Henseleit Three-Dee RIGID User Manual

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Three-Dee

RIGID

Version 2010-2011

M a n u a l

March 2011

Jan Henseleit

A T T E N T I O N!

I M P O R T A N T!

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Page 1 Three-Dee RIGID Version 2010-2011 M a n u a l March 2011 Jan Henseleit A T T E N T I O N! I M P O R T A N T!
Page 2: Table Of Contents
Please read the manual before opening the bags Table of Contents Safety instructions: p. 3 TD- Rigid: Description and technical data p. 4 Parts list: List of all parts of the single assembly groups p. 7 Technical data / Accessories p.
Page 3: Safety Advice
Three-Dee RIGID. The company Henseleit Metallverarbeitung and it sales representatives are not liable or responsible for any damage or injuries arising from products out of their supply programme and therefore are not responsible in any way, as proper use or assembly can not be supervised by us.
Page 4 T h r e e - D e e R I G I D was the first 1.6 meter class production helicopter worldwide which was only delivered with a Rigid main rotor for flybarless flying. In my opinion the flybar will not be used any more in future. Due to the technological progress the rise of the electric helicopter in all sizes cannot be prevented any more either.
Page 5 For people who have not much space in their cars it is especially advantageous that the tail boom including the front pinion, the struts and the push rod can be removed from the helicopter within less than a minute. In order to do so, you only have to detach both struts as well as the push rod in the front area of the mechanics, loosen the two lower attachment screws of the tail boom holder and pull out the tail boom to the back.
Page 6 Also bigger batteries will be necessary which also add up weight and the complete helicopter gets very hot under the canopy which may ends in electronic failure. A easy way to otimize the TDR with the recommended motor for speeding is to set the ESC to 100% and use 15 teeth pinion with a 12s setup than you will have plenty of power and speed ...
Page 7 Part-No. Term pcs. Part-No. Term Stk. Part-No. Term pcs. (-1-) M A I N R O T O R (-4-) M A I N S H A F T U N I T (-8-) T A I L B O O M RI - 0100 FLYBAR LINK GUIDE RI - 0400...
Page 8: Servos
Technical Data and Equipment Recommendations: Production and distribution: Henseleit Helicopters Diameter main rotor up to 1620mm Main rotor blades 680 - 720mm Recommended main rotor blades 710mm / approx. 63mm deep/ 185g Tail rotor blades up to 110mm carbon blades (recommended 105mm) Weight ready to fly equipped without drive battery 3.1kg...
Page 9: Assembly Group
General information for the assembly Before you start you should try to get an overview of the assembly by scrolling through the manual. It is recommended to assemble the helicopter next to your computer. You can also print the manual. Please start at the beginning of the manual and keep with the sequence of the assembly instructions.
Page 10: Chapter I Main Rotor
Chapter – I M a i n r o t o r ( Assembly Group 1 ) The swash plate driving fork 0100 has already been mounted by us. After having been inserted the stud was tightened in the middle using Loctite where it can be seen through the clamping slot of the centre hub. If the fork breaks during a crash it is recommended to cut one side of the fork using a pair of nippers to remove the the stud 0100a.
Page 11 At last the blade holder arms 0116 are tightened to the blade holder 0114 using the corresponding screws and Loctite. Before tightening the screws 0105b and 0105c pull the arms in the play of their holes towards the main rotor centre and make sure that they rest properly on the bottom of the blade holder cutout.
Page 12: Assembly Group
Chapter – II M a i n s h a f t u n i t ( Assembly Group 4 ) Note that you tighten the screws carefully, evenly, step-by-step and crosswise when mounting the main shaft gear 0416 to the flange 0414 in order to avoid uneven tension to the gear.
Page 13: Chapter Iii Intermediate Shaft Unit
Chapter – III I n t e r m e d i a t e s h a f t u n i t ( Assembly Group 5 ) Attention ! At first you have to decide whether you wish to build a right-hand rotation system as drawn in the manual or a left-hand rotation system (looking onto the helicopter from above = right-hand rotation system rotates clockwise / left-hand rotation system rotates anti-clockwise).
Page 14: Chapter Iv Tail Boom
Chapter – IV T a i l b o o m ( Assembly Group 8 ) The two ball bearings 0828b are pressed into the bearing flange 0828a until they are flush with the flange. The clutch insert 0831a is pressed into the clutch 0831.
Page 15: Chapter V Chassis
Chapter – V C h a s s i s ( Assembly Group 2 ) Pre-assembly of the upper part of the chassis (Bag 2-I) Put the bearing supports 0221/0222 with their bearings 0223 on the already pre-mounted intermediate shaft unit and main shaft unit, such that the bearings looking out of the one side of the support point to the gears ! The bearings of the lower supports point to the top - and the bearings of the upper supports point out to the bottom.
Page 16: Adjustment Of The Gear Play
Then pull the shaft in the play against the upper bearing and measure again, how far the shaft protrudes now. The difference of both measurements represents the amount you have to add – in the form of spacer washers – between the upper bearing and the spacer.
