fp-propeller Srl

via C. Colombo 37/E, 44124 Ferrara phone: +39 3482285973

IN FLIGHT VARIABLE PITCH PROPELLERS - OPERATION MANUAL

1) propeller installation The installation technique described here is related to the Rotax engine with reduction gear shaft. For other engines without gearbox, contact the manufacturer. Enter, from the engine compartment, the collector within the bore of the shaft of the gearbox. Insert, side flange, the stopper. Pull cables in holes and tighten the screws. Assemble the (brushes + sensor) on the manifold, using the threaded holes already on the back of the gearbox Screw the M8 threaded rod into the flange. Block the threaded rod by a standard nut from the rear of the flange. Hang up the propeller hub to one of the M8 rods protruding from the flange. Insert the shrinkable covers on the cables (two layers) and connect the cables from the propeller to the collector. Heat the shrinkable covers over the connection. Insert the hub base in the flange. Insert the special washers and the self-blocking nuts at the base of hub. Tighten the nut on the rear of the flange and tighten the nut on the side of the hub. Proceed to criss-cross fashion, gradually tightening up to completely pull the base of the hub flange. Tighten the bolts with torque of 2 kg*m. Assemble the blades as follows. Point the blade seat up and put in the package bearing (washer+cage+washer). Align the bronze sliding block at the center of the window. Looking at the alignement of the block and the hole in the center, the bearing, put in them, respectively, the shaft control by centering the spindle blade. Check the entry and verify that the rotation of the blade is locked. Screw the ring seal on to the thread and making sure the screw is going smooth. Complete tightening down with the compass wrench. In the event that the ring does not come down, it may be due to misalignment of the parcel of the bearing rings. In this case, remove one or two laps and try again. Tighten the screws protruding from the ring in order to block the ring. Connect the cables and verify that the control of blades (+) corresponds to the direction of rotation for the increase of the pitch and vice versa for (-). If the case, reverse the contacts. Set the pitch to the minimum limit. Start the engine and spin the propeller for a few minutes to fixed point and at maximum speed. Engine stop and repeat the tightening and locking nuts. Tie up the screws by steel wire. Proceed to the end stop adjustment.

2) end stop adjustment

The adjustment of the pitch limit switch is made by adjusting the screws protruding from the box on the front of the hub. The idle screw is retracted, the maximum is closer to the hub, as shown in the picture, adjustment of the end-run minimum. With the aircraft at fixed point, set the minimum pitch. Turn on motor and, gradually accelerating whether the motor reaches full throttle. There are 3 possibilities: a) the motor reaches the out-turn b) the motor reaches 5800 rpm c) the motor do not reaches 5800 rpm. a) case: the minimum is too low. Loosen the idle screw and move in the direction (+). Consider that 1 mm displacement of the screwis a variation of the minimum of 2,5 degrees about. Tighten the screw and repeat the test engine. If the overdive is not completely removed, repeat the whole cycle until to obtain the adjustment. b) case: the minimum is adjusted as it is. c) case: the minimum is too high. Loosen the nut and unscrew a few turn the screw in front of the box (minimum mechanical). Tighten the nut, Then , loosen the screw of the end-run minimum and move it in direction (-). Again, consider that 1 millimeter of displacement of the screw produces a change in the minimum step of 2,5 degrees. Tighten the screw and repeat the test engine. If the full rpm is not recofered, repeat the whole cycle up to get the adjustment. Then, restore the mechanicl minimum as follows. In the minimum pitch position, loosen the nut of the mechanical minimum. Then, seek contact with the shaft of the screw inside. Release of 3/4 ride. Holding down the screw, lock the nut much. Please not that the mechanical minimum is a security stop in order to prevent blade pitch reverse. It is located 2 degrees below the minimum end-run electrical system. It is noted that the mechanical limit stops the electric motor but does not interrupt the electrical current. Thus, the persistent drive of the electric motor against mechanical minimum destroy the motor itself. adjusting the end run maximum. Normal values of maximum pitch in propellers for Ultra Light aircrafts with a Rotax engine are in- between 25 and 30 degrees, depending from the aircraft top speed. Usually, the maximum pitch is positioned at 2-3 degrees above the top speed in level flight. To adjust the maximum step, verify that, coarsely, at least 15 degrees of pitch range are available from the minimum pitch. Then, make a first flight test. Flying in level flight, increase the engine set gradually to the maximum rpm. The automatic governor will adjust the pitch of the propeller. Switch the governor to manual control and land the aircraft. Loosen the screw of the maximum pitch range and move it in (-) direction, till to contact the internal micro switch. Then, move the screw in the opposite direction (+) for 2 millimeters. Tighten the screw 3) Pitch adjustment in case of electrical failure In case of electrical failure of the pitch driving system, the blade pitch remains fixed to a given value in the range between maximum and minimum or proceeds in one direction (partial failure) I all cases, after landing to be made as soon as possible, you should manually adjust the blade pitch to an optimal value and do nothing more to the pitch command. If the automatic governor is installed, switch to "manual". In this way, the propeller becomes in effect a "fixed pitch" To make the manual adjustment of the blade pitch, remove completely the end-run mechanical. Insert in the seat of the mechanical minimum removed an Allen

wrench n. 5 and engage the screw that produces the change of pitch. Turning (slowly) the wrench clockwise, the pitch increases. Turning it counter clockwise decreases the pitch. In order to have this option easily effective, it is highly recommended to mark the useful pitch position on one of the blade shanks. This marking is made by applying an adhesive on the shank stem and, aligned, the same adhesive on the corresponding locking collar. We means "useful pitch" the blade pitch compromise between a "reasonable" take-off" and a "suitable" cruise speed. As an indication, this position may be that step, at fixed point of the aircraft and all engine, which gives a number of 4900 rpm. It is found by the "manual" control of the governor. The marking of the useful pitch is to be done during the propeller set up.

fig. 1 adjustment of the pitch range

fig. 2 manual adjustment of then pitch in case of electrical failure

WARNING
In order to prevent any risk, take-off and landing must be carried out with governor in manual setting and without any pitch change command during these two flight phases. To this purpose: -- take off is to be made by setting the pitch to such a value that full throttle rpm = 4900; then go with governor settled in manual until the security altitude. -- landing is to be made with governor settled in manual and pitch the same as in take-off