INSTALLATIONS AND OPERATIONS MANUAL BWS-ELECTRONIC SYSTEM

Transcription

1 BWS Pirker & Storka Bug Wiper Systems - Mückenputzer INSTALLATIONS AND OPERATIONS MANUAL BWS-ELECTRONIC SYSTEM - 1 -

2 BWS ELECTRONIC SYSTEM is a device for removing bugs, flies, beetles and debris from the wing of gliders and motor gliders during flight. WARNING To avoid collisions and other hazardous situations during the whole cleaning procedure, don t forget to keep an eye on other gliders and planes in your environment. Remember, the operation of the device is always done at your own risk and responsibility. For proper and safe use read the operations and installations manual carefully. Perform the cleaning in straight flight only at an air speed of approximately 120 km/h. Avoid turbulent air, also abrupt deflections of rudder and ailerons. Any stall might cause the wipers to fall off from the wing. Make sure that the retrieval cable of the device cannot get hung up by any parts of the wings like covers, zigzag tape, gap between ailerons and flaps, wheels at the wing tips etc. Cable deflectors and other protecting means might have to be installed! Check the quality of the retrieval cable before each take off and renew it, if you detect any wear or damage. Change it before each season. If the cable is made out of stranded metal wire, don t kink it. Be aware that damaged or worn out cables might break. Although the blades are light, fly in such a manner that in case of a down falling bug wiper it may not hit any other glider or plane. Be sure that the bug wiper is able to move freely on the wing leading edge up to the end of the unwound retrieval cable. Knobs or wheels near the wing tip might be a hindrance. Before take off, test also by moving and pressing the bug wiper on the wing leading edge that the cleaning filaments (nylon strings) don t get caught at the gaps between the wing root and fuselage or between the outer and inner wing parts. The gaps might not have been sealed properly by a stiff plastic stripe or film underneath the adhesive tape. Don t repair the device BWS ELECTRONIC SYSTEM by yourself. This shall be done only by the producers or authorized persons. Inflictions on this, as well as any un-authorized modification of the BWS ELECTRONIC SYSTEM cause loss of warranty

3 General notes and remarks: Please, pay further attention to the following: The installation and operation of the BWS ELECTRONIC SYSTEM is done at your own risk and responsibility. We, the producers, don't take any liability for any damages caused by faulty installation or inadequate operation. Study the operations and installations manual carefully. Get familiar with the cleaning procedure. Improper operation might damage the bug wiper, the glider and might break the retrieval cable. If you operate the bug wiper system on ground by pulling out the bug wiper by hand, take care that if you wind up the cable again, it is never loose. Take care during upwinding that the cable is always under tension, otherwise you tangle the cable, get a cable mess and the reels might get stuck. In case of bad luck, you probably will have to renew the cables. The retrieval cable has a tensile strength of about 52.9 lb (24 kp). Exceeding this value will inevitably break the retrieval cable, causing the loss of the BUG WIPER blades. Make sure that the clutch at the reel works properly (approx. 3kp) otherwise the tension applied on the cable might be too high, breaking the cable. (With this clutch you limit the maximum pulling force the motor might apply on the cable during the automatic shut-off procedure at the fuselage.(for more see pages 28-31) In case of a motor glider: do not install the electric winches and the electronic box of the BWS ELECTRONIC SYSTEM near the lines, hoses and tank of the fuel system. If you smell gasoline, do not operate the BWS ELECTRONIC SYSTEM. The electric motor comprises a brush collector producing sparks which might ignite the fuel. Therefore appropriate provisions have to be taken to eliminate hazards of explosion and fire. Because of good ventilation in the cockpit, it is recommended to install the BWS ELECTRONIC SYSTEM in that area. Do not overstress the metal bug wiper blades by wrong adjusted clutches, pulling them too strong towards the fuselage, by flying too fast, dropping them on the floor, stepping on them accidentally or by bending them in any other careless action. Deformed bug wiper blades don t work properly and may need a careful re-bending or replacement. BUGWIPERS made out of carbon fibre are somewhat stronger and more resistant against rough treatment. Before you start with the installation, please read the complete instructions thoroughly and accurately

