PCM ERWIN XL slope User manual

Erwin XL building Instruction October 2012
www.pcm.at 1
Wing span [mm]:
3000
Aspect ratio:
14,67
Wing area [dm2]:
61,33
Wing loading:
Erwin XL slope:
45,6-70,1
Erwin XL ultralight:
20,4
Erwin XL ultralight Elektro:
23,6-24,5
Weight [g]:
Erwin XL slope:
2800-4300
Erwin XL ultralight:
1250
Erwin XL ultralight Elektro:
1450-1500
Airfoil:
VS1
BUILDING INSTRUCTION
ERWIN XL slope –ERWIN XL ultralight - ERWIN XL ultralight Elektro

Erwin XL building Instruction October 2012
www.pcm.at 2
CONTENTS
DATA
1. Kit –Contents
2. What else do you need?
3. Electronical equipment
4. Settings for the first flight
ASSEMBLING THE MODEL
5. V-tail –GLIDER version
5a. V-tail –ELECTRIC version
6. Gluing of fuselage
7. Electronic components in fuselage –GLIDER version
7a. Electronic components in fuselage (electric drive) –ELECTRIC version
8. Wing
9. Installation of antenna
BEFORE THE FIRST FLIGHT
10. Ballast system
11. Fixing of the wing
12. Check list before starting
13. Attention, Erwin XL is sensitive to the sun
3
3
4
5
6
6
7
8
9
13
15
16
17
17
17

Erwin XL building Instruction October 2012
www.pcm.at 3
DATA
1. Kit –Contents
Fuselage, in two parts, incl. canopy and cover for end of fuselage, 1 piece
Wing, in two parts
V-Tail
Steel-connector, 3 pieces (1x long, 2x short) (XL slope)
Carbon connector (bar), 2 pieces (XL slope)
Carbon connector (pipe), 1 piece (XL ultralight + elektro)
Covers for servos on wing, 4 pieces
Levers for rudders, 4 pieces
Servo board (XL slope, XL ultralight)
Assembly board for hook for winch start (XL slope, XL ultralight)
Installation frame for engine (XL ultralight Elektro)
Fuselage board with 2 sideboards (XL ultralight Elektro)
Ball connectors for the elevator, 2 pieces (XL slope, XL ultralight)
Brass pipes for the elevator, 2 pieces (XL slope, XL ultralight)
Pipes and push rod, 2 pieces each (XL slope, XL ultralight)
Cover for opening for receiver (XL ultralight Elektro)
Tube for 2,4 GHz-antennas (XL ultralight Elektro)
Plugs and frames for connection of wing and fuselage, 4 pieces each
Screws, 2 pieces, for fixing the V-tail
Covers for servos on V-tail (XL ultralight Elektro)
Plug for V-tail, 1 piece (XL ultralight Elektro)
Levers, 2 pieces (XL ultralight Elektro)
Template for cutting nose of fuselage (XL ultralight Elektro)
Template for cutting opening for receiver (XL ultralight Elektro)
Building instruction (please download from our homepage)
2. What else do you need:
Controls of the wing:
Connectors for push rods, M2,5mm, 8 pieces
Welding rod, d=2mm
Hook for winch start and nut
On-off switch / socket for loading
Cables (electricity)
Cable for antenna, possibly steel wire for extension of
antenna
Plugs
Epoxy-glue (for example UHU 300 endfest or Stabilit, no
fast hardening epoxy resin)
Cotton flocks to thicken glue
Hook for winch start
Connector for push rods, M2,5mm

Erwin XL building Instruction October 2012
www.pcm.at 4
3. Electronical equipment
Servos for the wing
Erwin XL slope:
Futaba
S3150
Graupner
DES 448
Erwin XL ultralight + elektro:
Dymond
D60
Hyperion
Atlas HP DS09SCD
Servos for the V-tail
Hitec
HS65HB or MG
Robbe
S3107 (weak)
Graupner
DES 281
C2081
C261 (these servos will fit into the gap of the servo board)
Erwin XL ultralight Elektro
Dymond
D60
Receiver:
35 MHz:
Graupner DS19
Simprop Scan 7
2,4GHz:
all (Erwin XL slope and Erwin XL ultralight elektro need
antennas which can be lead outside the fuselage)
Accumulator:
Eneloop 2000 mA/h
Erwin XL ultralight
Electric drive:
Engine:
Controller:
Accumulator:
Propeller:
Spinner:
Logger / Limiter:
Kira 480 - 38, mit Getriebe 5,2:1
Kontronik Koby 55 LV
Jeti spin 44
YGE 40
3S 2200 mAh Wellpower
Aeronaut 12/8
D=30mm
Unilog 2 für Wettbewerbeinsatz

