Pilots Manual for Propeller H60A series Propeller type: Serial No.: Date of sale: Stamp, Signature:
Index List of Revisions... 3 1 Description... 4 2 General specification of Helix-Propeller types... 5 3 Operating Limitations... 6 4 Functionality... 6 5 Basic Setup... 8 6 Operation... 8 7 Installation... 8 8 Pre-Flight Checks... 10 9 Maintenance... 10 10 Warranty... 11 11 Recycling... 11 H60A Pilots Manual page 2 / 11
List of Revisions edition (date) chapter description name 22.08.2018 all first edition RKS H60A Pilots Manual page 3 / 11
1 Description HELIX propellers are manufactured since 1990 in proven fiber composite construction of carbon fiber and aviation-certified epoxy resin. The unique combination of these materials leads to the special advantages in the areas: - Thrust - Noise emissions - Longlivity Bild 1: 3-Blade Propeller H60A series The propeller blades consist of several layers of carbon fiber fabric of different orientations, a set of carbon fiber belts and unidirectional tapes and in the blade tips area of Ultra High Modular Carbon material. These are connected with a glass fiber reinforced expanding epoxy resin in the "wet-in-wet process". The decisive for the strength of internal force transmission between the top and bottom of the sheet thus takes place over the entire surface. This design results in a good vibration damping as well as insensitivity to damage due to external influences. The leading edges are protected by a PU adhesive film against water exposure as standard. Optionally, the edge protection made of metallic nickel-cobalt alloy can be ordered as the ultimate erosion protection. H60A Pilots Manual page 4 / 11
2 General specification of Helix-Propeller types Helix H 60 A 1,75m L - CS - 08x - 3 ( ) Strength class 25 = 1-10 kw 30 = 5-25 kw 40 = 10-47 kw 45 = 10-55 kw 50 = 20-85 kw 60 = 40-133 kw Model H60 F = Fixpitch V = Variable Pitch A = in Flight adjustable Diameter in [m] Rotating Direction L = Left R = Right Profile and Shape for H60 -C- = Scimitar Shape with large profile-depth and -thickness -CS- = Scimitar Shape with medium profile-depth and small -thickness -CI- = Scimitar Shape with small profile-depth and -thickness -S- = Straight Shape with large profile-depth and medium -thickness -SI- = Straight Shape with small profile-depth and medium -thickness -I- = Straight Shape with small profile-depth and small -thickness -TS- = Straight Shape with very small profile-depth and very small - thickness -TM- = Straight Shape with small profile-depth and small -thickness -LS- = Straight Shape, speed range optimized shape Fixpitch in [ ] Number of Blades Customer Specific Modifications Table 1: Specification of the Propeller Type, Structure of the Helix Propeller Name H60A Pilots Manual page 5 / 11
3 Operating Limitations HELIX Propellers are constructed for giving thrust to aircrafts with an engine output of between 20 and 133 kw using 2-stroke, 4-stroke, Wankel- or electric engine. The operating limitations for the here described propeller types of H60A as 2- and 3-Blade-Version in clockwise and anti-clockwise rotation are for Diameters from 1,45m to 2,20m. There is to distinguish: For propeller types with Type / Profile -REM-, -GEL-, -C-, -LS- and S-: - Maximum propeller-rpm: 2.500 U/min - Maximum engine power: 133 kw For propeller types with Type / Profile -CI-, -CS-, -I-, -TS-, -TM- and SI-: - Maximum propeller-rpm: 3.400 U/min - Maximum engine power: 133 kw Warning: If the maximum operating values are exceeded the propeller, engine or gearbox may be damaged. If the propeller becomes damaged its balance will be affected which can cause extreme serious consequences. The imbalance affects the entire aircraft up to the structural break of the engine mount or other parts. Before starting the engine, the pilot must ensure that the area around the propeller is free from people and loose objects to avoid injuring and impacts on the blades by sucked objects. The engine can only be hand started by qualified personnel. The hard edges of the propeller can cause, in case of rapid starting of the engine, as well as in repelling severe injuries. Attention: If the propeller is not yet tested in the existing Aircraft / engine / propeller configuration. All operation is to be carried out with extreme caution and short inspection intervals of 5 operating hours until the end of the type approval. 4 Functionality The propeller adjusts during operation its angle of attack in such a way that at takeoff, climb, high-speed flight and cruising each of the optimal propeller pitch acts. A high engine speed is available at the start to be able to call up a high engine power. With H60A Pilots Manual page 6 / 11