4 Explosion drawing of the electric winch and the electronic box Cover electric motor rear part of the casing nipple for the bowden wire mounting part worm thread ball bearing cover for bearing casing for worm gear wheel of worm gear ball bearing big braking disc, brown reel small braking disc, brown disc with semi arced hole for preventing rotation micro switch for measuring the tension of the retrieval cable casing for the reels crank shaft with supporting disc pin for fixing the retrieval cable screw for fixing the pin cup disc springs, 5 pieces 0,7 mm thick terminating disc nut for adjusting the clutch electronic box off/on/go switch Potentiometer with screw for adjusting the maximum motor pulling force on the retrieval cable (2-5 kp) Motorabschaltschwelle L/R switch for cleaning right or left wing - 4 -

5 List of parts and components: The electric system comprises the following parts: 2 x BUG WIPERS (1, 1 ) with cleaning filaments (nylon), one for the left and one for the right wing. 2 x ELECTRIC WINCHES (2, 2 ), comprising motor driven reels (3, 3 ), cable tension sensing switches (4,4 ) and electric cables (5,5 ) connected to the electronic box (7). 1 x ELECTRONIC BOX (7) with the operating switches: OFF/ON/GO, LEFT/ RIGHT and electric cables (5, 5, 6, 6 ) for the two electric winches and the 12V supply. 2 x Bowden wire cable guides (10, 10 ) for the left and right bug wipers 2 x stranded steel or DINEMA retrieval cables (11, 11 ) of about 52.9 lb (24 kp) tensile strength, length according to wing span. 2 x brass or aluminum cable duct nipples (12, 12 ) for the holes in the fuselage L GO ON OFF R Fig.1-5 -

6 Operation of the BWS Electronic System: 1) Determine first which wing half you want to get cleaned by using the toggle switch L/R (left wing/ right wing). To clean for instance the left wing set the toggle switch to the position L (left wing). 2) Then operate the combined OFF/ON/GO switch and set it from the OFF into the ON (stand by) position. By this the electronic is turned on and ready after about 2 seconds. The electronic consumes in the stand by mode about 20 ma. 3) To start the cleaning process push the lever of the OFF/ON/GO switch for a short time into the trigger position GO. After that the lever will fall back automatically into the middle position ON again. 3.1) The bug wiper goes out: If the toggle switch is in the position L (left wing), then the motor and retrieval reel of the left winch starts to run and to wind off the retrieval cable. The left bug wiper from the retracted position at the fuselage unfolds its frames and - driven by the aerodynamic side load of the drive fin - slides along the wing leading edge to the wing tip until the cable is completely wound off. As the wiper moves toward the tip the insect debris is wiped off from the wing. 3.2) The bug wiper comes in again: Since the motor and the retrieve cable reel continue to run in the same direction, the reel now starts to wind up the cable and by this to pull back the bug wiper to the fuselage, where it is collapsed and pressed against the fuselage once more. 3.3) Switching off automatically: The bug wiper comes to a stand still now, the power consumption of the motor increases until it exceeds the pre-adjusted threshold level (about 5-8 Amperes at 3-5kp pulling forces) and the switch off automatic of the electronic shuts the motor down, finishing by that the cleaning process. The value of the threshold level can be adjusted by turning the potentiometer at the side of the electronic box with a small screw driver. This value is pre-adjusted to 3 kp (appr. 5-8 Amperes) for 15 m machines and to 3-5 kp for open class gliders. However, the maximum pulling force should be adjusted to the lowest possible value to keep wear and stress of the cable during the folding up and stopping procedure as low as possible. (For more: see also page 28-31) 4) Cleaning the wing again: To clean the wing again you have to press the off-on-trigger switch for a short time to the position GO. This causes, firstly, to start the motor and secondly to change the direction of the motor as the wound up cable has got to be wound off again. NOTE: At each tipping to GO the direction of the motor will change! 5) Cleaning a special spot on the wing for several times: - 6 -

