DUC Hélices FLASH-R Manuale utente

Aérodrome de Villefranche-Tarare (LFHV)

289 Avenue Odette & Edouard DURAND

69620 FRONTENAS - FRANCE

Phone: + 33 (0)4 74 72 12 69

E-mail: contact@duc-helices.com

ISO 9001:2015

TC EASA: EASA P.038

Part 21G EASA: FR.21G.0273

DH_FSH-R_BE_04_A Made in France 06/05/2019

Instruction manual

3-blade propeller

Certified FLASH-R

This instruction manual is to be maintained throughout the life of the propeller.

He may have to evolve. The owner must check with the DUC Hélices company

the latest version being valid applicable to the propeller.

Revision update

Date

Index

Object of modification

09/05/2019

Creation

Every amendment in this document made for the latest revision will appear in dark red.

Identification form

Date

Delivery note n°

Owner

Engine/Gearbox

ratio

Aircraft

1st recommended

pitch blade angle

Notes: ..............................................................................................................................................................................

..........................................................................................................................................................................................

ISO 9001: 2015

TCDS EASA: EASA P.038

Part 21G EASA: FR.21G.0273

Certified FLASH-R

3/27

Summary

1. Presentation of the Certified FLASH-R propeller.......................................................................................................4

Description ........................................................................................................................................................41.1.

Characteristics..................................................................................................................................................41.2.

Shielding leading edge in Inconel®....................................................................................................................51.3.

Accessories.......................................................................................................................................................51.4.

Sales references ...............................................................................................................................................51.5.

2. Applications................................................................................................................................................................6

3. Installation precautions..............................................................................................................................................6

4. Components of the Certified FLASH-R......................................................................................................................7

Mounting configuration of the FLASH-R propeller............................................................................................74.1.

Exploded view for propeller...............................................................................................................................74.2.

List of components............................................................................................................................................84.3.

List of required tools........................................................................................................................................104.4.

5. Assembly instruction of the propeller.......................................................................................................................10

Assembly of the propeller................................................................................................................................105.1.

Installation on the aircraft................................................................................................................................125.2.

Setting of the propeller & Finalization of the installation.................................................................................155.3.

6. Precautions..............................................................................................................................................................18

7. Continuing airworthiness .........................................................................................................................................19

Airworthiness limitations..................................................................................................................................197.1.

Schedule of propeller check............................................................................................................................197.2.

Regular maintenance (by the user).................................................................................................................207.3.

Maintenance of 100 hours or yearly maintenance..........................................................................................217.4.

Impact location on the blade carbon surface ..................................................................................................227.5.

8. General terms of sale...............................................................................................................................................23

Ordering procedure.........................................................................................................................................238.1.

Delivery ...........................................................................................................................................................238.2.

Price ................................................................................................................................................................238.3.

Right of withdrawal..........................................................................................................................................238.4.

Warranties.......................................................................................................................................................23

8.5.

Privacy Policy..................................................................................................................................................238.6.

Litigation..........................................................................................................................................................238.7.

9. Annexes...................................................................................................................................................................24

Dimension of the engine propeller-shaft .........................................................................................................249.1.

912H spacer –Table screw length vs. Spacer thickness .......................................Erreur ! Signet non défini.9.2.

Airfoil ...............................................................................................................................................................259.3.

Certified FLASH-R

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1. Presentation of the Certified FLASH-R propeller

Description1.1.

The certified FLASH-R propeller has a new innovative design,

specific about its twisting axis and center of pressure.

Its aerodynamic design allows a "Constant Speed" effect, limiting

variations in engine speed between on ground and in flight.

This propeller allows high efficiency throughout the flight envelope i.e.:

Improved takeoff and climb rate due to higher engine speed, then higher engine efficiency

Many cruise extension

A high user comforts

The blades and the hub of the FLASH-R propeller are manufactured according the DUC Hélices company

technologies, from unidirectional layers of carbon fibers prepreg epoxy resin.

The blade composite structure is defined to obtain the maximum strength in torsion and bending. Therefore

"constant speed" effect is not related to deformation of the blade but its geometry and specific profile.

Due to its specific geometric definition, excellent performance is obtained in both aerodynamic and acoustic,

but also in consumption.

Characteristics1.2.

