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  • Page 1 Č á á Č á á á á Ltd.
  • Page 2 Č á á Č á á á á Ltd. Glasflügel 304 eS Document No.: 304eS/MMSupp Date of Issue: 11/17...
  • Page 3: Table Of Contents

    Ltd. Table of contents Page ................IST OF FFECTIVE AGES ..................ECORD OF REVISIONS BASIC TECHNICAL DATA ................1-0 .................. 1-1 ASIC ECHNICAL DATA ................1-1 ECHNICAL ESCRIPTION 1.2.1 Fuselage ....................1-1 1.2.2 Wing ......................1-1 1.2.3 Horizontal Tail Unit ..................1-2 1.2.4 Vertical Tail Unit ..................
  • Page 4 Ltd. 3.13 L ..................3-9 UBRICATION SCHEME 3.14 T ............3-9 IGHTENING ORQUE OMENTS ABLE 3.15 S ..................3-9 AFETY ARNESS 3.16 P ........ 3-9 ITOT AND TATIC INES AND NSTRUMENT ONNECTIONS 3.17 L ..................3-9 IST OF INSTRUMENTS 3.17.1 Airspeed Indicators ................... 3-9 3.17.2 Altimeters ....................
  • Page 5: List Of Effective Pages

    Ltd. 0.1 List of Effective Pages Section Page Date Section Page Date Section Page Date Cover page 3-11 11/17 3-12 11/17 11/17 3-13 11/17 11/17 3-14 11/17 11/17 11/17 11/17 09/16 09/16 09/16 11/17 11/17 09/16 11/17 09/16 09/16 09/16 09/16 09/16 09/16...
  • Page 6: Record Of Revisions

    Ltd. 0.2 Record of revisions Any revision of this Manual must be recorded in the following table and in case of approved Sections endorsed by the responsible airworthiness authority. The new or amended text in the revised page will be indicated by a black vertical line in the left hand margin, and the Revision No.
  • Page 7: Basic Technical Data

    Ltd. Document No.: 304eS/MMSupp Date of Issue: 09/16...
  • Page 8: Basic Technical Data

    Ltd. 1.1 Basic Technical data Power-plant Sailplane is equipped with a high-tech powerful FES front electric propulsion system developed for high performance sailplanes. Main parts of the FES system are:  Brushless electric motor  Controller for motor  Foldable propeller ...
  • Page 9: Horizontal Tail Unit

    Ltd. 1.2.3 Horizontal Tail Unit Not affected. 1.2.4 Vertical Tail Unit Not affected. 1.2.5 Water ballast system Not affected. 1.2.6 Power-plant We spent a lot of effort to develop FES system to be simple and reliable, but also that it would need as little as possible of maintenance. However some minimal maintenance is still required.
  • Page 10 This motor can work only in combination with suitable electronic motor Controller which transform DC current from Battery packs to 3 phase current which supply motor. Electrical motor power ratings (type FES-HPH-M100) at 116V on motor controller and loaded with propeller (type FES-HPH-P1-102): Maximum torque...
  • Page 11 Ltd. 1.2.6.2 Propeller The foldable fixed pitch carbon fibre composite propeller is high quality product. Technical data and limitations of the propeller: Number of propeller blades: Maximum power on a propeller shaft: 23 kW; Maximum rotational speed: 4500 RPM; Propeller blade mass excluding attaching bolts: approximately 245 g each blade;...
  • Page 12 Ltd. 1.2.6.3 FCU instrument FCU instrument was developed for LZ design’s FES system by LXNAV company, who is otherwise well known in gliding community by their excellent flight computers (LX8000, LX9000) - electronic variometers. LXNAV produce FCU instruments exclusively for FES system of LZ design. Technical specification: •...
  • Page 13 Ltd. 1.2.6.4 Battery packs and its chargers Standard FES battery pack contains 14 cells which are all wired in serial. For FES application you need two of them. They are marked with serial number and a letter first as A pack and second as B pack! We are using one of the best high power SLPB (Superiol Lithium Polymer Battery) cells available on the market produced by world renowned manufacturer Kokam.
  • Page 14 Ltd. Battery packs care Charging: Only approved charger can be used. For chargers description see FES BATTERY PACK GEN2 manual. Charging procedure: Place Charger on a safe, secure position. Keep away from dust, direct sunlight, fire, smoke, children and any unatendent person! 1.
  • Page 15 Ltd. 8. Red »Error LED« is ON only during the initial test procedure. After the test is completed it turns OFF. Some system errors are also indicated with red »Error LED« by the number of ON blinks, followed by a longer OFF state. Number of blinks identifies the error: Number of ON blinks Error...
  • Page 16 Ltd. Storage: When you will stop flying before the winter (or any other longer period of no flying) it is advisable to discharge Battery packs to middle voltage which is 3,7V per cell. (This is about 52V per pack, or 104V on FCU instrument). Store packs at room temperature of 20 degrees or lower.
  • Page 17: Sailplane Systems