7 After having passed the area which you want to clean again: just tip the switch to the GO position and the bug wiper will change its direction. 6) Cleaning the other wing: Turn the lever of the toggle switch into the opposite direction. Then press the trigger switch shortly to GO. By this the motor and reel of the other winch starts to run. NOTE: It could happen now that the motor runs in the wrong direction and therefore, instead of winding the cable off, tries to wind the cable up. After about 2 seconds, the switch off automatic turns the motor off. In this case: just press the trigger switch again to GO which causes the electronic to reverse the motor direction and to start the cleaning again. NOTE: The switch off automatic for automatically finishing the cleaning process serves also as a means against overload. If the pilot should fly too fast during the cleaning process, then the drive fin of the bug wiper could bring up an aerodynamic side load which exceeds the adjusted level of the maximum pulling force (3 kp for instance) and therefore turns off the motor. In this case reduce your flying speed and start the cleaning process again by pressing the trigger switch to GO. 7) The cable tensioning automatic : To prevent tangling of the cable a special micro switch (mounted on the winch) measures the tension of the cable. If the cable is loose the motor is switched off and turned on again only after the cable is tense again. 8) An additional function of the trigger switch in the position GO : It may happen that during cleaning the bug wiper comes to a stand still or halt and the cable tensioning automatic, detecting loose cable, keeps the motor switched off. To be able to wind up the cable again and to allow the motor to run although the cable is loose at the beginning, you just keep the switch pressed to the position GO. This suppresses the cable tensioning automatic. If the cable is tense again then you can let go of the trigger switch. Remember that each time you press the lever to the GO position the motor will change its direction, too. To avoid this first press the trigger switch for a short time (which will reverse the motor only) and after that press it again (which will reverse the motor the second time) and keep it now pressed to GO. 9) If it should be necessary to turn the motor off, then set the lever of the OFF/ON/GO switch to the position OFF. 10) To reduce unnecessary power consumption during the stand by mode (20 ma), turn off the electronic by setting the lever of the switch to OFF

8 Review of the operating switches: 1) L / R toggle switch: Set to position L : Set to position R : cleaning left wing only cleaning right wing only 2) OFF/ON/GO switch: Set to position OFF : Set to position ON : Tipping shortly to GO : (lever returns to ON ) Pushing and holding the switch to GO :1) motor and electronic switched off electronic switched on (power consumption in stand by mode 20 ma) 1) starting the motor in case it was switched off 2) changing the rotating direction of the motor starting the motor if it was switched off, 2) changing the rotating direction of the motor 3) enables working of the motor in spite of loose retrieval cable (tension sensor being bridged) Procedure for cleaning the wing (either left wing or right wing): 1.) Select wing (right or left) to be cleaned: 1.1) If you select the left wing: Set toggle switch S1 from R to L Switch S1 : R L 1.2) If you select the right wing: Set toggle switch S1 from R to L 2.) Switching the electronic on: Switch S1 : L R Set the switch S2 from OFF to ON ON Switch S2 : OFF ON OFF - 8 -

9 3) Starting the cleaning procedure: GO Tip shortly switch S2 to GO Switch S2 : ON GO ON ON Lever of the switch returns automatically to the position on 4.) Changing the direction of the motor: GO During the cleaning procedure: Tip the lever to go ON Switch S2 : enables: ON GO ON 1) To return the BUG WIPER to the fuselage 2) To repeat the cleaning of a special spot. 3) To repeat the cleaning of the whole wing 5.) How to keep the motor going although the retrieval cable is loose: GO Set the lever to the position GO and hold it in this position ON Switch S2 : ON GO enables: To get the BUG WIPER back to the fuselage although the retrieval cable is loose and the micro-switch would shut down the motor Take care that the motor runs in the right direction. If it runs in the wrong direction and unwinds the cable then just let go of the lever so that it turns back to the ON position (GO ON) and then push it back and hold it again in the position GO (ON GO) so that the motor will run now in the correct direction to wind up the cable until it gets tensioned again

