PCM FW5 FloW Instruction Manual

FW5 FloW Building Instruction Juni 2010
Wing span [mm]: 1500
Wing area [dm2]: 22,4
Aspect ratio: 10
Take-off weight [g]: from 250
Airfoil: Zone 52-21
BUILDING INSTRUCTION
SAL-DLG FW5 FloW
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FW5 FloW Building Instruction Juni 2010
CONTENTS
DATA
1. Kit – contents
2. What else do you need?
3. Electronic equipment
4. Settings for the first flight
ASSEMBLING THE MODEL
5. Installation of the CFR-stab
5.1 Torsion spring for rudder
5.2 Connection of the wire
6. Fuselage structure
6.1 Radio board
6.2 Ballast
6.3 Accumulator and receiver
6.4 Canopy lock
6.5 Installing 2,4Ghz
7. Controlling the ailerons
7.1 Push rods
8. Installation of throwing blade
9. Optimizing
9.1 Centring the masses
9.2 Ends of ailerons
9.3 Leading edge of wing
9.4 Voltage control
10. Installation of antenna 35MHz
OTHER
11. Check list before starting
12. Notes for the use
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FW5 FloW Building Instruction Juni 2010
DATA
1. Kit – contents
Fuselage + canopy
Wing
Rudder and elevator
Radio board
Carbon rods for fixing the elevator, 2 pc.
Lever for controlling rudder, 1 pc.
Kevlar wire for controlling rudder
Steel wire for torsion spring (rudder), 1 pc.
Brass pipes for levers of ailerons, 2 pc.
Carbon pipes for push rods for controlling ailerons, 2 pieces
Screws for fixing wing, 2 pieces (1x 25mm)
Throwing blade, 1 pc.
Magnets for lock of canopy
Lead balls for ballast
Steel wire (1,5mm) for ballast
Building instruction
Kit parts
2. What else do you need:
Epoxy-glue (for example UHU 300 endfest or Stabilit, no fast
hardening epoxy resin)
Sekundenkleber
UHU POR
Super glue
Cotton flocks
Electrical equipment (On/Off-switch, cables, plug, ...)
Electronic equipment
Steel wire, shrinking tube...
3. Electronic equipment
Servo elevator - Hitec HS-45HB (cuttings on radio board are prepared for this servo)
(Attention, don’t use HS-5045!)
- Graupner C 261
- Graupner DS 281
Servo rudder
- Dymond D-47 (cuttings on radio board are prepared for this servo)
Same style:
- Futaba FS31
- Modell Expert X31
Servos aileron
- Hitec HS-45HB (cuttings on radio board are prepared for this servo)
- Graupner C 261
- Graupner DS 281
Accumulators: - GP NiMH Accu 35AAAH, Weight/cell 6g
(1,2 Volt 0,35 Ah 1/2AAA)
- 240mA/h Li-Ion Accus, 2 pc. parallel with pusher
Receiver: - 2,4GHz possible due to kevlar fuse cone
Logger: - Logo
- Lola
- Ram3
- Z-Log
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FW5 FloW Building Instruction Juni 2010
4. Settings for the first flight
Centre of gravity: 65-70mm (measure from the leading edge of the wing to the back)
Ailerons (measure near fuselage)
Flaps negative (start, speed) (measure near fuselage)
Flaps negative (cross-country) (measure near fuselage)
Flaps positive (thermal 1) (measure near fuselage)
Flaps positive (thermal 2) (measure near fuselage)
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FW5 FloW Building Instruction Juni 2010
Landing position (measure near fuselage)
Snap Flap (measure near fuselage)
Rudder (measure at deepest point)
EWD (Difference in angle of attack between wing and elevator) for first flight:
Elevator parallel to axis of fuselage, slightly pulled.
Don’t make a SAL-start at your first flight. Hold the glider on the fuselage and throw it gently.
