The provided document is an instruction manual for the DUC Hélices Certified FLASH-R 3-blade propeller.
Function Description
The DUC Hélices Certified FLASH-R propeller is an innovative 3-blade propeller designed for aircraft, featuring a unique twisting axis and center of pressure. Its primary function is to provide propulsion with high efficiency across the entire flight envelope. A key aerodynamic design feature is the "Constant Speed" effect, which aims to limit variations in engine speed between ground and in-flight operations. This design contributes to improved takeoff and climb rates due to higher engine speed, enhanced engine efficiency during cruise, extended cruise range, and increased user comfort. The propeller is suitable for various aircraft types, including Ultra-light and LSA, depending on the specific model and diameter.
Important Technical Specifications
Propeller Type: 3-blade, ground adjustable propeller.
Configuration: Tractor configuration, available in right rotation.
Diameters: Available in a range from Ø1520 mm (59.8") to Ø1900 mm (74.7").
Blade Material: Unidirectional layers of carbon fibers prepreg epoxy resin. The composite structure is engineered for maximum strength in torsion and bending.
Leading Edge: Shielded with Inconel®, a superalloy primarily composed of nickel, known for its very high surface hardness, offering enhanced durability and protection.
Hub Material: Carbon composite hub with metallic inserts.
Safety Features: Protected against lightning strike; includes safety marking on the tip of the propeller.
Mounting: Direct assembly on propeller-shafts with a P.C.D. of Ø101.6 mm (Ø4"). Adaptor spacers are available for other mounting types (e.g., SAE1, SAE2) to accommodate different engine propeller-shafts and adjust the propeller plane.
Spinner: Available in diameters from Ø250 mm (9.8") to Ø340 mm (14.4").
Certifications: ISO 9001:2015, TCDS EASA: EASA P.038, Part 21G EASA: FR.21G.0273.
Airworthiness Limitations: The three-blade Certified FLASH-R has a limited flight potential of 2000 hours. A program is organized by DUC Hélices to improve this flight potential. This paragraph on airworthiness limitations is approved by EASA according to Part 21.A.31 (a) and CS-P 30(b).
Engine Compatibility:
- ROTAX 912S, 912IS, 914: Gearbox 2.43. Propeller limits 160 HP, 2700 RPM. Blade angle range (°) for Ø1730 is 24°±2° (22°→30°), for Ø1800 is 19°±2° (17°→25°), for Ø1850 is 19°±2° (17°→25°), for Ø1900 is 18°±2° (16°→24°). TBO is 2000 hours or 6 years.
- CONTINENTAL O-200: Blade angle range (°) for Ø1660 is 20°±2° (18°→26°).
- LYCOMING O-235: Blade angle range (°) for Ø1660 is 20°±2° (18°→26°).
- LYCOMING O-320: Blade angle range (°) for Ø1900 is 20°±2° (18°→26°).
- Note: The maximum period of propeller use is allowed by propeller type certificate. Compliance with CS-P, Subpart D has not been demonstrated as part of the propeller certification.
Usage Features
Assembly: The propeller is recommended to be assembled on a worktable before installation on the aircraft. The assembly process involves placing the rear half-hub, then the hub spacer, positioning the blades in their hub slots, and finally fitting the front half-hub. Screws and washers are then set up for hub assembly, followed by initial moderate tightening. The hub clamping washer is placed on the front of the propeller hub (logo side) with the rounded edge outwards. The 6 fixing screws and their washers are then installed. For pin contact washers, the pins should be oriented towards the screw head.
Installation: The manual describes three main mounting configurations:
- Directly on propeller-shaft: For engines like Rotax with a P.C.D. Ø101.6 mm (Ø4"). The rear half-hub's metal inserts' bore diameter is larger than the front half-hub's. The propeller-shaft should not extend outside the engine hood by more than 14 mm.
- Using a spacer: For Rotax engines, if the propeller-shaft extends too far, a spacer (e.g., 912H spacer) is used to adjust the position. The spacer length is determined by measuring the distance X between the propeller-shaft and the engine hood limit, then adding 14 mm.
- Using an adaptor spacer: For other engine types (e.g., SAE1, SAE2, Lycoming, Continental) with different P.C.D. fixations. Adaptor spacers are available in various lengths (e.g., 30mm, 70mm, 80mm, 100mm) and types (SAE1 AN6, SAE2 AN6, SAE2 AN7, SAE2 AN8) to match specific engine models. Brake plates are placed under the heads of the fixing bolts to prevent unscrewing.