    Ltd. 1.3 Sailplane systems 1.3.1 Control systems in the fuselage Not affected. 1.3.2 Control systems in the wing Not affected. 1.3.3 Rudder control system Not affected. 1.3.4 Main landing gear system Not affected. 1.3.5 Control surface deflections and dimensions Not affected. 1.3.6 Electric system FES wiring consists of power, signal and 12V wires, and different types of connectors.
  • Page 18 Ltd. automatic propeller positioning. There is located also 2A fuse, potentiometer for adjusting of electronic braking and DB9 female connector for FCU update. -12V battery is not really required for operation of FES system, but is there mainly to be able to set other instruments if main battery packs are still charging. Battery should be equipped with 3A fuse.
  • Page 19 Ltd. Document No.: 304eS/MMSupp 1-12 Date of Issue: 09/16...
  • Page 20 Ltd. Fire and smoke alarm wiring scheme Document No.: 304eS/MMSupp R01 1-13 Date of Issue: 11/17...
  • Page 21: Hangaring, Transport, Rigging

    Ltd. Document No.: 304eS/MMSupp Date of Issue: 09/16...
  • Page 22: Hangaring, Parking, And Ground Handling

    Ltd. 2.1.1 Hangaring, Parking, and Ground Handling 2.1.1.1 Tie down and ground-towing Do not leave FES equipped sailplane outside on the rain, unless it is completely covered with high quality all weather covers. Protect motor and battery compartment from water entering. Take Battery packs out of the glider and store them on dry place, and not on direct summer sunlight, in order to prevent to be overheated.
  • Page 23: Rigging

    Ltd. 2.2 Rigging Not affected. 2.2.1.1 Installation of Battery packs into sailplane: Make sure that both battery packs are fully charged before Warning: installation into sailplane. Both battery packs must have approximately the same voltage level of each cell (close to 4.16 V per cell). There should be less than 0,4V difference, between total voltage level of each battery pack! ...
  • Page 24: D E - Rigging

    Ltd. 2.3 De-rigging Not affected. 2.3.1.1 Taking Battery packs out of sailplane:  Check that Power switch (or Key switch at Silent) is OFF  Check that FCU instrument and all other instruments (Flight computer, Flarm, Radio, Transponder, PDA...) are switched OFF ...
  • Page 25: Maintenance

    Ltd. Document No.: 304eS/MMSupp Date of Issue: 09/16...
  • Page 26: Mandatory Maintenance

    Ltd. 3.1 Mandatory Maintenance In this section there is defined a list of inspections to ensure safe operation of FES during its lifetime. The periodical inspections shall be performed by qualified staff authorized to perform the work at the time of sailplane inspections. 3.1.1 Inspections periods ...
  • Page 27: Motor - Propeller

    Ltd. 3.1.4 Motor – Propeller After propeller change (each 200 motor hours) Motor – propeller assembly must be balanced to the vibration value lower than 0,1 IPS. 3.2 Regular Maintenance 3.2.1 Annual inspection It is necessary to check the sailplane every 12 months in accordance with the 100 flight hours inspection.
  • Page 28: Motor Maintenance

    Do not at all simply keep on using the drive. Be especially aware of cuttings which can almost irremovably stick to the magnets. In this case, the only thing that helps is a disassembly of the drive by the manufacturer. For detail description refer FES HPH M100 MOTOR manual. Document No.: 304eS/MMSupp...
  • Page 29: Propeller Maintenance

     Cracks or deformations in a center part of the propeller are not allowed. If such occurs, send propeller back to manufacture for the overhaul. For more detail refer FES HPH P1 102PROPELLER manual. 3.2.6 Battery packs maintenance With proper and careful use of FES battery packs, there is practically no maintenance required.
  • Page 30 Ltd. Suitable uses and treatment that will reduce this deterioration include:  During powered flight, use low power settings as much as possible and practical.  Do not discharge cells below 3,4V (total voltage at 95V), if is not really necessary.
  • Page 31: Special Inspection Procedure

    Ltd. 3.3 Special Inspection Procedure 3.3.1 After hard landing, ground loops and battery pack impact In case of battery pack impact (for instance fall to the ground during manipulation or hard barking during car transport) provide battery pack test according procedure in chapter 3.3.1.1.
  • Page 32: Free Play In The Control Circuits

