subpart J.
This manual is intended to comply with CS‐22.1903, providing the essential
information for installing, servicing, and maintaining the propeller.
4.2 Construction Material
Propeller blades are made of CRFP (carbon fiber reinforced plastic). They are
produced in accurate metal molds, which were manufactured using modern CNC
technology. This made it possible, to have very accurate profile geometry. At attachment
point of propeller blade is integrated hardened steel bushing with very accurate tolerance,
so that play is minimal.
Propeller hub is CNC milled part, from Aluminum alloy 7075, black anodized.
4.3 Surface finish
High quality acrylic white paint (PPG D700) is used to protect the composite body
against moisture and erosion. Each blade pair is sanded and polished so that mass
difference is only about 0,1g (0,3g is maximum weigh difference tolerance). Paint is
resistant against fuel, oil and other chemical products. This type of paint has also an
excellent flexibility. Only tips of the propeller blades can be painted in other colors as a
safety mark. Otherwise only allowed color is white as this is structural part.

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5. Removal of propeller blades
1. Carefully remove white round stickers which are glued over 6 bolts, which hold the
spinner. Unscrew all six M4x6 countersink screws, with 2,5mm sized hex key, to remove
the spinner.
2. Before starting removal process of propeller blades it is strongly recommended to close
motor openings with a tape, as show on photo above to prevent any of the small parts
entering the motor, if it falls through the fingers by coincidence. When this happens, it is
usually necessary to remove and open motor, which is quite demanding job, so it is much
easier to tape openings.
Flatten and remove split pin, which secure M8 crown nut on each end of propeller blade
attachment bolt. Carefully unscrew crown nuts and remove M8 spring spacers.
3. Push attachment bolt out of the hub. If is not possible to push them out with hands,
you can use small plastic or wooden hammer and carefully push them out completely.
Propeller blades are then free to take out.

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6. Installation of propeller blades
1. Before installation of new propeller blades, check that marking on the label, which is
located on lower inner surface, confirms the correct type. For DG1001-e, propeller type is
FES DG P1 102. Left blade is marked as L and right blade is marked as R.
2. Left and right propeller blade have slightly different shape of top center surface due to
asymmetric shape of the spinner. When each of them is installed on proper side, and
aligned with the fuselage, top surface of the first 3cm need to have contour aligned with
spinner shape.
3. Before inserting the bolts, lubricate the shaft of the bolt with thin layer of grease. We
recommend using white silicon grease (use only clean grease, from closed tube). Then
insert such lubricated bolts to each propeller blades bushing, from each side, so that thin
film of the grease will be also transferred to inner surface of bushing. Clean away any
exceed amount of grease. If there is too much grease, it will be later spilled to inner
surface of the spinner by centrifugal force, so we recommend using only a minimum
amount of grease. Take out the bolts, and put them on clean surface, to be ready for
assembly.
4. Align propeller blade so that its fixing hole is nicely aligned with hole of propeller holder.
From back side of the holder, insert lightly lubricated, special bolts. This means that
head of the bolt must be on trailing edge side of propeller as on picture below!
One of the two special bolts is marked on the head with a small dot. Be sure to install it
to proper side of propeller holder which is marked with small dot.

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5. Before placing spring washers, crown nuts, and split pins, it is strongly recommended to
close motor openings with a tape, as show on photo in previous chapter to prevent that
any of the small parts could enter the motor, if it falls through the fingers by coincidence.
When this happen, it is usually necessary to remove and open motor, which is quite
demanding job, so it is much easier to tape openings.
6. Place M8 Inox spring washer to the threaded side of a bolt, and then a crown nut M8.
Tighten the crown nut with key number 13, so that there is some tension in spring
washer, which create enough friction so that bolt cannot rotate freely. If there is too much
tension in the forks, propeller blades would not be able to open and close freely. If this is
the case, un-tight crown not so that blades can move free, and it is also possible to insert
split pin into the hole in the pin trough crown nut. Carefully insert new safety pin of
1,4mm diameter x 22mm length, and bend its two ends, around crown nut.

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7. Fix the spinner with six Inox M4x8mm countersink head screws. Tightening of all 6
screws should be gently with small torque (do not use high torque, as thread in the
aluminum plate could be damaged). Please do not use any glue to secure them, as during
rotation centrifugal force to the screws create high enough friction, which prevent
unscrewing. We prefer to cover heads of the screws with white round stickers (diameter
about 14mm), which additionally secure the screws from unscrewing, and it also looks
nicer!
7. Operating instructions
To ensure reliability and safety of the propeller, preflight check of the propeller should be
done before each flight by the pilot/owner:
- remove protection fluorescent fabric cover
- make sure that propeller surfaces are clean before each flight. Propeller full of bugs
is less efficient and in worst case they can even increase level of vibrations. For
cleaning, use wet cloth as used for other parts of the glider.
- check visually the leading and trailing edge at the root. If there are visible any
cracks or other major damages, please contact manufacturer for advice before next
flight. If is not clear, please check next chapter about acceptable minor damages.
- check that each blade is opening and closing freely with only small friction. If there
is too much friction, it is necessary to clean and lubricate the attachment bolts and
bushing. To perform this is necessary to remove the propeller blades.
8. Acceptable minor damages
1. Thin cracks up to 10 mm of length in paint are allowed, but not in the root section. Only
in the outer part of the propeller blade (15 cm or more from attachment point) such
cracks in paint are acceptable. If such cracks do occur, it is anyway advisable to consult
with qualified service or manufacturer regarding airworthiness. Please send a good photo
and information about operating time.
2. Only small damages of the paint on the leading edge are acceptable, as they are
unavoidable after long time of usage.
3. Structural cracks, deformations or de-laminations of composite structure are not
acceptable for the propeller blades. If they occur, please send propeller blades to
manufacturer for the inspection.

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9. Maintenance and repair
1. Periodic control of propeller is required after every 50 hours of motor run or after 12
months, whatever comes first, by air-worthiness controller:
- check visually the leading and trailing edge at the root. If there are visible any
cracks or other major damages, please contact manufacturer for advice before next
flight. If is not clear, please check chapter about acceptable minor damages.
- check that each blade is opening and closing freely with only small friction. If there
is too much friction, it is necessary to clean and lubricate the attachment bolts and
bushing. To perform this is necessary to remove the propeller blades.
- check condition of rubber part, glued to the root section of each propeller blade. If
rubber parts have signs of wear or they are damaged, they should be removed and
replaced. New rubber part should be glued to each propeller blade with Loctite Super
Attak quick glue or similar.
- inspect the leading edge of the blades for minor paint damages from small stones;
If such damages are found, they should be repaired with small droplets of white
acrylic paint. When droplets of paint are dry, any excessive paint need to be carefully
sanded so that is in line with other surface. Only qualified persons are allowed to
perform such minor repair. Do not repaint complete propeller blades, as repainting
might affect balancing of the propeller. Maximum acceptable weigh difference
between the propeller blades is 0.3g.
2. Special control of the propeller is required at 200h of motor run. It can be performed by
manufacturer or by workshops which are approved by manufacturer.
10. Shipping and storage
Note: During the transport in the trailer, we recommend using a 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 covers for propeller blades
to prevent the propeller blades from opening when pulling the fuselage out
of the trailer.
If shipping or storage is required, careful packing is the best protection against
damage. Especially the tips and trailing edge should be sufficiently protected. The easiest
way is to use a few layers of bubble wrap for each propeller blade, and then place them
into thick cartoon or wooden box.
The propeller blades should not be stored close to heat source or in rooms with
extreme changes in temperature or humidity.
11. Revision history
May 2022
Initial release of manual, v1.23