Pitch Angle Setting: The propeller's pitch angle is adjustable. This involves slightly untightening the propeller fixing screws and the hub assembly screw. An adjustment tool (inclinometer) is used to set the desired angle. The propeller mounting flange must be perfectly vertical. The adjustment tool is placed at 25 cm from the tip of the blade, intrados side (flat), handle down. The level of the adjustment tool (measured value = 90°) indicates the longitudinal axis of the aircraft. To change the angle, gently tap on the foot of the blade in the desired direction.
Tightening: Final tightening of the bolts is performed progressively and with a torque wrench. Specific torque values are provided for different mounting types (Rotax, SAE1/SAE2) and screw sizes. For Rotax mounting with a 912H spacer, the tightening torque for hub assembly screws is 2.5 Kg/m (25 N.m). For adaptor spacer mounting, the tightening torque varies based on screw size (e.g., AN6 (3/8"): 3.5 Kg/m / 35 N.m, AN7 (7/16"): 3.5 Kg/m / 35 N.m, AN8 (1/2"): 4.5 Kg/m / 45 N.m).
Spinner Installation: After final verification of parts position and orientation, the spinner is mounted on the plate by tightening the spinner screws to a torque of 4 Nm (0.4 Kg/m) with the appropriate tools.
Maintenance Features
Continuing Airworthiness: This instruction manual must be maintained throughout the life of the propeller and may evolve. Owners are advised to check with DUC Hélices for the latest valid version.
Schedule of Propeller Check:
- Screws tightening: After the first working flight.
- Regular: Each pre-flight.
- General: Every 100 hours or annually.
- TBO: Every 2000 hours (refer to manual DH_TBO_BE_01_A – Instruction Manual TBO).
Regular Maintenance (by the user):
- Fixation of the propeller: Manually manipulate the blade to check for play. If play is detected, stop use, check propeller fixation screws, and the entire mounting.
- Degradation of propeller: Visually check the entire propeller (blade root, hub, spinner, shielding leading edge).
- Blade root: Check for big scratching (stop use), small scratching (continue use), crack (stop use), lifting (stop use).
- Shielding leading edge in Inconel: Check for significant impact (deep scratches, break, deformation – stop use) or low impact (non-deep scratches – no mechanic risk, continue use).
- Blade carbon surface: Check for significant impact (depth > 1mm, surface > 5mm² – stop use) or low impact (depth < 1mm, surface < 5mm² – no significant risk).
- Blade: Check for local delamination (stop use), low impact (no significant risk), propeller adhesive loss (no significant risk).
- Fixation of the spinner: Check visually the spinner fixation screws. If play/gap is present, check screws, tighten to proper torque, and perform a visual check of the general maintenance.
Maintenance of 100 hours or yearly maintenance:
- Fixation of the propeller: Remove the spinner, check and tighten propeller fixing screws with a torque wrench. If necessary, change the propeller fixation screws and check the entire mounting. Refer to step 7 of § 5.3 for propeller adjustment & finalizing the installation.
- Degradation of propeller: Visual check of the propeller (Blade root, hub, spinner, shielding leading edge in Inconel).
- Blade root: Check for big scratching (stop use), small scratching (continue use), crack (stop use), lifting (stop use).
- Shielding leading edge in Inconel: Check for significant impact (deep scratches, break, deformation – stop use) or low impact (non-deep scratches – no mechanic risk, continue use).
- Blade carbon surface: Check for significant impact (depth > 1mm, surface > 5mm² – stop use) or low impact (depth < 1mm, surface < 5mm² – no significant risk).
- Blade: Check for local delamination (stop use), low impact (no significant risk), propeller adhesive loss (no significant risk).
- Complete hub: Check for crack, delamination (stop using this part).
- Surface deformation: Check for surface deformation (stop using this part).
- Hub screws: Check for Nylstop self-locking nut damage (stop using this part).
- Fixation of the spinner: Check visually the correct fixing of the spinner and its fixing bolts. If play/gap is present, check screws, tighten to proper torque, and perform a visual check of the general maintenance.
Impact Location on Blade Carbon Surface: The manual defines "Blade root area" (from blade root to 20 cm from the tip) and "Blade tip area" (20 cm from the tip of the blade).
- Blade root area: Significant impact (depth > 1mm, surface > 2mm²), Low impact (depth < 1mm, surface < 2mm²).
- Blade tip area: Significant impact (depth > 1mm, surface > 5mm²), Low impact (depth < 1mm, surface < 5mm²).
- Note: If there is any doubt about the blade surface, contact DUC Hélices company.
Cleaning: A cleaning treatment for composite propellers is recommended to maintain efficiency and decrease fuel consumption.
Propeller Balance: All blades are balanced together. When a blade is changed, the blade has to be balanced to keep this balancing. For this, contact the DUC Hélices company.
To Next Page
Need help?
General