10 6) Switching off the motor and the whole BWS ELECTRONIC SYSTEM: GO Set the switch to the position OFF ON Switch S2 : ON OFF OFF In the same time the electronic will be switched off. Electrical wiring scheme of the BWS ELECTRONIC SYSTEM: Bug Wiper for the right wing Winch Micro-Switch sensing the tension of the cable: if the cable is loose the motor will be switched off. Nut for adjusting the clutch (do NOT open for fixing the cable on the reel!!) (+) yellow, red mark mark (-) yellow Bug Wiper for the left wing Potentiometer with small screw for adjusting the maximum pulling force of the winch (2 5kp). The level at which the motor will be switched off is pre-adjusted and might need final adjustment. OFF/ON/GO switch trigger GO ON + OFF L/R toggle switch to select the L R cleaning of the left or right wing Electronic Box The clutch shall be adjusted as weak as possible (by the nut on top of the reel), but strong enough to enable the electronic to shut off the motor at the adjusted switch-off level (clutch is pre-adjusted, but might need a readjustment)

11 Cables for power supply 12 V: (+) RED (yellow cable, red mark), (-) YELLOW (yellow cable) 2 long yellow and 2 long brown cables go from the Electronic Box to each electric winch. The 2 short yellow cables, one of which is marked red, are for the 12 V power supply. The cable with the red mark shall be connected to a 10 A fuse and then to the + pole of the 12 V supply, the other short yellow cable to the Minus Pole. The electronic is protected against wrong connection to the power supply (red marked cable connected to the minus pole instead to the plus pole etc). In such a case the electronic just does not work. The above mentioned 2 brown cables may be exchanged with each other, as well as the 2 yellow cables. NOTE: The BWS Electronic does NOT comprise a fuse for protection against any malfunction or short cuts. Therefore, install an external (electronic or automatic) fuse of at least 10 A. (It is recommended to use a main fuse of 20 A) Layout, position of the parts: off/on/go switch-trigger L/R toggle switch for cleaning the right or left wing Bug Wiper for the right wing Cleaning filament Retrieval cable Fuse 10A Battery 12V, 7,5A Electric winch Seilrolle Retrieval cable Electronic Box with switches 2x 4 electric cables 2 Bowden wire Cleaning filament Bug Wiper for the left wing

12 Layout of the retrieval cable: Depending on the span and type of glider the retrieval cable may be led and connected to the BUGWIPER above or below the wing. To position the retrieval cable on the upper side of the wing has the advantage that in case of gliders with large wing span the cable will not get caught so easily by the gap between the ailerons and the flaps or by the zigzag tape at the underside of the wing as the cable will be well above the wing during the cleaning process. Especially gliders from Schleicher tend to catch the retrieval cable at the underside of the wing in the aileron. The mounting of the retrieval cable on the upper side of the wing is therefore favoured for some of these gliders. For all other gliders the retrieval cable is located under the wing. The retrieval cable under the wing Retrieval cable under the wing Retrieval cable under the wing

13 The retrieval cable above the wing Retrieval cable above the wing Retrieval cable above the wing Mounting the BWS ELECTRONIC SYSTEM Search for a suitable place to mount the electric winches of the BWS ELECTRONIC SYSTEM. Of advantage are positions which allow to place short Bowden cable guides without much bending from the nipple of the electric winch to the cable duct nipple at the hole through the fuselage. It is recommended to mount the electric winch on a board made out of wood or an ALU-plate. This makes the assembly, maintenance and dismantling easier. Recommended mounting positions for different glider types are shown in the following outlines:

14 Gliders from Schempp Hirth Mounting on the landing gear cover with the aid of a board made of wood, an ALU plate or angle-alu (40x40x3mm). Oblong hole Electric winch Landing gear Board made of wood or ALU plate Back rest Wing leading edge Cockpit Gliders from Schneider Mounting the electric winches at the right and left side of the landing gear cover on the rear cockpit wall. Bowden cable fastening Board made of wood or ALU plate Landing gear cover Electric winch Place for oxygen tank Cockpit