The Certified FLASH-R propeller range is available:

Ground adjustable propeller

Tractor configuration available in right rotation

Diameters Ø1520 to Ø1900mm (Ø59.8 to Ø74.7")

Shielded leading edge in Inconel®

Carbon composite hub with metallic inserts

Protected again lightning strike

Direct assembly on the propeller-shaft Ø101.6mm

Safety marking on the tip of the propeller

ISO 9001: 2015

TCDS EASA: EASA P.038

Part 21G EASA: FR.21G.0273

Certified FLASH-R

5/27

Shielding leading edge in Inconel®1.3.

The leading edge of the Certified FLASH-R blades is equipped with a metallic shielding in Inconel®. This material is a

superalloy containing mainly nickel, with a very high hardness of surface.

Accessories1.4.

Aluminum mounting spacer (Direct mounting on P.C.D Ø101.6mm/Ø4”)

Moves the plane of the propeller to adjust the position according the engine hood

Aluminum adaptor spacer (Other mounting as SAE1, SAE2, …)

Move the propeller plane and adaptor the P.C.D fixation of the propeller

Spinner available in diameter Ø250mm (Ø9.8") to Ø340mm (Ø14.4”)

Adjusting tool for the setting of the pitch angle of the blades

Neoprene cover protection of the blade

Cleaning treatment for composite propellers

Save money! A clean propeller is more efficient and decreases the fuel consumption.

Sales references1.5.

Designation

Reference

Part number

Three-blade Inconel FLASH-R Right (ROTAX mounting)

01-40-001

H-FSH_3-D-R_I_RX_C

Three-blade Inconel FLASH-R Right (AN6 mounting)

01-40-011

H-FSH_3-D-R_I_AN6_C

Three-blade Inconel FLASH-R Right (AN8 mounting)

01-40-021

H-FSH_3-D-R_I_AN8_C

Note:

Specify the flight regulation aircraft (E.g.: Ultra-light, LSA…) and diameter when ordering (E.g.: ref. 01-21-001/1730).

Inconel shielding

Certified FLASH-R

6/27

2. Applications

DUC propellers are given for a flight potential under normal operating conditions. To maintain this potential, DUC

Propellers has determined a TBO (time between revisions) for a propeller based on the engine it equips. See the

section 7.1 Airworthiness Limitations for Information Benefit.

Engine

Gearbox

Propellers limits

Propeller diameter

(mm)

Blade angle

(°)

Blade angle

allowed

range (°)

TBO- Time Between

Overhaul*

(hour)

ROTAX 912S

ROTAX 912iS

ROTAX 914

2.43

160 HP

2 700 RPM

Ø1730

24°± 2°

22° → 30°

2 000 hours

6 years

Ø1750

24°± 2°

22° → 30°

Ø1800

19°± 2°

17°→25°

Ø1850

19°± 2°

17°→25°

Ø1900

18°± 2°

16°→24°

CONTINENTAL O-200

Ø1660

20°± 2°

18°→ 26°

LYCOMING O-235

Ø1660

20°± 2°

18°→ 26°

LYCOMING O-320

Ø1900

20°± 2°

18° → 26°

* It is the maximum period of propeller use allowed by propeller type certificate.

Compliance with CS-P, Subpart D has not been demonstrated as part of the propeller certification.

Remark

The values of the pitch angle are defined by flight test on each engine. If necessary, this setting should be adjusted

according to the aircraft.

For proper use of the propeller, refer to section 7.Continuing airworthiness

3. Installation precautions

WARNING

Make sure the ignition is turned off before starting any type of operation on the propeller.

Do not run the engine without propeller, engine damage will result

IMPORTANT

The blades of a propeller are part of a whole. DO NOT INTERCHANGE with other similar blades from propeller. The

propeller blades are manufactured to their application. Their structure, weight and balance are different from a propeller

to another.

The spinner is an important element for cooling the engine. The aircraft must not fly without a spinner.

Fitting a different spinner will be an addendum to this manual approved by the DUC to confirm its compatibility with the mounting of

the propeller.

The propeller is delivered with the appropriate screws. The change of the screws is contrary to our recommendations unless

validated by the manufacturers.

WARRANTY CONDITIONS

The user is still flying under its full responsibility (see.8.General terms of sale).

ISO 9001: 2015

TCDS EASA: EASA P.038

Part 21G EASA: FR.21G.0273

Certified FLASH-R

7/27

4. Components of the Certified FLASH-R

Mounting configuration of the FLASH-R propeller4.1.

Here is a configuration table of the three-blade certified FLASH-R propeller mounting according the propeller-shaft of

the engine.