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FW5 FloW Building Instruction Juni 2010
ASSEMBLING THE MODEL
General information on DLG-models
DLG-models are constructed strong enough to withstand the demands of starting, flying and landing
and at the same time light enough to achieve the least possible flying weight. Each part is
dimensioned to its possible minimum and produced using lightest and fewest material.
In order to continue this concept, please account the following when you assemble the model:
- Always use glue sparingly. Grind all gluing spots thoroughly, before you apply the glue.
- Electronic components should be placed as far as possible to the front, as you normally need
additional lead in the nose of the fuselage to achieve the necessary centre of gravity.
- For the same reason try to save weight especially when you finish and mount the stabilizer.
- If you don’t have any experience in working with resin or if you prefer an easier method, you can
combine the carbon rovings and glass fibre with super glue: Put some drops of super glue on
the rovings or the fibre, spread and press it with a (rustling) plastic bag. You will also save one or
the other gram with this method.
As FW5 FloW has developed from the Fireworks-family, you will find some pictures of Fireworks 4 and
also Mini-Fireworks in the following instruction. Don’t let yourself be confused by this, the way of
building described is quite the same.
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FW5 FloW Building Instruction Juni 2010
5. Installation of the CFR-stab
Sand the rudder wedge-shaped on the hinge line, so that
you can move it in both directions. Note that the hinge line
must be placed on the left side (looking towards flight
direction) for right-handers and the other way round for left-
handed persons.
Next, glue the lever in extension of the axis of the boom. The
hole of the lever should be above the hinge line.
Before you fix the control surface of the rudder with adhesive
tape, put some UHU-por on the gluing spots to improve the
gluing force of the tape.
Spread the UHU-Por with your finger.
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FW5 FloW Building Instruction Juni 2010
Fix the rudder with 2 small stripes of tape to keep it in the
right position. (As soon as you have applied the tape on the
UHU-por, you can’t remove it anymore without destroying the
surface.)
Now you can apply the adhesive tape.
5.1 Torsion spring for rudder
Bend the wire according to the drawing below. Then, tip
back the control surface of the rudder completely. Stick the
spring into the rudder, one end into the unmoved part, one
end into the control surface near the lever.
Then harden the spots with super glue.
Fix the carbon rod (2mm) with superglue in the rudder.
Now you can mount the elevator.
The elevator will keep the distance between the two carbon
rods. If you move the spring without the elevator mounted,
the spring may disappear inside the rudder. Only when the
elevator is mounted, the spring will move along the track cut
out.
Nevertheless, check the elevator for free movability. If
necessary, enlarge the hole in the rudder.
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FW5 FloW Building Instruction Juni 2010
Push the rudder (first for a test) into the oval end of the
boom as far as it will go. Before you do so, thread the kevlar
wire into the fuselage. Grease the wire to avoid that it will
also be glued.
Then check, if the stabilizer is aligned correctly on each
axis.
Now glue fuselage and rudder with thin super glue, where
they touch each other.
You should enforce the join between boom and rudder
additionally with a thin carbon roving, which you glue with
thin super glue.
Stick the 2 halves of the elevator to each other on the
leading edge with an adhesive tape to avoid unintended
demounting during start or flight.
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FW5 FloW Building Instruction Juni 2010
5.2 Connection of the wire
Now you can hook in the kevlar wire into the lever.
Make a loop, twist the end and fix it with a drop of super
glue.
Note: Don’t use a shrinking tube, as the kevlar wire could be
damaged by the high temperature during shrinking.
Drill a hole in the boom to lead the wire inside the fuselage
to the servo.
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FW5 FloW Building Instruction Juni 2010
6. Fuselage structure
(Systemzeichnung)
6.1 Radio board
At the moment we recommend the servo HS-45HB due to its
accurate setting back to the initial position. Therefore the
radio board which is enclosed in the kit has cuttings prepared
for this servo. For the rudder we still recommend D47 from
Dymond.
The assembly plates of the D47 are situated a bit deeper than
the ones of the HS45. Therefore we supply a U-formed part
to put below the assembly plates and lift the D47 to the same
height.