increasing airspeed, the propeller pitch is controlled so that the engine speed does not exceed its maximum value. The propeller is designed as an autonomous unit. There are no necessary procedures to be performed by the pilot during operation. The functionality is explained as follows in sequence of the typical flight phases: Takeoff The propeller controls with increasing engine speed, the pitch in the way that the preset allowed maximum short term engine speed is maintained. When the preset safe airspeed is reached, the control unit switch to the maximum permitted continuous engine speed Climb The maximum permitted continuous engine speed is maintained during the climb below a preset maximum climb speed. Cruise Upon reaching the preset cruising airspeed, the propeller controls the maximum engine speed to the preset cruise engine speed. Fast flight In order to perform a high-speed flight at higher engine speed, the control mode must be switched from Automatic-Mode to Constant-Speed-Mode. The pilot activates the Constant-Speed-Mode at the Propeller-Instrument. There, the chosen engine speed can be specified. Warning After manually activating the Constant-Speed-Mode with the set engine speed accordingly, neither the flight speed nor the flight phase detection is taken into account for the speed specification. To return to the Automatic-Mode, it must be activated again by entering from pilot. Decent If the throttle position is retracted so far that the propeller cannot maintain the target value even at the lowest gradient, the engine speed drops accordingly. The propeller recognizes the actual airspeed and propeller speed and regulates a pitch that produces little drag to avoid unnecessarily obstructing the gliding flight. Also, this will prevent over speeding in the event of a sudden increase in power. This feature is not active in Constant-Speed-Mode. Landing approach The propeller recognizes at the low airspeed that a landing approach exists (flight phase landing approach) and regulates a flat propeller pitch to quickly come to high speed in case of sudden increase in power. A possible over speed is tolerated in favor of increased safety through faster response. H60A Pilots Manual page 7 / 11
Attention In the Constant-Speed-Mode and in the Automatic-Mode, sudden over speed conditions are possible for a short time, especially at high speeds. Therefore, the power should be increased only slowly so that the maximum speed of the engine or propeller is not exceeded. The scheme must be given the time to readjust. 5 Basic Setup The electronic of the propeller has a fixed memory containing the parameters of the propeller behavior, as specified by the aircraft manufacturer. These parameters determine the control behavior of the propeller can be changed if necessary. In addition to this pilot manual there is an installation manual which can be downloaded from Helix. It is also describes how to change the parameters. To understand the behavior of the propeller in flight, it is important to know the set values of the following parameters: Maximum short term engine speed Transition speed takeoff <-> climb Maximum permitted continuous engine speed Transition speed climb -> cruising flight Transition speed cruise -> climb Regeldrehzahl Reiseflug 5800 U/min 100 km/h 5400 U/min 200 km/h 160 km/h 4800 U/min 6 Operation In all phases of flight, the aircraft is operated as in the case of being equipped with a fixed-pitch propeller. In opposition to the fixed-pitch propeller, the takeoff acceleration will be stronger at a correspondingly higher engine speed without overrunning the engine during increasing airspeed. It can be observed how the control unit maintain the optimal engine speed by modifying the propeller pitch. This does not require active operation from the pilot. 7 Installation Any change to the mounting condition may only be performed by a qualified person. The necessary specialist knowledge cannot be part of this manual. This activity requires fundamental knowledge in aircraft maintenance. Carrying out installation work without this qualification can cause great dangers to safe flight operations. H60A Pilots Manual page 8 / 11