If needed, see annex 9.1 Dimension of the engine propeller-shaft

MOUNTING

ENGINE PROPELLER-SHAFT

Ø4" / Ø101.6mm

(Rotax)

Type SAE1

Ø4-3/8" / Ø111.125mm

(Ex: Continental O-200)

Type SAE2

Ø4-3/4" / Ø120.65mm

(Ex: Lycoming O-320)

direct on propeller-

shaft (without spacer)

with spacer

with adaptor spacer

Exploded view for propeller4.2.

Remark

This exploded view shows the principle of the certified FLASH-R propeller assembly. The size of all of these

components changes depending on the configuration of the propeller (diameter hole of the metallic inserts of the half-

hub, length of the screws…).

Inconel FLASH-R

blade right(x3)

Screws & washers

for hub assembly (x6)

Hub camping washer (x1)

Locking nuts & washers

for hub assembly (x6)

Rear half-hub (x1)

with rear metallic inserts (x6)

According to mounting

Fixing screws and washers of the propeller

adapted according the mounting (x6)

Internal hub spacer (x1)

Caution when handling the blades

CUTTING TRAILING EDGE

Front half-hub (x1)

with front metallic inserts (x6)

According to mounting

Certified FLASH-R

8/27

List of components4.3.

Designation

Optional

(According to

the recommend

mounting)

Part Number

Quan

tity

Spacer (optional)

912H spacer - 3mm

EI-912H-3

912H spacer - 6mm

EI-912H-6

912H spacer - 10mm

EI-912H-10

912H spacer –15mm

EI-912H-15

912H spacer - 20mm

EI-912H-20

912H spacer - 45mm

EI-912H-30

912H spacer - 30mm

EI-912H-45

912H spacer - 60mm

EI-912H-50

912H spacer - 30mm

EI-912H-60

912H spacer - 70mm

EI-912H-70

912H spacer - 75mm

EI-912H-75

912H spacer - 80mm

EI-912H-80

912H spacer - 100mm

EI-912H-100

912H spacer - 120mm

EI-912H-120

Dowel spacer DUC Ø13 L20

PI-DUC13-20

Dowel spacer DUC Ø13 L30

PI-DUC13-30

Dowel spacer DUC Ø13 L40

PI-DUC13-40

Dowel spacer DUC/ROTAX Ø13 M8 L28

PI-RX-28

Dowel spacer DUC/ROTAX Ø13 M8 L30

PI-RX-30

Screws CHC M8x40mm

(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)

V-CHC8-40

Adaptor spacer (optional)

SAE1-AN6 adaptor spacer - 30mm

E-SAE1AN6-30

SAE1-AN6 adaptor spacer - 70mm

E-SAE1AN6-70

SAE1-AN6 adaptor spacer - 80mm

E-SAE1AN6-80

SAE1-AN6 adaptor spacer - 100mm

E-SAE1AN6-100

SAE2-AN6 adaptor spacer - 30mm

E-SAE2AN6-30

SAE2-AN7 adaptor spacer - 90mm

E-SAE2AN7-90

SAE2-AN7 adaptor spacer - 100mm

E-SAE2AN7-100

SAE2-AN8 adaptor spacer - 30mm

E-SAE2AN8-30

Dowel spacer DUC Ø17 AN6

PI-DUC17-AN6

Dowel spacer DUC Ø17 AN8

PI-DUC17-AN8

Safety washer DUC AN6

RS-AN6

Safety washer DUC AN8

RS-AN8

Screws 3/8" UNF 1-3/4"

V-3/8-1_3/4

Screws 1/2" UNF 1-1/2"

V-1/2-1_1/2

Screw 3/8" UNF 2-1/2"

V-3/8-2_1/2

Screw 3/8" UNF 3"

V-3/8-3

Hub

3-blade rear half-hub Certified FLASH-R ROTAX

DMFSH-3-AR_RX_C

3-blade rear half-hub Certified FLASH-R AN6

DMFSH-3-AR_AN6_C

3-blade rear half-hub Certified FLASH-R AN8

DMFSH-3-AR_AN8_C

Certified internal FLASH-R hub spacer

EMFSH_C

3-blade front half-hub Certified FLASH ROTAX

DMFSH-3-AV_RX_C

3-blade front half-hub Certified FLASH AN6

DMFSH-3-AV_AN6_C

3-blade front half-hub Certified FLASH AN8

DMFSH-3-AV_AN8_C

Screws CHC M8x30

(Included narrow plain washer Ø8mm and Nylstop self-locking nut M8)

