PCM Erwin XL Ultralight Electro User manual

Erwin XL Ultralight Electro - building Instruction August 2018
www.pcm.at 1
Wing span [mm]:
3000
Aspect ratio:
14,67
Wing area [dm2]:
61,33
Wing loading:
from 20,9
Weight [g]:
from 1280
Airfoil:
VS1
BUILDING INSTRUCTION
ERWIN XL ultralight Electro

Erwin XL Ultralight Electro - building Instruction August 2018
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CONTENTS
DATA
1. Kit –Contents
2. What else do you need?
3. Electronic equipment –electric drive
4. Settings for the first flight
ASSEMBLING THE MODEL
5. V-tail
6. Gluing of fuselage
7. Electronic components in fuselage (electric drive)
8. Wing
9. Installation of antenna
BEFORE THE FIRST FLIGHT
10. Ballast system
11. Fixing of the wing
12. Check list before starting
3
3
4
5
6
7
8
12
14
15
15
15

Erwin XL Ultralight Electro - building Instruction August 2018
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DATA
1. Kit –Contents
Fuselage, in two parts, incl. canopy and cover for end of fuselage, 1 piece
Wing, in two parts
V-Tail
Covers for servos on wing, 4 pieces
Levers for rudders, 4 pieces
Installation frame for engine
Fuselage board with 2 sideboards
Cover for opening for receiver
Tube for 2,4 GHz-antennas
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
Plug for V-tail, 1 piece
Levers, 2 pieces
Connectros / ballast (more ballast available on demand):
Segler / Glider
Elektro
Normal (Slope)
2x Kohlestab / carbon rod
2x Stahl kurz / steel short
1x Stahl lang / steel long (auf Anfrage / on demand)
2x Kohlestab / carbon rod
Medium
1x Kohlestab / carbon rod
2x Stahl kurz / steel short
1x Kohlestab / carbon rod
1x Stahl kurz / steel short
Ultralight
1x Kohlerohr / carbon pipe
1x Kohlerohr + Stahl innen /carbon pipe + steel core
1x Stahl kurz / steel short
1x Kohlerohr / carbon pipe
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
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
Connector for push rods, M2,5mm

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3. Electronical equipment
Servos for the wing
Dymond
D60
Hyperion
Atlas HP DS09SCD
Servos for the V-tail
Dymond
D60
Receiver:
2,4GHz:
all (antennas must be led outside the fuselage)
35 MHz:
Graupner DS19
Simprop Scan 7
Electric drive
Variante 1
Flying weight:
Engine:
Controller:
Accumulator:
Propeller:
Spinner:
Price (app.):
Variante 2
Flying weight:
Engine:
Controller:
Accumulator:
Propeller:
Spinner:
Price (app.):
Variante 3
Flying weight:
Engine:
Controller:
Accumulator:
Propeller:
Spinner:
Price (app.):
Logger / Limiter:
strong (calculated app. 2,6kg thrust), high quality, heavy (391g)
app. 1510g
Kira 400 - 39, with gear 5,2:1 (110g+60g)
Jeti spin 44 (36g)
Wellpower DS Lipo 3S 2200mAh (185g)
Aeronaut 13/8
D=30mm
EUR 340,- (Inkl. 20%Vat.)
strong (calculated app. 2,4kg thrust), cheaper, heavy (374g)
app. 1490g
Typhoon EDF-2W-20, with gear 5,2:1 (93g+60g)
Jeti spin 44 (36g)
Wellpower DS Lipo 3S 2200mAh (185g)
Aeronaut 14/8
D=30mm
EUR 270,- (Inkl. 20% Vat.)
weak (calculated app. 2,0kg thrust), light, low-priced (166g)
app. 1280g
Hyperion GS 2218-12 (83,5g)
Dualsky XC-45 Lite (12,5g)
Wellpower DS Lipo 3S 1300mAh (70g)
Aeronaut 11/7
D=30
EUR 125,- (Inkl. 20% Vat.)
Unilog 2 for use in competition
The stronger the drive, the more camber

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4. Settings for the first flight
(measure from the leading edge of the wing to the back)
Centre of gravity: due to little weight 100mm is possible without danger
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)

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ASSEMBLING THE MODEL
5. V-tail
The v-tail is ready prepared with holes for screws to be
fixed on the fuselage.
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.

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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.
Furthermore, check, if the difference in angle of attack of
+1° can be set without problems.
For this, put the 2 parts together and place the fuselage on a flat surface. The distance between
fuselage and surface should be 7mm at the joining spot. You can f.e. check this with a small
piece of wood, which you place under the fuselage.
If you can’t assemble the 2 parts of the fuselage in this position, grind at the fitting.
Then glue the parts together. Use epoxy-glue and some cotton flocks to thicken the glue.

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7. Electronic components (electric gear) inside the fuselage
Glue the installation frame for the engine with UHU 300
endfest or Pattex Stabilit into the fuselage.
The tip of the fuselage cone is ready prepared for correct
mounting of the engine. Just glue the frame flush with
the cut of 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.
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 …

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… 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.
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.

Erwin XL Ultralight Electro - building Instruction August 2018
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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.
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.

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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.

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8. Wing
The openings for the servos are big enough for all
appropriate standard servos including mounting frame,
such as Futaba S3150.
The connection to the levers on the rudder goes crosswise
through the wing.
Lead the cable through the wing as shown below.
The holes in the servo boxes for cables a.s.o. must still be
thrilled.
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.

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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,
connect the two control surfaces with an adhesive tape.

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9. Installation of antenna
Due to the installation of the engine there is no space for
the receiver in the fuselage cone of Erwin XL ultralight
Electro.
If you want to install 2,4 Ghz, let the antennas stand out
of the carbon fuselage as shown on the photo
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.
The angle between the antennas should be 90°.
Always test the reception on ground before you fly!

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BEFORE THE FIRST FLIGHT
10. Ballast system
Erwin XL ultralight Electro has just one connector. The kit includes 1x carbon pipe with 20g.
If you want to add ballast, you can easily change the weight by varying between the different
connectors.
If desired, 1x carbon pipe with a steel core with 220g and 1x steel bar with 460g can be added
to the kit.
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)