These are the tried and tested lengths for the levers of the
servos:
Lever for aileron: 13mm
Lever for elevator: 10mm
Lever for rudder: 9mm
The servo for the elevator is situated in the front, the servos
for the ailerons behind and the servo for the rudder is placed
under the servos for the ailerons.
In order to gain full strength, it is absolutely necessary to fix
the radio board in the fuselage!
Before you glue the radio board, you should first find out the
optimal position. To do so, place the radio board inside the
fuselage without gluing and mount all servos. The front
aileron servo should be situated 110mm from the fuselage
Tipp.
Make sure that all levers are freely movable (also with
canopy mounted), and that the deflections of the levers are
big enough. Note that the pushrods for the ailerons must be
lead beside the ballast. (see drawing at the top).
Before you fix the radio board in the fuselage, grind all
gluing spots thoroughly.
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FW5 FloW Building Instruction Juni 2010
You can fix the radio board with a drop of super glue to
make the position check easier.
Glue the board carefully with epoxy-glue (for example UHU
300 endfest or Stabilit, no fast hardening epoxy resin).
You can fill the glue into a small plastic bag and cut a whole
on one corner. By this, it will be easier to apply the glue
exactly.
You can add carbon rovings left and right of the gluing spots
for additional strength.
If you have a hard landing, always check if the radio board
is still fully glued before you make the next start!
6.2 Ballast
As ballast we use lead balls from the fishing shop. One ball
weighs about 10g. You can easily assemble and vary this
kind of ballast.
The balls are strung on a 1.5 mm steel wire. With a small
hook at the end of the steel wire the ballast can be locked on
the radio board.
To locate the exact position of the ballast inside the fuselage,
lay the model on a device for measuring the centre of
gravity (see picture). Move the ballast until you get the
desired centre of gravity.
The long screw, which fixes the wing in the front, serves as
separation between ballast and push rods. When you mount
the ballast, thread the wire with the balls into the fuselage left
of the front screw.
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FW5 FloW Building Instruction Juni 2010
The hook of the ballast package is locked in the servo
board.
6.3 Accumulator and receiver
Depending on the size of battery and receiver different ways
of shapes for the accumulator package are possible.
In any case, we recommend to assemble the battery cells
with adhesive tape first. Check, if it fits inside the fuselage
together with the receiver, before you solder the cells.
At the side you see two possible shapes for the battery
package.
If you want to use a big 8 channel 2,4 GHz receiver, you can
remove the plugs and solder the servos directly onto the
board. With our indoor colleagues this is already quite
normal.
6.4 Canopy lock
The canopy is fixed with adhesive tape on the bottom and
can be closed with two magnets on the upper side.
Glue the first magnet on the radio board on the upper side
of the fuselage with super glue.
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FW5 FloW Building Instruction Juni 2010
Then put the second magnet onto the first one. The
magnet should be sanded as well as the inside of the
canopy. Now put a drop of super glue on the second
magnet and spray activator into the canopy. Then you lift
the hood carefully over the magnet in the desired position.
You should check the good fit of the canopy before, as this
process defines the position of the canopy.
Wait a few seconds, then you can strip off the canopy and
close it again. Check the fit of the canopy. If you are still not
satisfied with the fit, you can easily break the magnet out of
the canopy again.
When you are satisfied with the position of the magnet, you
can put more glue around the magnet to improve the join.
6.5 Installing 2.4 GHz
The installation of the 2.4 GHz receiver should be in the
front of the fuselage, where the fuselage is made of kevlar.
Make sure that the antennas are not covered by the receiver
battery. That means the antennas should be placed directly
on the side of the fuselage.
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FW5 FloW Building Instruction Juni 2010
7. Controlling the ailerons
Anlenkung des
Ruders
Bend, press and
grind the brass
pipes according to
the picture.
Drill holes with a
diameter of 1mm for
hooking in the push
rods.
Glue the brass levers
with thickened
epoxy glue or
epoxy resin to the
wing.
The levers should be
situated as near as
possible to the
turning axis of the
aileron.