V-CHC8-30

Certified hub clamping washer FLASH ROTAX

RS-FSH-RX_C

Certified hub clamping washer FLASH AN6

RS-FSH-AN6_C

Certified hub clamping washer FLASH AN8

RS-FSH-AN8_C

ISO 9001: 2015

TCDS EASA: EASA P.038

Part 21G EASA: FR.21G.0273

Certified FLASH-R

9/27

Designation

Optional

(According to

the recommend

mounting)

Part Number

Quan

tity

Blade FLASH-R

Certified Inconel FLASH-R blade, Right

FSH-D-R_I_C

Fixing screws

Screws CHC M8x130

(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)

V-CHC8-130

Screws CHC M8x140

(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)

V-CHC8-140

Screws CHC M8x150

(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)

V-CHC8-150

Screws CHC M8x160

(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)

V-CHC8-160

Screws CHC M8x180

(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)

V-CHC8-180

Screws CHC M8x200

(included pins contact lock washer Ø8mm and Nylstop self-locking nut M8)

V-CHC8-200

Screws DUC AN6-52

(included washer 960-616)

V-AN6-52

Screws DUC AN8-52

(included washer 960-816)

V-AN8-52

Accessories: Spinner & Mounting plate

3-blade spinner mounting plate Ø250mm ROTAX

P-250_3-RX

3-blade spinner mounting plate Ø250mm Ø17

P-250_3-17

3-blade spinner mounting plate Ø260mm ROTAX

P-260_3-RX

3-blade spinner mounting plate Ø260mm Ø17

P-260_3-17

3-blade spinner mounting plate Ø270mm ROTAX

P-270_3-RX

3-blade spinner mounting plate Ø270mm Ø17

P-270_3-17

3-blade spinner mounting plate Ø290mm ROTAX

P-290_3-RX

3-blade spinner mounting plate Ø290mm Ø17

P-290_3-17

3-blade spinner mounting plate Ø300mm ROTAX

P-300_3-RX

3-blade spinner mounting plate Ø300mm Ø17

P-300_3-17

3-blade spinner mounting plate Ø340mm ROTAX

P-340_3-RX

3-blade spinner mounting plate Ø340mm SAE1-AN6

P-340_3-SAE1AN6

3-blade spinner mounting plate Ø340mm SAE2-AN6

P-340_3-SAE2AN6

3-blade spinner mounting plate Ø340mm SAE2-AN7

P-340_3-SAE2AN7

3-blade spinner mounting plate Ø340mm SAE2-AN8

P-340_3-SAE2AN8

3-blade spinner Ø250mm

C-250_3

3-blade spinner Ø250mm L

C-250L_3

3-blade spinner Ø260mm

C-260_3

3-blade spinner Ø270mm

C-270_3

3-blade spinner Ø290mm

C-290_3

3-blade spinner Ø300mm

C-300_3

3-blade spinner Ø340mm

C-340_3

Spinner closure plate

CC-250_350

Spinner screws M5x16mm

V-P5-16

Spinner screws AN-525-10R8

AN-525-10R8

Certified FLASH-R

10/27

List of required tools4.4.

Rotax mounting

SAE1/SAE2 mounting (Lycoming, Continental, …)

6 Torque Allen Wrench (Torque: 25 Nm)

Flat key 13

Inclinometer (angle adjustment tools)

Nylon mallet

Torque screwdriver (Torque: 4 Nm)

6 Torque Allen Wrench (Torque: 25 Nm)

Flat key 13

3/8 or 1/2 Torque Wrench (Torque: 30 to 45 Nm)

Inclinometer (angle adjustment tools)

Nylon mallet

Torque screwdriver (Torque: 4 Nm)

5. Assembly instruction of the propeller

The assembly of the Three-blade Certified FLASH-R propellers is shown below. It is recommended to assemble the

propeller on a worktable before installing it on the plane.

For further information, contact the DUC Hélices Company.

Assembly of the propeller5.1.

A « Propeller Form » will be done to insure a propeller follow-up. Parts Number and component serial number of

propeller will be written on this form.

STEP

Place the rear half-hub on a worktable.

Be careful not to invert with the front hub half.

Depending on your installation, the rear half-hub is one

mounted on the propeller-shaft of the engine or on a

spacer. The diameter of the bore of the metal inserts of

the rear half- hub is larger than the bore of the metal

inserts of the front half-hub.

STEP

Place the hub spacer in the center of the rear half-hub.

STEP

Positioning the blades in their hub slots by placing them

outwards.

The three blades of the propeller have been

balanced at DUC Helices before their dispatch.

Position the DUC Hélices logo facing you.

Note that the metal inserts of the half-hub allow a

locking of the blades in their axis within the hub.

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