TAGB5-145 Art.No. 30182 Application Guide Balancer/Analyzer 8500C for use with EC145 Tracking & Balancing of Main Rotor and Dynamic Balancing of Tail Rotor Application Guide Revision: 28. March 2007 Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, D-86609 DonauwoerthEC145 Track & Balance 8500C Application Guide Required Equipment ‘The following equipment is required to perform the Tail Rotor Balance and the Main Rotor Track & Balance (using the Optical Tracker). This list can be used to check that all equipment is available. lem Qty. Deseription New P/N Old PIN 1 1 Balancer/Analyzer 85000(+) 10800-1(-2) 8500-6 2 1 Signal Selector 85206 41130-1 8520-1 3 1 Optical Tracker, FasTrack 1180-3, 104201 4 1 Cable Assy, Optical Tracker 12700 1247-25 5 4 Gahla Asay, DC ta 8520(C) 40813-12 9851 6 1 Cable Assy, 85206 to 8500(C) 40811-12 9849 7 1 Seale, Pocket Pro, 320g +/- 0,19 cM 302-1 11245 8 1 Camying Case 85000/85200/135M-12 11270(-1) 3830-2 9 4 Velocimeter 7310 10 2 Cable Assy, Veto, 15ft 11210-15 7308-1 111 Cable Assy, Velo, 50ft 11210-50 7308-2 12 1 Magnetic Pickup, BO/BK/EC 6343 131 Bracket, 0.250" Hole, L-Type 3382(-1) 141 Bracket, 0.250" Hole, Z-Type 3575 15 1 Target Patches (min. 2 strips) 3300 16 1" Target Patches (optional) 4270-41 17 1 Probe, Photocell 1020-1 7598 18 1 Cable Assy, Photo, Soft 10185-50 7396-2 19 1 Processor, Photocell 10170-1 7400 20 1 Printer Paper (spare) 610-199 21 1 Circuit Protection Module, 5A 6045, 22 1 Cable Assy #1, BK117, XMSN t0114 23° 1 Cable Assy #2, BK117, Cabin 10112 24 1 Bracket, Velo., BK117 MR XMSN 6408 25 1 Bracket, Velo/Photo, BK117 T/R 10307 26 1? Bracket, Tracker, EC135/145, Nose Mnt. 14651 27 17 Bracket, Tracker, EC135/145, Universal 17283, 2B 1 ‘Tab Tool, BO105, BK117, E0135, EC145 | TTT-135 T4117 29° 1 ~~ Chart Set, EC145, 17138-1 30 1 Application Guide, EC145 (this one) TAG85-145 (this manual) 31 1 Guide, Quick Reference, 8500(C) a2 10955 32 1** Sight Black, None Refi, Color, 100g Can 33925 331 Spray Can, Color, flat black (not reflective) —-~- - Optional Equipment For visual Track observation only Strobex 135M-12 8620 Tip Target, Color, EC135 1120-70-706 (ECD-Part) Dots, Color Retro, 0.5" (spare) 8503 * = Not required if the Optical Tracker is used. ** = None reflective water soluble coor for acourate track measurement with Optical ‘Tracker, only required for shiny leading MR blade edges and/or bright light conditions. *** = This part is supplied by Eurocopter Deutschiand only. ? = Bracket P/N 17283 is the universal version that fits also on helicopters with Wire Strike ‘Assy and/or Radar Dome. It also replaces older Bracket P/N 14851 Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, 86609 Donauwoerth Page 2 of 12EC145 Track & Balance Installation Main Rotor This section describes the correct installation of the Balancer/Analyzer @500C(+) for Main Rotor Tracking & Balancing, 1. Rotate main rotor so that the perma- nent interrupter bolt in the rotating swash- plate is over the threaded mounting hole for the Magnetic Pickup (in the fixed swashplate). In this position, blade BLUE Points in flight direction (12.00 o'clock). 8500C Application Guide 3. Install Velocimeter 7310 "XMSN Lat.” with Bracket 6408 on the top main transmission flange with its connector pointing to the LEFT of the aircraft (9.00 O'clock direction). Red Blue Yel iGreen Rotor position when Interrupter is over Magn. P/U 2. Install Magnetic Pickup 6343 (not 3030) in the threaded mounting hole of the fixed swashplate. Adjust gap between Magnetic Pickup and interrupter bolt for 1,2 to 1,5 mm. Tighten and wire-lock jam nuts and recheck for correct gap. “MIR LAT" Velocimeter on main transmission 4. Connect Cable 10111 to Magnetic Pickup, Velocimeter and to aircraft hardwiring, on the rear side of the main transmission. ‘Magnetic Puickup installation (CAUTION! Allow enough stack in the Cable 10111 so it can follow all moyements of the swash plate. Cable must not be| under tension if the swash plate is in the highest