Erwin XL building Instruction October 2012
www.pcm.at 5
4. Settings for the first flight
(measure from the leading edge of the wing to the back)
Erwin XL slope
Centre of gravity: weak conditions: 88-94mm (f.e. plain, soft wind on slope)
strong wind on slope: up to 110mm possible
Hook for winch start: 10-20mm before centre of gravity (start with 20mm)
Erwin XL ultralight
Centre of gravity: due to little weight 100mm is possible without danger
Hook for winch start: 5-10mm before centre of gravity (start with 10mm)
Difference in angle of attack: +1°
Ailerons und flaps (soft)
(measure between aileron and flap and on deepest point of the elevator)
Ailerons und flaps (strong / dual rate)
(measure between aileron and flap and on deepest point of the elevator)
Butterfly (landing position)
(measure between aileron and flap and on deepest point of the elevator)
Flaps positive
(measure between aileron and flap and on deepest point of the elevator)
Flaps negative
(measure between aileron and flap and on deepest point of the elevator)

Erwin XL building Instruction October 2012
www.pcm.at 6
ASSEMBLING THE MODEL
5. V-tail –GLIDER version
The v-tail is ready prepared with holes for screws to be
fixed on the fuselage.
Controlling of the elevator:
Bend two brass levers as shown below and glue the ball
connectors to one end each. Then glue the levers to the
control surfaces of the elevator. The gluing spot should
be as near as possible to the turning axis of the controls
(silicone hinge).
(Here shown using the example of 2-metre-Erwin.)
Ready mounted levers with ball connectors.
(Here to be seen on Erwin –2 meter)
5a. V-tail –ELECTRIC version
As the electric version is equipped with an engine, there is
only little space in the fuselage cone. Therefore it makes
sense to install the servos in the tail. By this means you
can also save weight, as you need no or only little lead.

Erwin XL building Instruction October 2012
www.pcm.at 7
6. Gluing the fuselage
Check the alignment of the V-tail regarding the axis of the
fuselage, so that it is fixed symmetrically.
To do this, mount v-tail and wing on the fuselage. Look at
Erwin XL from the front and slowly lower the tail, until the
ends of the elevator disappear behind the wing.
If both ends of the elevator disappear at the same time,
the v-tail is aligned correctly.
If the v-tail isn’t aligned correctly, chamfer the edges of
the fitting. Put the two parts of the fuselage together again
and turn one part until the v-tail is mounted symmetrically.
Then glue the parts together. Use epoxy-glue and some
cotton flocks to thicken the glue.

Erwin XL building Instruction October 2012
www.pcm.at 8
7. Electronic components inside the fuselage –GLIDER version
Glue pipes into the fuselage every 25 cm with 5 minute
epoxy mixed with cotton flocks.
Prepare the pipes outside the fuselage: Put the 5 minute
epoxy onto the pipes. Then, thread them into the fuselage
from the front and place them as shown. Beware that the
last gluing point should be about 10-12cm from the end of
the pipes.
The servos for the elevator are mounted on the servo
board. The wholes are prepared for Graupner servos
C261.
Glue the servo board into the fuselage as shown on the
photo. Grind the gluing areas thoroughly and glue with
“UHU endfest 300” (epoxy 2 component glue) thickened
with cotton flocks.
Thread a push rods into the pipes, which act as
pushrods for controlling the elevator. Fix the remaining part
of the ball connector to the pushrods.
(Here to be seen on Erwin –2 meter)

Erwin XL building Instruction October 2012
www.pcm.at 9
7a. Electronic components (electric gear) inside the fuselage –ELECTRIC version
First, cut off the tip of the fuselage, so you can fix the
frame for the engine.
To do so, put the parts enclosed together to a template,
which you can put over the tip of the fuselage cone.
In order to get a correct cut, the template must be aligned
very precisely. Place the fuselage together with the
template on a plane surface. Put a level on the flat part on
the fuselage as shown. Now the fuselage can be aligned
horizontally.
The tip of the fuselage can be cut best with a fine blade
along a marked line.
The tip of the fuselage cone is now ready prepared for
correct mounting of the engine. Just glue the frame flush
with the cut of the fuselage.
Glue the installation frame for the engine with UHU 300
endfest or Pattex Stabilit into the fuselage.
Note that the screws are positioned up, down, left and
right. So you can correct the mounting of the engine later
by adding thin washers.
As there is no space for the receiver in the fuselage cone,
it is placed behind the wing joiner.
Use the template enclosed to mark the opening in the
right position and cut it.

Erwin XL building Instruction October 2012
www.pcm.at 10
For reception of 2,4GHz you can drill holes on the rear
lower end of the connecting rib to the wing to lead out the
antennas.
Insert plastic tubes inside these holes. You can easily
thread the antennas through these tubes later.
The tubes should be long enough …
… to cover the sharp edge of carbon fibre at the holes ...
… and to be still easily accessible inside the fuselage
when threading the antenna.
Secure the receiver in the fuselage with foam against
dislodgement.

Erwin XL building Instruction October 2012
www.pcm.at 11
If you want to use a large receiver, try to save space
when soldering the plugs for the wing.
Close the opening with the cover enclosed.
Bend a steel wire as shown for fixing the accumulator in
the fuselage.
Fix the wire first with adhesive tape on the accumulator.
So you can find the correct centre of gravity.
You can drill small holes in the sidebars of the fuselage
board as a locking mechanism for the accumulator. Do
this before you glue the sidebars.