View from below:
You see the brass
levers standing out.
The 2nd picture
shows the fuselage
with its whole for
mounting the wing.
Use a pair of
tweezers to mount
the levers through
this whole.
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FW5 FloW Building Instruction Juni 2010
7.1 Push rods
The push rods are made of CFR-pipes, into which you glue a
bent 1mm steel wire. A 0.5-0.8mm steel wire will serve as
protection against dismantling.
First you must sand
the hook
thoroughly.
Then you drop thin
super glue on the
prepared spots and
push the hook into
the pipe.
Before you glue the hook on the other end of the carbon pipe,
mount the push rod in the fuselage and switch on the radio
control. Fix the hook after trimming in the right position with
super glue.
Note that you must pull out the hook to apply super glue
and then push it back again.
It is not enough to let the super glue run into the pipe when
the hook is already inside.
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FW5 FloW Building Instruction Juni 2010
8. Installation of the throwing blade
Alignment
Side view:
Tilt the blade on the upper side of the wing a little bit in the
direction of flight.
Front view:
Mount the blade right-angled to the wing.
View from above:
Turn the axis of the blade a little bit to the fuselage (looking
in direction of flight).
Grind the blade, so that it gets an aerodynamical cross-
section and it feels handy when you hold it in your fingers.
Don't make the trailing edge too sharp. You might injure
yourself when throwing your DLG.
Lay the paper
template on the
wingtip and thrill a
hole at the marked
spot.
(Both wingtips - left
and right - are
prepared for the
installation of a
throwing pin or
blade.)
Mark the length of
the blade.
Remember, that the
axis of the blade
should be turned a
little bit to the
fuselage (looking in
direction of flight).
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FW5 FloW Building Instruction Juni 2010
Now cut an opening
into the wing with a
small driller or a
milling cutter.
If the cut is big enough, put the blade through and align it in
all directions (see above).
When the position is correct, fix the blade with super glue.
Ready mounted
throwing blade
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FW5 FloW Building Instruction Juni 2010
9. Optimizing
9.1 Centring the masses
During our extensive tests we have found out, that centring
the masses in the middle of the glider is even before the
take-off weight the most important fact to optimize the
throwing height. That means it is better start with ballast in
the middle of the glider than to start very light. Every pilot
should optimize his model, so that he can easily handle the
weight of his glider when launching it, but carry as much
ballast as possible. In addition, the amount of ballast of
course also depends on the wind and thermal power.
As you see, there are still many ways to optimize.
Mark Drela has developed a method to measure the yaw of
gyration. This defines how good or bad a glider has centred
its masses:
Hang your model upside down on two 1,5m long threads,
which you fix 30mm from the centre of gravity. Now move the
glider for 45° and the let it swing. Take the time of 5 swings.
Repeat this process several times to get an average value.
The faster the model swings, the faster it will stabilize after
the launch and the higher it will start.
9.2 Ends of the ailerons
In order to move the triangular ends of the ailerons, stick a
0.5mm steel wire with adhesive tape on the trailing edges of
both control surfaces.
9.3 Leading edge of the wing
As you nearly don’t recognize a damage of the leading edge of the wing (f.e. after hard landing), we
advise to put a strip of adhesive tape over the leading edge.
The film is thin enough not to disturb the aerodynamic, but it surely will extend the lifetime of your
glider.
9.4 Voltage control
We recommend DLG-saver from Simprop against power
failure of your glider.
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FW5 FloW Building Instruction Juni 2010
10. Installation of antenna 35Mhz
In order to have an undisturbed reception a part of the
antenna must be situated outside the model.
An easy 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.
Another possibility is to lay the antenna inside the gap of the
aileron. For improving reception on carbon wings you can
solder the antenna to a steel wire, d=0.3mm, which you fix at
the end of the wing and let stand out to the back about 10-
15cm.
Always TEST THE RECEPTION on ground before you fly!
For installing 2,4 GHz: look at chapter “fuselage structure”
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