position. Also make sure cable does not interfere with| any moving parts, “MIR LAT Velocimeter, Magnetic Pickup and Cable 10111 on main transmission Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, 86609 Donauwoerth Page 3 of 12C145 Track & Balance 8500C Application Guide 5. Install Velocimeter 7310 *Console Vert." with Bracket 3382(-1) on the left side of the center console with connector pointing UP. Console Vert Velocimeter on center console 6. Connect Cable 11210-15(-20) to the Velocimeter and run it to the rear seat or front catgo atea. For safe flight operation, make sure the cable cannot interfere with any controls. 7. Install Velocimeter 7310 *Cargo Vert." with Bracket 3575 in the right rear of the ‘cargo area on the floor (near the right loading door post) with connector pointing uP. {Cargo Vert" Velocimeter on right cargo door post 8. Connect Cable 11210-15(-20) to the Velocimeter and tun it to the rear seat or front cargo area. 9. For automatic track measurement install the Optical Tracker 11800-3 on the nose of the aircraft, using the Bracket 14651, as illustrated below. Normal Tracker installation IMPORTANT ‘To make sure the Optical Tracker works reliable also at high airspeed and load, bend the original Bracket 14651 0 that the axis is about 5 degrees UP trom the original position. That means the Tracker measures about 4: meter more inside (from blade tip) and is not missing the blades. NOTE: In case the helicopter has a Wire Suike installation and/or a radar dome installed, use Bracket 17283 as illustrated below. ‘Tracker installation with Wire Strike Assy Telemeter Electronic GmbH, Joseph-Gaonsler-Strasse 10, 86609 Donauwoerth Page 4 of 12EC145 Track & Balance 10. Connect Cable 13279-25 to the Optical Tracker 11800-3. Run cable through the nose door into the cabin and to the rear seat or front cargo area. 11. For reliable and accurate track & leadflag measurement with the Optical Tracker, paint the shiny leading edges of each main rotor blade about 4 cm (1,5 Inch) wide and about 1,2 meter (4 feet) from blade tip, with none reflective flat black color. NOTE: In dry weather, the water resolvable spray color ‘Sight Black P/N 33925 (or equivalent) may be used. In ‘wet or snowy weather, use a solid flat black color to ensure best blade contrast (lo sky) forall est Might 7 a paint this area fiat biack Biade painting for best contrast CAUTION! ‘To ensure comect polarity of the aircraft's 28VDC| supply voltage for the Acquisition Unit (AU) and to avoid a short circuit, the Cireuit Protection Module| [6045 must be used !! 8500C Application Guide 15. Connect Circuit Protection Module 6045 to the 28 VDC bulkhead connector on the right wall of the loading area. main transmission sensors 16. Connect Cable 10813-12 to Circuit Protection Module 6045. 17. Connect Cable 10112 to sensor hardwiring from the main transmission, on the ceiling above the left sliding door, as. shown above. 18. Place Balancer/Analyzer 8500C(+) on the rear seats or on the copilot's seat. 19. Connect main rotor sensor cables to Signal Selector 8520(C) as follows: 12. Place Signal Selector 8520C on the rear seats or on the floor. 18. Connect Balancer/Analyzer 8500C to Signal Selector 8520C using Cable Assy 10811-12. 14. Connect Signal Selector 8520C to the Circuit Protection Module 6045 using Cable 10813-12. XMSN Lat... CHANNEL 1 Console Vert. CHANNEL = (2 Cargo Vert. CHANNEL 3 Magn. Pickup ... INPUT A Opt. Tracker (optional). INPUT B OPTIONAL: For visual track observation place also STROBEX 135M-12 on the copilot’s seat and connect itto Balancer/Analyzer 8500C(4), Telemeter Electronic GmbH, Joseph-Gaenslor-Strasse 10, 86609 Donauwoerth Page 5 of 12EC145 Track & Balance 8500C Application Guide Current Main Rotor Settings In order to calculate balance weights which can be executed and which do not exceed any limit (max. Weight = 400 g & Tab Range = 4,0 +/-3 mm), the actual rotor settings must be entered under SETTINGS, before the final track & balance solution is