Erwin XL building Instruction October 2012
www.pcm.at 12
Now mount the fuselage board to the sidebars with
screws. You can pack the board in plastic to prevent it from
being glued.
Glue the sidebars with UHU 300 endfest or Pattex Stabilit
into the fuselage. Sidebars and fuselage board provide
additional strength and assembly facilities for further
components.
Wait until the glue has hardened, then you can remove the
fuselage board.
If you want to use the model for competition, you can place
logger, limiter or current sensor on top of the board.

Erwin XL building Instruction October 2012
www.pcm.at 13
8. Wing
The openings for the servos are big enough for all
appropriate standard servos including mounting frame,
such as Futaba S3150.
Lead the cable through the wing as shown below.
The connection to the levers on the rudder goes crosswise
through the wing.
Before you glue the levers into flaps and ailerons, grind
the gluing spots on the control surfaces and on the
levers.
Aileron Flap
For gluing the lever use epoxy-glue with cotton flocks.
When fitting the lever in the correct position, notice that the
hole in the lever should be situated vertically above the
hinge line.

Erwin XL building Instruction October 2012
www.pcm.at 14
To connect the servos to the levers use two connectors
M2,5mm. In between, use a welding rod (diameter 2mm),
which you solder inside the both connectors.
To find the right length of the welding rod put all servos in
0-position. If the length isn’t exact after soldering, you can
heat the soldered point with the soldering iron until the
the wire can be moved to the correct position.
The root ribs have recesses for the plugs between
fuselage and wings for easy electrical connection.
Fix the covers of the servos with a double-sided adhesive.
In order to move the triangular ends of the ailerons, you
can bend a piece of steel wire (1mm) and glue it into the
end of the aileron as shown. Let the wire jut out about
6mm.
You can also fix a piece of steel wire to the trailing end of
both control surfaces with adhesive tape. Let the wire be
movable inside the tape on one control surface.
If you want an easier solution, connect the two control
surfaces with an adhesive tape.

Erwin XL building Instruction October 2012
www.pcm.at 15
9. Installation of antenna
As Erwin XL slope is completely made of carbon, a part
of the antenna must be situated outside the model.
One possiblity is to „extend“ the fuselage at the rear end
with a steel wire of about 450mm. Fix the end of the
antenna to this steel wire.
Another solution is to fix the antenna to the end of the
elevator. Lead the antenna inside the fuse behind the wing
and then leave the fuselage. You should add the length
between receiver and the breakthrough of the fuselage to
the end of the antenna, so that the original length of the
antenna is completely outside the fuselage.
Always test the reception on ground before you fly!
If you want to install 2,4 Ghz, let the antennas stand out
of the carbon fuselage as shown on the photo of Elvira.
The antennas can also stand out on top and on the side.
The angle between the antennas should be 90°.
Erwin XL ultralight has a fuselage cone made of aramid
or glass. So you can place the receiver in this area.
Due to the installation of the engine there is no space for
the receiver in the fuselage cone of Erwin XL ultralight
ELEKTRO. You can place the receiver behind the wing
joiner and thread the antennas out of the fuselage at the
rear lower end of the connecting rib to the wing.

Erwin XL building Instruction October 2012
www.pcm.at 16
BEFORE THE FIRST FLIGHT
10. Ballast system
You can easily change the weight by varying between the different connectors.
You should always use two connectors when flying Erwin XL slope. Erwin XL ultralight has
just one connector.
If the glider accelerates too slowly, don’t hesitate to add further weight. Erwin XL slope can do well
with more weight, in the air as well as when landing.
2x carbon short, 150g
1x carbon short, 1x steel short, 450g
1x steel short, 1x steel long, 1125g
2x steel long, 1500g
(Order an additional steel bar if you need it)

Erwin XL building Instruction October 2012
www.pcm.at 17
11. Fixing of the wing
When attaching the wings, make sure that the connector
will not be postponed again.
First, push the connector into the first wing half as far
as possible. Note, that the shorter part of the connector
should disappear inside the wing. Then, push the
fuselage onto the connector and finally the 2nd wing
half.
Close the gap between wings and fuselage with adhesive
tape. By this way, the wing halves are fixed to the
fuselage.
12. Check list before starting:
1. Check centre of gravity (the angle of attack is pre-set)
2. Check rudders:
Do rudders move in the correct direction?
Check the greatest swings of the rudders
All control surfaces are continuously connected to the wing along the hinge line.
3. Check reception:
Leave the antenna inside the radio control and go away from the glider up to a distance of
about 60m. The rudders should not tremble.
2,4 Ghz: depending on radio controller (f.e. reduce transmission power)
13. Attention, ErwinXL is sensitive to heat!
Pay attention, that Erwin XL does not heat up! That means,
- don’t let the model lie in the car, when the sun is heating up the car.
- don’t let the model lie in the sun too long. Protect wing and elevator with bags, if you don’t fly.
- Avoid all other possibilities to heat up Erwin XL.
The model is heated up to 50° during production, but in the sun the model can easily reach higher
temperatures. During flight the model is sufficiently cooled by the airstream.
This sensitiveness is high shortly after production / purchase and will get less gradually.