15 Gliders from Schleicher and DG Mounting in the baggage compartment on a board made of wood or on an ALU plate. Baggage compartment In most cases it is required to make a cover to protect the reels from loose luggage parts, particularly to cover the lever of the cable tension sensing micro switch to avoid malfunction which would end up in cable mess or tangling of the cable. A protective cover made out of aluminum sheet, properly bent and screwed to the rear wall or mounting plate would be fine. Installation of the electronic box and electric cables: Mount the electronic box with the operating switches on the instrument panel. 4 cables (2 brown and 2 yellow) go from the electronic box to each electric winch. You may lay the cables (from the instrument panel to the winches in the rear) underneath the seat. Use cable fasteners to fix them on the bottom. 2 cables are for the power supply. Connect the red marked cable (+ pole) via a Fuse of 10A to the common 12 V supply or to an extra battery

16 Drilling a hole in the fuselage for the retrieval cable duct nipple: To be able to lead the retrieve cable from the electric powered reels inside the fuselage out to the bug wipers at the wing roots you have to drill a hole at each side of the fuselage with a diameter of 5 mm. Proceed as follows: 1) Rig the glider 2) Seal the gap between the fuselage and the wing root by a tape. 3) Mark the location of the hole: According to the following figures fold up the Bug Wiper and place it on the wing in retract position. Push the Bug Wiper up to the fuselage and use a scriber, a thin long pencil lead or a thin drill to mark the location of the hole on the fuselage. To do this, the scriber, lead or drill has to be stuck through the cable guide eyelets of the Bug Wiper. The gap between the wing leading edge and the Bug Wiper should be about 0,5 to 2 cm, but not less to prevent squeezing of the Bug Wiper in the retract position. During the marking the adhesive tape for sealing the wing-fuselage gap has to be put on. 4) Remove the Bug Wiper and drill a hole with a diameter of 5 mm at the marked position. Take care not to damage the wing by the drilling machine. To be on the safe side dismount the glider. 5) At gliders with double board walls, like Ventus or Discus, drill the holes of the outer and inner wall together in the same direction. Then drill the hole of the inner wall up to 17 mm so that you are able to mount and glue the fuselage cable duct nipple through it into the outer hole from inside. Retrieval cable below the wing A Schnitt A-A Detail X A

17 Retrieval cable above the wing A Schnitt A-A Detail X A Detail X for the retrieval cable below the wing Underside of the wing Wing Gap, space between fuselage and wing root Tape Lead pencil or thin drill Mark the hole here Fuselage Wing BUGWIPER Mark the hole here 0,5 2 cm Distance depends on the type of the glider

18 Detail X for Retrievalcable above of the wing cable guide eyelets for the retrieval cable in the driving frame and stabilizing frame of the BUGWIPER. Top side of the wing Mark the hole here Tape Wing Space between fuselage and wing root Fuselage Distance depends on the type of glider Mark the hole here 0,5 2 cm Wing BUGWIPER

19 Mounting the fuselage cable duct nipples: a) for gliders with a single cockpit and fuselage wall : e.g.: LS 3, 4, 6, 7, ASW 20, 22, 24, Pik 20 E, Jantar 2, 2b, Nimbus 2, 3, 3D, DG 300, 400, DG500, 600. Saw off the cable duct nipple to the correct length and smooth the rim of the nipples hole with a triangular scraper or sharp knife carefully. Stick the nipple into the fuselage hole and glue it with a 2 minutes epoxy adhesive. b) For gliders with a double cockpit wall e.g.: Ventus, Discus Stick the cable guide nipple from inside through the 17 mm diameter hole into the 5 mm hole from the outer wall and like for the gliders with a single wall cut off any exceeding length of the nipple after marking and rounding off the inner border or rim of the nipples hole. Glue in the nipple by quick hardening epoxy adhesive. Fixing the bowden cable: Lay the bowden cable from the fuselage nipple to the nipple on the electric winch. Cut the bowden cable guide to appropriate length. Fix the bowden cable on suitable places in the cockpit with the enclosed fastening adhesives. Avoid any S- loops or any other superfluous loops or bending