Page 17: Pre-Assembly Of The Lower Part Of The Chassis
In order to facilitate the handling during a later assembly, the tail boom can now be pulled out. To find the correct tail boom position it is recommended to wind some fabric tape around the tail boom just behind the rear tail boom holder 0233. It serves as stop mark when re-inserting the tail boom (never mark the boom with a sharp knife or something like that).
Page 18 Assembly of the upper part to the lower part of the chassis Put the prepared controller supporting plate between the two side-frame plates of the upper part of the chassis according to the drawing. The remaining third stud 0238 is positioned between the free holes just behind the front tail boom holder. Widen the two side-frame plates of the lower part of the chassis at the top such that it can be slipped over the lower edge of the upper part of the chassis.
Page 19: Chapter Vi Rc Preparation
Chapter – VI R C p r e p a r a t i o n ( Servos ) At first the metal protective sleeves for the screws are pushed through the damping rubbers of the swash plate servos from below and of the tail rotor servo from above.
Page 20: Chapter Vii Control And Servo Assembly
Chapter – VII C o n t r o l & S e r v o A s s e m b l y ( Assembly Group 6 ) Assembly of the cyclic servo (Bag 6-II) At first, use thin double-sided tape to attach the four servo attachment plates 0642 on the inside of the side-frame plates of the chassis such that they are aligned to the holes.
Page 21 For a better few the left chassis plate is not shown ! The prepared fore & aft cyclic servo is at first tightened provisionally and loosely to the right frame plate of the chassis according to the drawing. Use a M3x8 lens head screw 0645c to tighten the two support framing squares to the chassis in the centre at the top and at the bottom.
Page 22 Assembly of the tail servo Mount the two tail servo supports 0646 to the tail servo (pull the supports to the outside when tightening the screws in the play of the sleeves) using the washers 0643a and the M2.5x12 cross-head screws 0643. The clevis 0636 can also already be mounted at a distance of approx.
Page 23: Chapter Viii Assembly Of The Electric Motor
Chapter – VIII A s s e m b l y o f T h e E l e c t r i c M o t o r ( Assembly Group 7 ) The picture above shows the assembly of the recommended Pyro 700-52 motor with standard shaft and M4 attachment holes on a 30mm hole circle.
Page 24 Pinion assembly with Scorpion motors (stepped 8mm and 10mm shaft with circlip) First, remove the shaft circlip from the groove of the motor shaft (see red arrow in right picture). Then remove any eventually existing spring washers from the shaft. Be careful, don't pull the motor housing, since it is only after the assembly of the pinion secured again.
Page 25: Chapter Ix Tail Gear
Chapter – IX T a i l G e a r ( Assembly Group 9 ) (Bag 9-I) The bearings 0900b on the side are fixed with a little amount of Loctite from inside the housing 0900a. Parallel pliers or a similar tool can be helpful.
Page 26 (Bag 9-II) At first push only the bevel gear 0902 and the spacer 0907 together provisionally between the two bearings of the gear box (do not yet add the spacer washers). Put the tail output shaft 0910 through the unit. Press the bevel gear against the bearing and now check the play between the two bevel gears.
Page 27 (Bag 9-IV) Sequence of assembly steps for tail blade holders: (If missing the little spacer washers 0920 please have a look into the blade grips) Grease and insert the three parts of the bearing 0921 in the right order in the blade holder 0927 from outside (first the ring with the larger hole of 5.2mm, then the ball cage, after that the ring with the 5mm hole).
Page 28 (Bag 9-V) This image shows the assembly of the tail rotor of the right-hand rotation system. When chosing a left-hand rotation system the entire gear box is assembled in a mirror-inverted way and turned by 180°, so that the tail rotor points to the left (according to the flight direction).
Page 29 (Bag 9-VI) The screw 0939h should be screwed down carefully, in order not to damage the hole in the plastic piece. The screw 0939i (M3x16) has to be tightened to the mounting bolt 0938 carefully. In addition, use plenty of Loctite, as the thread can easily be damaged.
Page 30: Chapter X Assembly And Struts Of The Tail Boom
Chapter – X Assembly and struts of the tail boom ( Assembly Group 8 ) At first push the tail boom into the clamping flanges of the mechanics as already described on page 16 and adjust the correct position of the pinion to the crown gear. This is easy, if you have wrapped, as recommended, an adhesive tape around the boom at the corresponding place.
Page 31 Now push the already prepared push rod through the upper hole of the clamp 0809 from behind. The second support 0808 has to be thread also to the push rod. Later it has to be fasten at the boom with thin dobble side adhesive tape exactly in a position were the mounted canopy touch the boom.
Page 32: Chapter Xi Assembly Of The Electronic Parts
Chapter –XI Assembly of Electronic Parts ( V-Stabi / receiver / controller / batteries ) These images show the reasonable installation of the receiver as well as the 3 axis stabilisation electronics in the example of the Mini V-Stabi. If you use a different system, proceed correspondingly. If you use the normal two-part V-Stabi, it is recommended to download the TDR manual 2009.