calculated. Therefore, it is recommended to check and record the actual balance weights and position of the trim tabo, before the first test flight. Use a copy of the form fon the right to record the actual rotor settings, before working with VXP. NOTE: The actual rotor sottings may also be entered aller the measurement(s), when the solution is calculated and displayed, if not available before. In this cease, the 8500C(+) calculates a new solution for P/L, weight and trim tab changes which respects the entered rotor settings and given rotor limits ‘The trim tab position is defined as the distance between the upper trim tab surface (at the rear edge) and the bottom of the Eurocopter’s original Tab Bend Tool PAN 105-15103 W2 as shown below, This distance is about 4 mm on ECH4S blades if the trim tab is in trailing (neutral) position. This is why the standard trim tab setting in the EC145 Application Software is 4.0 mm (default setting). Eurocopter Tab Tool 4a 1408 WE , eiere a = Z, rt v Rotor Blade ‘Tab position relative to original Tab Too! RECOMMENDATION: Since the original Tab Bend Tool PIN 105-15103 W2 does not allow to measure the trim tab position as accurate as required for accurate adjustments, the Precision Tab Tool P/N TTT-135 is recommended. This tab tool is described on the following page. EC145 Main Rotor Settings Current Tab settings: Nominal / Tang Tab Poston «4mm Tab Range = 1010 7.0mm BLADE iugoanp = OUTBOARD BLUE mm RED mm YELLOW mm GREEN mm Current Weights: Max. 400 game BLE weigitr aLUE grams RED grams YELLOW grams GREEN “grams ikea qe ou ior: en Main Rotor position if Interrupter is aligned with the Magnetic Pickup Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, 86609 Donauwoerth Page 6 of 12EC145 Track & Balance Precision Tab Tool ‘The Precision Tab Tool P/N TTT-135 is small-size, tugged and simple to use for BO105, BKI17, EC135 and EC145. It enables quick and accurate measurement of the current trim tab position, while bending the tab. TTT-195 assembled ‘The Tab Tool TTT-135 exists of the following parts: ea. Measure Plate, Assy TTT-105-D-M Yea, Bending Plate TIT-105-2-D lea. Micrometer, Assy TMU-42553/20-M To put the Tab Too! into the 8500C(+) Carrying Case, the Micrometer can be quickly disassemblad and reassembled. If the basic adjustment is done, the Micrometer can be installed and removed easily without any readjustment. NOTE: The Tab Tool TTT-135 is adjusted and ready for use when delivered. However, make sure the Micrometer is fully inserted into the Measure Plate before use. This is important to ensure that the correct readings are indicated on the Micrometer. 8500C Application Guide NOTE: The basic adjustment of this Tab Tool is done by adjusting the three M6 bolls. The Tab Tool is correctly adjusted if the M6 bolts show the dime 4s illustrated below, with jam nuts htened. Basic Tab Too! Adjustment CALIBRATION CONTROL DIMENSION: With above deseribed adjustment the (Fully inserted) Micrometer should read 9,5 mm (#/-0,2 mm), if the three M6 bolts and the Micrometer Probe rest on a plane surface (on a commer). To use the Tab Tool, insert the Micrometer into the Measure Plate. Press tho Micrometer firmly into the hole and clamp it tight, using the clamp nut, To measure the current position of the trim tab(s), place the tab Tool on the top side of the rotor blade, and read actual tab position on the Micrometer. ‘The Micrometer should read the following, when the trim tab is in neutral (trailing) position. Helicopter Type ‘Micrometer Reading Ec145 4mm NOTE: Pay atention to read correct numbers on mm scale. For example, 4.90 mm can easily be misread as '5.90 mm because the millimeter pointer is close to the 5 mm Tine, A Imm reading error can make a big difference in the track & balance results (good or bad). To change the tab setting, use the Bending Plate PIN TTT-105-2-D and bend the tab until the ‘Micrometer reads the required tab setting, REMEMBER: Bending the tab DOWN (for lower track) makes a bigger reading on the Micrometer Bending the tab UP (Tor higher track) makes a smaller reading on the Micrometer. Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, 86609 Donauwoerth Page 7 of 12EC145 Track & Balance Installation Tail Rotor This section describes the installation of the Balancer/Analyzer 8500C(+) for dynamic Tail Rotor Balancing. 1. Install Bracket 10307 on the outer tail rotor gear box flange as shown below. Use the original srews without washers and lighten will correct torque (8 to 10 Nm). 2. Mount Velocimeter 7310 on Bracket 10307, tighten and wirelock for safe flight operation. Velocimeter and Photo Probe Installation ‘on Tail Rotor 3. Mount Photo Probe 10200-1 on Bracket 10307 with lense pointing to the tail rotor. Tighten jam nuts and wirelock, {or safe flight operation. 4. Connect Cable 11210-50 to Velocimeter and tighten nut for safe flight operation. Connect Cable 10185-50 to Photo Probe. “IMPORTANT. DO NOT WIRE-LOCK the connector nut of the Cable 11210-XX to the Velocimeter or aircraft ground, ‘because it may cause a measurement problems due to a 0 called “Ground Loop” effect. Instead use a tape to, lock the nut against its backshell if desired. 8500C Application Guide 5. Run Velocimeter Cable and Photo Probe Cable along the tail boom through the rear loading doors into the cabin. Secure cables for safe flight operation, using tie wraps and high-speed tape. 6. Attach two stips Reflective Target 3300 or one strip Reflective Target 4270-1 or 10444 on the inner side of one blade grip so that it meets the light beam of the Photo Probe. my / Azimuth Reflector attached to blade grip NOTE: If the Photo Probe is powered via the ‘Acquisition Unit or by the Battery Module 10220 ‘emits @ red light beam. This allows to check if the reflective target on the blade grip meets the Photo Probe light beam when passing. View from the Photo Probe side because the light is reflected back to the Photo Probe. REMARK: The numbering of the balance points (Qvcight locations) is relativ to the attached Azimuth Reflector on (only one) blade grip, as illustrated below. Teresa 3 Weight location relative to Azimuth Reflector (view from left side of aircraft) Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, 85609 Donauwoerth Page 6 of 12EC145 Track & Balance HIGH DANGER! [The Pedal Position Fixture PAN B642 M1002 102} |G822-01 is only allowed for Ground Runs. The Pedal Position Fixture MUST BE REMOVED before fight, ‘because of the potential danger thatthe pedals ean lock when pushed into extreme left or right position. 7. To reproduce the required pedal positions exactly from run to run, install the Pedal Fixture P/N B642 M1002 102 822-01 (or equivalent) on pilot's pedals. Pedal position fixture installed on pilot's pedals 8500C Application Guide 9. Place Balancer/Analyzer 8500C(+) on the rear seats or on the copilot seat in the cabin. 10. Place Signal Selector 8520C on the tear seats or on the floor behind the copilot seat. 11. Connect Balancer/Analyzer 8500C(+) to Signal Selector 8520C using Cable 10811-12. 12. Connect Signal Selector 8520C to the Circuit Protection Module 6045 using Cable 10813-12. 13. Connect Photocell Processor 10170-1 to Photocell Cable 10185-50. 44. Connect tail rotor sensors cables to the Signal Selector 8520C as follows: Velocimeter Photo Probe CHANNEL 7. INPUT ie CAUTION? To ensure correct polarity of the aircraft's 28VDC| supply voltage for the Acquisition Unit (AU) and t0| avoid a short circuit, the Circuit Protection Module| [6045 must be used |! 