In addition to this pilot manual there is an Installation Manual which can be downloaded from Helix. It describes all important aspects of installation. In the event that a check of the tightening torques of the propeller bolts is to be checked, the most important information is listed here: The propeller is screwed from behind through the motor flange with 6 M8 bolts (8.8). In this case, exactly matching bushings are to be used which must not protrude longer than 5mm from the gearbox flange in the direction of the propeller. Screw design and tightening torques are prioritized to the manual to be taken and used by the aircraft manufacturer. The nominal tightening torque of M8-8.8 fixing screws is 23 Nm. The propeller can safely be mounted with a torque in the range of 21 Nm up to 25 Nm. Compliance with the selected tightening torque must be ensured with suitable tools. To secure the screws against unintentional release due to vibration, the following applies: - The fuse is made by thread locking wire. - For passing through holes on the motor flange, new, self-locking nuts can be used. If both alternatives were not possible, medium-strength thread locking adhesive, e.g. Loctite 243 can be used. After 3 hours of operation, the tightening torques of the propeller bolts must be checked and tightened if necessary. H60A Pilots Manual page 9 / 11
Before each flight the following must be checked: - no play in turning the blades around their axis - tight fit of all blades without play - no damage to blades due to cracks and chipping from small stone impacts - tight fit of the hub on the engine flange - Screw lock in proper condition - tight fit of all spinner-cap screws - correct gap of 1.0mm to 2.0mm on the magnet ring to the rotor Only minor chipping by foreign small particles can be accepted, but should be repaired soon. This repair must be done by qualified person at propeller maintenance and repair station. If the check is unsatisfactory, the operation must be stopped and the propeller repaired. The combination of propeller hub and blade foot bearing is designed as a backlash-free fit. As a result, the blade feet in the propeller hub must not have any play. If play has been detected, stop operating the propeller immediately. If an unsteady run is detected during operation, or unusual vibrations occur, the engine power must be reduced and the aircraft landed at the lowest engine speed at the nearest airfield. The propeller must then be checked before next usage. Warning Propeller failure is more dangerous than engine failure! Failures caused by damaged blades can tear the engine out of its anchorage and thus change the center of gravity of aircraft so that a stable flight can no longer be maintained! Before starting the engine, the pilot must check that there is nothing and nobody is in the propeller's spinning plane. The entire area of the plane of rotation is fundamentally to be avoided because of the risk of accidents due to parts flying off radially. 9 Maintenance After flight operation the propeller is to be cleaned with soft detergent. This prevents the buildup of dried grass, insects etc. on the blades. Flight performance increases and the preflight check can be done easily. H60A Pilots Manual page 10 / 11
Cleaning of the blades should be carried out with a soft sponge using a weak detergent solution. If it seems necessary, the blade surface can be polished from time to time with carpolish paste. The necessary maintenance activities are specified in the manual of the aircraft. The propeller mechanism is designed to be maintenance-free within the scheduled TBO. A fixed time to overhaul (TBO) is not yet set for this type of propeller because the trial is still ongoing. The responsibility for determining the adequate TBO is the responsibility of the aircraft manufacturer. We recommend that you send the propeller to Helix or its authorized agent for maintenance after 500 operating hours. During the overhaul, the condition of all components is checked and the lubrication points are provided with new grease. Certified propellers are in the name plate with appropriate Cert. No. Marked. These propellers are to be overhauled after 500 hours of operation by the manufacturer. The maximum running time is 2000 operating hours. 10 Warranty HELIX-Carbon GmbH grants the warranty for absence of production error over the duration of 2 years from delivery. The warranty covers only the delivered material and does not include consequential damages. 11 Recycling After using the propeller, disposal of the propeller as follows: The non-recyclable propeller blades are sawn off flush with a metal saw directly at the outlet on the hub. The propeller blades are disposed of as residual waste and can be thermally recycled. The hub with control unit can be completely recycled to metal recycling. The electronics contain no heavy metals or precious metals which should be recycled differently. Alternatively, the hub can also be sent to Helix for analysis of the traces of use by 2025. H60A Pilots Manual page 11 / 11