Page 33 Receiver: The receiver is attached to the bottom of the tail servo in an upright position with the connection plug board pointing to the left. Use double-sided tape for damping purposes and place the housing as far as possible at the right side without touching the chassis.
Page 34 Assembly of the controller Shorten the yellow cables of the Jive controller to a length of approx. 75mm and solder the 3.5mm gold bushes to the ends. Plus and minus cable remain unchanged. Only 4mm gold plugs are added. Glue a heat sink on the metal plate of the controller using heat conduction glue. Otherwise the heat conduction is too low. The controller is attached to the centre of the carbon plate using two small strips of double-sided tape, so that the front edges of the two capacitors are aligned to the front edge of the plate.
Page 35 The white dashed line shows the way of both cables from the controller to the back The LiPo battery is pushed into the mechanics from the front and secured using the two Velcro strips. Tighten the Velcro fastener well. Then the battery is pressed onto the silicon supports, has a strong hold and cannot slip during the flight. The rear Velcro fastener should be positioned directly in front of the skids.
Page 36: Chapter Xii V-Stabi Connection And Programmation
Chapter –XII V-Stabi - Connection And Programmation is a truely „rigid“ helicopter, i. e. it cannot be operated by a flybar, is completely flybarless and requires an electronic control system. My recommendation is the Mini V-Stabi 5… Express distributed by Mikado. Ulrich Röhr was the inventor of the first electronic control system for model helicopters world wide (V-Stabi 1999) and has the greatest experience in this field.
Page 37 Wiring of the central unit After the assembly the central unit is connected to the servos and the receiver. Adjust the transmitter such that only 4 single channels are transmitted (Mode H1, mechanically mixed swash plate – as you know from the simulator -). The mixing of the swash plate is ensured by the central unit, every control function is individually transferred to the central unit (pitch, fore &...
Page 38: Chapter Xiii Final Tasks
Otherwise you would damage the thin GFK material. The (www.henseleit-helicopters.de) - decal sheet can be attached to the side of the tail boom directly in front of the strut clamp, so that everyone sees where the Rigid comes from ...
Page 39: ( V-Stabi, Rotor Blades, Throttle Curves Etc. )
Chapter –XIV Adjustments ( V-Stabi, rotor blades, throttle curves etc. ) Adjustment of the rotor blades Now mount your rotor blades. Please note the following: If you use the recommended Rigid or Radix blades (length of 710 mm) with a blade root of 12mm you should use the plastic spacers added to the kit in any case but not any aluminium spacers, because they jam in the aluminium of the blade holders and leave ugly traces.
Page 40 Maximum and minimum pitch: Now adjust the maximum and minimum pitch values using the setup of the 3 axis stabilisation system (chapter XII – p.44). At first adjust the maximum value by adding the 6 mm lock 0394b to the 12mm lock 0394a and adjusting the way electronically such that the swash plate rests on the 18mm strong support at maximum pitch.
Page 41 Adjustment of the throttle curves and the motor: At first programm your controller in the correct mode according to the instructions of the manufacturer (Mode 4 at the Jive controller). Mode 11 is not working perfect every time. Some times there are some moves arround the yaw axis with this setup.
Page 42 Chapter –XV Directions For Initial Flight ( RPM, operating limits, recommendations, hints etc. ) Let’s get to the point, you’re waiting for! Take your time and wait for good conditions, before you start with the first flights. Neither spectators nor commentators are helpful for these flights. Always be alert to unforeseen surprises. Carefully check the whole helicopter, including your transmitter at home before leaving for the airfield.
Page 43 Some hints for high-speed flights. Because of its performance and excellent aerodynamics, the helicopter can be noticeably fast. The V-Stabi allows normal pilots to control these velocities. When using a paddle head the helicopter would pitch up at a speed of up to 200km/h and the smallest fore & aft deflections. The electronic stabilisation allows to keep the helicopter on track, whereas it cannot overcome the laws of physics.
Page 44 For your safety: Do not under-estimate the danger of the flight object. The low operation sounds also at high RPM can be deceiving. When tapping the full potential, the Rigid is more powerful than any 91 type glow version! You may be tempted to fly the helicopter in the garden or to do other mischief. But do not do this in any case. The Rigid is not designed for flying indoor.
Page 45 M a i n t e n a n c e / S p a r e P a r t s Always leave a palm for air below the rotor  Maintenance advice It is advisable, especially after the first flights to check the helicopter carefully. Important screws and ball links may have loosened.
Page 46 However, it all comes down to me, and I am afraid, I can’t read and answer all these mails in time. Specific problems may require a direct, voice-to-voice-contact, which would possibly be more effective. Up-to-date information of general interest will be published via the web on my website www.henseleit-helicopters.de...