    Ltd. a) Measure voltage between the negative terminal and the housing. Check in multiple places on the housing (i.e. bolts on the housing, bolts on fans, etc.). b) Measure voltage between the positive terminal and the housing. Check in multiple places on the housing (i.e. bolts on the housing, bolts on fans, etc.).
  • Page 33: Removal And Re-Installation Of Releases

    Ltd. 3.9 Removal and Re-Installation of Releases CG release: Procedure of removal and reinstallation of CG release is not affected. Front release: For removing or reinstallation of front release follow next steps:  remove front 12V battery cover  unscrew bolts holding front 12V battery compartment bottom ...
  • Page 34: Lubrication Scheme

    Ltd. 3.13 Lubrication scheme There are only 3 parts in FES system which requires lubricating:  two propeller pins which hold propeller blades should be very slightly lubricated  ventilation valve pin which goes through the shaft of motor should be very slightly lubricated, so that travels forward and backward easily under spring pressure.
  • Page 35: Comm

    Other service instructions related to the FES power-plant can be found in following manuals:  G 304eS/AFMSupp  FES HPH M100 MOTOR manual  FES HPH P1 102 PROPELLER manual  FES BATETRY PACK GEN2 manual  FES BMS CONTROL manual  FES BMS LCD Display manual ...
  • Page 36: Motor Removing And Installation

    Ltd. 3.21 Motor removing and installation To remove the motor from the glider (complete with spinner and propeller) 1. Open ventilation (fully forward position) 2. Remove round laminated cover from centre of front motor mounting rib (from cockpit side) 3. Unlock springs which hold DB15 cable connector and then carefully unplug connector from motor rear wall.
  • Page 37: Installation Of Propeller

    Ltd. 3.22 Installation of propeller  Check propeller type and condition. Clean propeller and let it dry.  Oil on any of the surfaces must be avoided. Check bolts for cracks, thread and corrosion. Replace if needed (important that the bolts would be of the same length, so as not to damage the motor bearings).
  • Page 38: Controller Alarm Codes

    Ltd. 3.24 Controller alarm codes This chapter contain list of controller alarm codes and required maintenance actions. These alarm codes are displayed by red blinking of right bottom FCU diode. Diode code Description Maintenance action  Battery voltage is higher than max. Over voltage error Operating voltage of controller.
  • Page 39 Ltd. Frequent  The controller will stop driving after reset detect too many resets  Mostly because of B- or return wiring. Check return wires. *** *  Could be over current protection.  Restart will clean the error  Contact manufacturer if happens repeatedly.
  • Page 40: Airworthiness Limitations

    Ltd. Document No.: 304eS/MMSupp Date of Issue: 09/16...
  • Page 41: General

    Life limited parts - Glasflügel 304 eS Manufacturer Address Product Type Brod 3D, 50 hours of LZ design FES HPH P1 102 1370 Logatec, HPH P1 102 motor run d.o.o. Propeller Slovenia time Document No.:...
  • Page 42: Center Of Gravity

    Ltd. Document No.: 304eS/MMSupp Date of Issue: 09/16...
  • Page 43: Center Of Gravity Position

    Ltd. 5.1 Center of Gravity position CG position must be established in sailplane configuration intended for flight. CG position must lay within the limits specified in G 304S/FM chapter 2.5. Following configurations are allowed:  Motor and Battery packs installed - standard configuration ...
  • Page 44: Instructions For Repairs

    Ltd. Document No.: 304eS/MMSupp Date of Issue: 09/16...
  • Page 45: Checklist

    6.1.5 Motor Do not open or disassemble the motor! It could be very dangerous, Warning: due to very strong magnets on rotor! See HPH-M100-Motor Manual. 6.1.6 Batteries No maintenance action is required to Battery packs. See FES Battery pack GEN2 manual.
  • Page 46: List Of Potential Problems

    Ltd. 6.1.7 List of potential problems Charger do not start charging Check if power cord is plugged into wall outlet Charger do not start charging Check if connecting cable is connected between Battery pack (DATA) and charger Charger do not start charging Check grid fuse Capacity bottles on FCU do not fill up You must wait about 8 second after power...
  • Page 47: Structure Of Components

    Ltd. 6.2 Structure of Components Not affected 6.3 Materials Repair of minor damage on propeller blades. -use white polyester filler (or epoxy resin), for repair of small damages on the propeller blades -sand away excessive filler with fine sanding paper (initially granulation 360, later 600 and 800, and finally 1000) 6.3.1 List of FES spare parts -propeller blades...

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