8. Connect Circuit Protection Module 6045 to the 28 VDC bulkhead connector on the right wall of the loading area, ‘Connection to aircraft's 28 VDC power und main transmission sensors 15. Place helicopter on a convenient area with the head into the wind to execute the ground run for the tail rotor balance measurements. NOTE: The ECI4S tail rotor may be very sensitive to cross wind. Therefore, balancing may become difficult (or even impossible, during strong ground wind, Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, 86609 Donauwoerth Page 9of 12EC145 Track & Balance 8500C Application Guide Current Tail Rotor Balance Weights In order to calculate balance weights which can be executed and which do not exceed the maximum allowable weight of 75,0 grams per balance point, the currently installed balance weights must be entered under SETTINGS. Therefore, itis recommended to check and record the actual balance weights, before the first balance measurement. A copy of the form on the right may be used to record the actual balance weights, before working with the 8500C(+) NOTE: If not available before, the current balance weights may also be entered after the balance measurement, when the solution is calculated and displayed. In this case, the 8500C(+) ealeulates a new solution which respects the entered balance weights and the given weight limits, RECOMMENDATION: In order to add small balance ‘weights, it might be helpful 10 install bolts (and the required small aluminum washer) on all 6 weight Tocations. In this case, the weight of the bolts should be considered as "zero" and entered as "0.0 grams” in the ‘current weight SETTING, when using the 8500C(+) In other words, only additional (removable) weight should be entered as "Current Weight" ILis also recommended to label all balance points with ‘2 water resistant pen per illustration on the right, (0 avoid confusion (mistakes) when changing balance, weights EC145 Tail Rotor Set Tal NUMBER: nnn Run No. Current Balance Weight record removably weight only (max. 75,0 grams per location) BoltNo. Weight RON eaca 2 URES: Position of balance points relative to the interrupter on the Fenestron rotor Telemeter Electronic GmbH, Josoph-Gaonsler-Strasse 10, 86609 Donauwoerth Page 10 of 12EC145 Track & Balance 8500C Application Guide EC145 Chart Set, P/N 17138-1 The above 8500 Chart Set for EC145 includes the following Smart Charts: PIN Revision Chart Type Azimuth Sensor 17092-1 19Sep 05 M/R Smart, FasTrack MagP/U 16553 28Jan03 TR Smart Auto-Corr Photo The Main Rotor Smart Chart #17092-1 supports the Optical Tracker and use the latest features and functions of 8500 Smart Chart Technology for main rotors such as: IMPORTANT HINT: Do not perform intermediate solution for regime “Hover IGE” because it may Wake the following Ground Track & Balance worse again. © Integrated Track optimization, with solution option * Intermediate Solutions (after each regime). But, DO NOT perform intermediate solution after measurements on Ground and Hover only, becaue it may result in too high ground balance (above 0,4 IPS). Respects current rotor settings in solutions Respects rotor limits in solutions Prediction of vibration goals Smoothing of all (measured) regimes Auto-Bookkeeping NOTE: This Main Rotor Smart Chart is not fully validated, yet. But there is a high confidence that it works properly. In this case, and if correctly used, excellent low/acceptable balance levels should be reached with a small number of runs/flights. The Tail Rotor Smart Chart, Photo #16553 supports the latest features and functions of 8500 Smart Chart Technology for tail rotors such as: Respects current balance weights in solutions Respects weight limits (min. and max.) in solutions Prediction of vibration goals Auto-Correction (to adapt to actual weight response) ‘Auto-Bookkeeping NOTE: This Tail Rotor Smart Chart is successfully in use by Eurocopter Deutschland since middle of 2003. Therefore, if correctly used, excellent low/acceptable balance levels should be reached with a small number of runs. Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, 86609 Donauwoerth Page 11 of 12EC145 Track & Balance 8500C Application Guide Main Rotor SOLUTION OPTIONS (Smart Chart 17092-1) To select the best SOLUTION OPTION, please note how the option works. The option allows the Main Rotor Smart Chart to ‘choose what the most appropriate solution option for the current regime should be, For example, TAB: AUTO sets the tab solution option to NO for a ground solution (tab is ‘exoluded), and YES for a cruise solution (tab is included). The user can always override AUTO by changing it to the desired option (YES, NO, etc.). The options that are actually used to create the solution always. appear on the solution printout. The softkey SHOW DEFLT on the Options screen also shows how AUTO is. being translated by displaying the actual options that are in effect. SOLVE FOR: is alittle more complex. For all [C145 regimes, SOLVE FOR: Is translated to VIB+TRACK. For cruise regime solutions however, there ate two conditions that cause AUTO to be translated to VIB ONLY. They are: 1. If the VIB ONLY solution is predicted not to exceed the given track limits, then the VIB ONLY solution is presented, and the track optimization pass is not performed. This means that the most simplest solution is calculatad/presented which does not cause track limits to be violated. Remember: VIB ONLY solutions are ALWAYS simpler than VIB+TRACK solutions, by definition. 2. If any vibration measurement exceeds its vibration limit by 25% or more (Le., limit X 1.25), then the VIB ONLY solution is presented, and the track optimization pass is not performed. This enforces the Honeywell Chadwick (HC) methodology that requires vibrations to be smooth before concentrating on the track. HG recommends this methodology because high vibrations lead to complex VIB ONLY solutions, which are then ‘made more complex when VIB+TRACK solutions are computed, thereby increasing the likelihood of a poor result It is HC experience that engine starts are ultimately saved by first smoothing any high vibrations and ignoring the track (ie., VIB ONLY), then using VIB+TRACK to smooth the track while conserving the low 1 P vibration level For example, a “80 KIAS Cargo Rear Vertical 1P" at 0.581 IPS exceeds the vibration limit of 0.200 IPS X 1.25 = 0.250 IPS. In this case, SOLVE FOR: AUTO is translated to VIB ONLY to smooth the vibrations to an acceptable level before working on the track split. In other words, the used methodology in AUTO is to smooth the vibrations first and forget about track; THEN smooth the track AFTER the vibrations are smooth. Remember also how VIB+TRACK solutions are computed: FIRST, the VIB ONLY solution is calculated (track is ignored), THEN the 1P solution is manipulated so that track is improved WITHOUT violating the 1P solution. This is done by reflecting P/L and tab changes across blade pairs, and applying equal amounts of P/L and tab to both blades in a pal. ‘The operator may override the SOLVE FOR: AUTO option at any time to force the desired solution option. In Run 2, for example, | might want to force the option to VIB+TRACK in order to compare this solution to the VIB ONLY solution created by SOLVE FOR: AUTO. If the VIB+TRACK solution doesn't look very complex, | might use it instead of the VIB ONLY solution. CONCLUSION: The Smart Chart, while being very ‘smart," cannot duplicate the knowledge and intuition of an experienced user. MRSCs create their solutions based on an inflexible set of logical rules. The rules represent our attempt to generalize the best way to smooth an aircraft. Most main rotors will respond favorably to these rules. Unfortunately, there will always be situations where the Smart Chart, using these rules, won't pick the best solution to implement, even though all solutions are valid for the options that are in effect. FINAL RECOMMENDATION: In order to help the blade track, we (Telemeter Electronic) recommend not to use AUTO. Instead, we recommend to use VIB+TRACK normally. This ensures that the blade track is also being improved with smooting the 1P vibration. Only, if the solution becomes too complex and the blade track is about acceptable, a VIB ONLY solution might be selected. But, remember that VIB ONLY solutions ‘smooth vibrations only, and NEVER takes track into consideration. Telemeter Electronic GmbH, Joseph-Gaensler-Strasse 10, 86609 Donauwoerth Page 12 of 12