20 bad bad good Procedure in detail: Shorten the bowden cable to the right length with a cutting tool. Prepare the ends of the bowden cable before sticking them into the cable duct nipples and the nipple of the electric winch. Make sure that the Teflon tube inside the bowden cable is not crushed or squeezed. If necessary open the end of the tube with a tapered or sharpened nail. Cut the bowden cable with a cutting tool Trim the bowden wire. Remove sharp edges totally!! Bowden wire Sharpened nail black plastic coat Teflon tube

21 Some examples for the Installation of the bowden cable. Nimbus 2, Nimbus 3, Nimbus 3D, Nimbus 4D, DG 200, DG 300, DG 400, DG 500, DG 800, DG 1000 ASW 20, ASW 27, ASW 28, ASW 22, ASH 25, ASH 26, Bowden cable without S-bows Rear wall Wing leading edge Back rest Cockpit ASW 24: On the right side of the fuselage you have to drill a little bit upwards with a slope or inclination of about 30. Drill so that the bowden cable still goes a little bit through the driving work cover. On the left side like for ASW 20 etc. ASW 20, ASW 27, ASH 25 Driving work cover

22 Discus and Ventus Double board in the fuselage Landing gear cover Electric winches oblong hole Use board made of wood or use an ALU plate Back rest Wing leading edge Stick the one end of the bowden cable into the fuselage nipple and the other end into the nipple of the electric winch. If necessary, fix the bowden cable to the fuselage or cockpit by using fastening means. Drawing the retrieval cable into the bowden cable: Push the end of the retrieval cable from outside through the hole at the fuselage into the bowden cable till to the other end of the bowden cable. Tie the retrieval cable to the reel of the electric winch according to the following figures

23 Tying the retrieval cable to the cable reel Make knots carefully as they can reduce the tensile strength of the cable by half!! Therefore: Fold the end of the cable to a lengthy flat loop to double the cable. Bind it to the fastening pin of the reel by forming a simple knot with the doubled cable end. The knot must sit tightly on the fastening pin, however it must be able to swivel. Add some tight knots and pull the loose ends of the cable up to the top of the reel. Only one single knot Fastening pin Fix the knot by soldering it (use electronic solder). Grip Fixing screw M2,5x2,5 Cylinder head retrieval reel retrieval cable with a tensile strength of about 24 kp Secure the cable to the pin by a single knot and fix the knot by soldering it (use electronic solder). Pull the loose end of the cable to the upper side of the reel

24 Cutting the retrieval cable to proper length. Pull the end of the retrieval cable to the wing tip until the whole cable is wound off from the reel and tensioned. Cut now the cable according to the figure below so that the cable does not reach beyond the wing tip - or the Bug wiper, when attached to the cable, cannot come closer to the wing tip than appr. 20 cm. ca. 10cm The bug wiper shall not come closer to the wing tip than 20 cm. Forming a loop at the end of the retrieval cable. To be able to fasten the retrieval cable to the BUGWIPER form and knot a loop. retrieval cable of about 24 kp tensile strength Form a loop and solder the cable Securing the retrieval cable to the BUGWIPER (applies to all types). Insert the loop of the retrieval cable into the eyelet of the small stabilizing frame, then pass it onwards through the corresponding eyelet on the big driving frame, then through the adjacent eyelet and finally hang the loop on to the hook. Then tighten the cable a little bit

25 BUGWIPER Driving frame Stabilizing frame Eyelet of the stabilizing frame Retrieval cable Eyelet of the driving frame, opposite to the stabilizing frame Hook Critical place for cable wear. adjacent eyelet in the driving frame Fixing the BUGWIPER to the fuselage in the retracted and collapsed position After having secured the retrieval cable to the BUG WIPER, ask somebody to hold the BUG WIPER and to tension the retrieval cable, while you operate the trigger switch (OFF ON GO ON) to turn the winch motor on and to up wind the cable. NOTE: Be sure that the cable is always tensioned during the up winding and retracting to the fuselage. The winch pulls now the BUG WIPER to the fuselage (keep always the cable under tension!) until it collapses and the BWS electronic switches the motor off automatically. Then the electronic of the BUG WIPER SYSTEM is in the stand by mode, unless you switch the BWS electronic off again (ON OFF). Replacing the nylon cleaning filament by a new one: If the cleaning nylon should break, then install a new one by the following steps: According to the figure below draw in a new nylon filament of 0.2 mm diameter and 3 4 kp tensile strength through the appropriate eyelets to form an endless loop

26 To adjust for the proper length place the Bug Wiper on the wing about 20 cm away from the wing tip. There, the profile is the thinnest. Now, knot the nylon filament in such a way that by pressing the Bug Wiper against the wing leading edge only the filaments and NOT the drive frame comes into touch with the wing leading edge, otherwise the filaments would not be able to shear off the bugs from the wing. Retrieval cable below the wing 4 knots, bind filament also to the stabilizing frame Cleaning nylon Leading edge retrieval cable under the wing Distance between driving frame and wing leading edge shall not be less than 5mm. (There will be no cleaning effect if the bug wiper slides on the driving frame and not on the cleaning filaments.)

27 Retrieval cable above the wing 4 knots retrieval cable above the wing and cleaning filaments wing leading edge Distance between driving frame and wing leading edge shall not be less than 5mm at the thinnest part of the wing near the wing tip. Cleaning nylon Wing 5 mm BUGWIPER The distance between driving frame and leading edge shall not be less than about 5 mm at the thinnest part of the wing

28 Taping the gap between the inner and outer wing To avoid that the filaments might get caught in the gap between the outer and inner wing of open class gliders etc. you have to bridge this gap in the right manner. Use a stripe of about cm length you might cut out from an overhead foil, from a film or the plastic cover of a folder and put it over the gap in the front area of the wing. Then cover this area with a thin adhesive folio or with thin adhesive tapes you are using normally. NOTE: It is Important to test the taping by simulating the cleaning procedure by pressing the Bug Wiper on to the wing leading edge and by sliding it over the taped area. The filaments should pass without getting caught. It might be also beneficial to cut a horizontal V at each side of the tape at the wing leading edge so that the filaments which run rectangular to the cut get heaved over the tapes. broad tape thin tape Gap between two wing parts stiff foil, film, stiff plastic tape or strip which prevents the falling in of the more softer tapes Perhaps cut a horizontal V into the tapes. Adjustment of the electronic threshold level for the switch off automatic : With the switch off automatic the cleaning process is stopped automatically if the pulling or retracting force at the retrieval cable exceeds a certain value: 3kp for the 15 m gliders and 3 5 kp for the open class gliders. In this case the current of the electric motor exceeds the pre-adjusted value of appr. 5 8 Amperes. The proper value can be adjusted at the side of the electronic box with the aid of a small screw driver (see also figures on pages 11 and 30, 31). It should be adjusted in such a way that the pilot is able to clean the wings up to a practicable gliding speed (for instance 140 km/h), but not too high to keep the wear and stress of the cable as low as possible

29 Coarse adjustment: See also figures on page 31 and 11. 1) With the aid of a small screw driver turn the trim potentiometer at the small hole in the cover of the electronic box to low values in clockwise direction. 2) Make a loop at the end of the retrieval cable and hook it to a proper springbalance for measuring the pulling/attracting force on the cable. 3) Push the trigger switch to GO (ON GO ON) to wind up the cable. In case of wrong motor direction push once again. 4) By using the spring-balance pull at the cable and fix its position until the switchoff-automatic will switch off the motor. From the scale of the spring-balance read the switch off force. This will be low for low adjusted threshold levels. 5) Successively (step by step) turn the trim potentiometer in anti clockwise direction to higher values, tip the switch to GO, withhold the attracting force of the winch until it is automatically switched off again and repeat this procedure until the electronic switches the motor off at a force of about 3 kp (3-5 kp for the open class gliders, at a power consumption of about 5-8 A). Fine adjustment: 1) Turn the pre-adjusted trim potentiometer by two rotations anti-clockwise to higher values. 2) To measure the forces again hook the end of the retrieval cable to the springbalance again. 3) With the aid of a fork wrench loosen the nut of the clutch on top of the reel. 4) Turn the motor on again to wind up the cable by tipping the trigger switch to GO (ON GO ON). (In case the motor runs in the wrong direction tip to GO once more) 5) By using the spring-balance hold the cable back and stop the reel from rotating although the motor keeps running. From the scale of the spring-balance read the maximum force the clutch is able to put on the cable. 6) Successively (step by step) tighten the nut of the clutch till the clutch is able to put 3 kp (3-5 kp for the open class gliders) on the cable with the motor still running. 7) Now turn the trim potentiometer with a small screw driver clockwise to lower values until the switch-off-automatic switches the motor off. By this procedure you are able to adjust the threshold level precisely. Adjustment of the mechanical slipping clutch: The clutch is necessary for the following reasons: At the end of the cleaning process the Bug Wiper folds up and blocks the cable and the reel. The current of the motor increases until the pre-adjusted value of the threshold level is exceeded and the motor is switched off. Although the motor is brought to a quick

30 stop by an electronic brake the motor still makes some revolutions which in - absence of a clutch - would create extremely high forces on the blocked cable and therefore would inevitably tear it off. To limit these unwanted forces on the cable the clutch has to uncouple the reel from the motor. The clutch is adjusted properly if the maximum force at which it starts to slip (and therefore is able to apply to the cable) is just high enough to activate the switch-offautomatic (e.g. 3 kp), but not higher than necessary to minimize stress and wear of the cable. NOTE: If you tighten the clutch too much, then the cable might brake after the folding up of the Bug Wiper at the end of the cleaning procedure. Take care that the clutch works properly and that it limits the forces at the lowest possible values. Adjust the clutch in the following manner: 1) Adjust the threshold level of the switch-off-automatic as pre-scribed in the foregoing chapter 2) Successively, step by step, tighten the nut of the clutch on top of the reel until the electronic is able to switch off the motor safely. As mentioned before, to limit the maximum forces the nut should be as loose as possible, but tight enough to enable the electronic to switch off the motor properly. Electronic Box with the switch OFF/ON/GO und L/R (left/right) toggle switch for selecting the right or left wing to be cleaned + trim potentiometer for adjusting the motor switch off level instrument panel hole of 6 mm L/R toggle switch OFF/ON/GO switch/trigger

31 System view of the electric motor: Slipping clutch Nut to adjust the mechanical slipping clutch. Micro-switch (retrieval cable tension switch: the micro-switch causes stop of the motor if there is no tension on the cable Washer of hard paper large Retrieval cable nipple Fastening pin for the retrieval cable Fixing screw M2,5x2,5 Cylinder head Washer with nose Washer of hard paper small Nut for adjusting the slipper clutch. Gide washer Cup spring, 5 pieces Take care of the proper arrangement of the cup springs: each second cup has to be placed inverted (up side down)!!

32 Technical Data: Dimension in mm: Weights: 2 pieces Electric Winch Gramm piece Electronic Box with Switches Gramm pieces Bowden Wire Guide Line and Retrieval Cable Gramm 65 2 pieces Cable Duct Nipple Gramm 15 2 pieces Bug Wiper (DG 800D) Gramm 300 Total weight Gramm 1845 Power consumption (12V power supply, battery): 1 piece Electric winch during winding the cable off the reel A 1,8-2,1 1 piece Electric winch during retrieving the bug wiper A 3,5-5,5 1 piece Electronic Box in the stand by mode ma 20 current at motor shut down with 0,2 sec duration A

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