Assembly
Assembly of the TEKK Remote Stick Handle for ClearNav Control
Handle Models:
This wooden handle is available in various types such as Mahogany, Walnut, Plum, Cherry, Elm, Apple, and comes in stick tube sizes of 16, 18, 19, 20, and 24mm.
The surface Finish is done in natural hard wax. Special grip shapes or other wood on request.
Parts:
The remote pad is inserted into the upper cavity. The integrated PTT pushbutton with 2 seperate cables connects to the radio harness. Fastening to the wooden grip is via 2 screws of BSW, OD 1,45mm fine thread x length 15 to 20 mm.
CAN – Cable assembly:
The 4 wire flat cable (data bus) directs the remote control pushbuttons, the 2 free wires have to be connected into the cable coming from the microphone (PTT). The cable channel from the pad cavity ends in the larger hole for the stick tube.
The hole for the cable exit in the stick tube must be big enough to allow the cable to pass easily (deburr!) Protect the cable in this area (shrink tube). The cable will only pass the metal tube without the crimp - connector. The best place to connect the cable coming from the stick handle on the way to the Radio is below the stick arrangement on the control bulkhead near the fuselage floor (max. 60cm from the pad down). The coupling 4p6c with RJ11 connectors, and the RJ10 (4p4c) connector for the cable ending into the NEXUS are attached in the delivery. See later! A Crimp tool is available on loan or to purchase.
Option for powered glider:
With the option Motor glider we add an extra flat high quality pushbutton with 2 wires. This button is inserted on the rear side of the stick. (Example: Operating the fuel pump or the starter). Please order this option before we deliver! We also insert a toggle switch as an option (Example: running the electric trim, or the engine spindle drive).
Preparation:
Before removing the existing stick grip, measure the total length from the trim/brake handle fastening to the top as reference length. It is advisable to carefully remove the remote pad from the handle to make the grip fit as wanted. The grip should slide onto the metal pipe without force. If it is not exactly fitted by TEKK already onto a known stick tube, it should end as far down the stick as possible, even sideways along the trim actuator (cut a slot). Measure the depth of the tube diameter hole inside the handle, and if necessary, shorten the metal tube by up to 3 cm. Best tool to do this work is a tube cutter. Deburr the tube, and remove excess paint on the tube.
Connecting the PTT wires:
Connect the red wire to the active inside core wire (mostly red) of the microphone of the radio harness. Green = ground, which will mostly be the outside copper mesh. If the radio is always transmitting, the wire connections have been done the wrong way (no harm done to the radio!). Connecting the RJ10 cable, see later.
Mounting the remote stick handle
The handle position should be approx. 20° off centre towards the right, since from this side the pilots hand holds the stick. Try!
The bore is done 0,5mm larger as the stick diameter to allow for oval or not perfectly straight tubes, and to avoid the wood to burst. If the tube seems too fit too tight, it is advisable to do some rework.
On the lower end it should end on the metal tube without lots of wood material left. The more the handle ends down the stick tube, the better the "control stick feeling" will be later, since when flying relaxed most pilots hold the handle further down.
The RJ10 4p4c Crimp connection to the NEXUS
The flat cable has one side flat, and the other side has a line in the centre. After feeding the cable through the tube and the hole on the side, the new connector nose pin must be located to the flat cable side. If done wrong, the remote control does not work (No harm to the CN is done). Looking at the cable end, the connecting nose down, the yellow cable has to be on the right, black on the left.
Securing the handle to the pipe:
Version "M3"
With an M3 countersunk screw. The handle must be drilled on the right side with 2,4mm (a sharp drill!), and the mark done by the drill on the metal tube with the handle off must be marked with a punch, to avoid that the drill drifts off finding its way through the hard metal of the tube Enlarge the hole through the tube to 3,2mm, and cut a long M3 thread through the wood. Best position for this screw is 3-4 cm from below half right, where there is more wood material.
Version "Silicone"
When the wire is pulled through the pipe, lift up the handle 2 to 3 cm, and add Silicone (as used in sanitary) to the tube. Thereafter slide the handle onto its final position.
This way it is also possible to pull the handle off the stick later if required. You may also "mix" both versions. After all is in place, secure the cable tight to the control tube. Check free stick travel to the end stops. Fasten the cables to he control mechanism with tie wrap.
Option: add a metal ring* around the remote module top:
This ring is available, made of anodized aluminium. It can be glued with epoxy to the upper wooden ring around the remote pad, and later to be matched to the outside shape.
302 Mounting Tips
Mounting into a panel hole of 57mm
Remove the 3 screws M4 and pull off the little cap of the Actuator with the fingernails. Loosen the M3 screw, and remove the knob from the actuator shaft**. Make sure that the hole of min. 4,2 mm allows the shaft to turn free, otherwise in may be blocked from coming out again easily when pressing the knob to operate the instrument. The actuator knob should be fastened in such a position, that it will not touch the panel when being pressed for operation.
Mounting into an existing panel hole of 80mm **
Better do not make the necessary adapter ring for this situation yourself. Why this? The instrument holes from 57 to 80 mm diameter are located very close to each other. This ends in a complicated job. Therefore we offer a special black adapter ring with a threaded counter plate at the back to easily prepare a clean 57mm location for the 302. This way the installation becomes a quick job, also behind the panel face.
**In this case there is no need to remove the actuator shaft.
The 10 wire connector rail
On the side of the 302 you may read all connection pin locations. Pin Nr. 1 and 2 are for the +12 Volt power, and are marked in red, also to clarify the basic location direction in the 302 adapter. Pin 2 will be used if one wants to switch on and off 12Volt power via the actuator switch (press once), or via the ON button of the 303 GPS Display. Pin 1 brings power onto the 302, as soon as the main power battery switch is on. Pins 1 to 10 are described on the label of the left side of the 302, and in the manual. We recommend to crimp the cable ends with crimp shells. The ground cable may be split into several single cables.
The GPS Antenna / Temperature sensor***:
***To secure the temperature sensor from slipping out, fix the Antenna cable and temp. sensor cable together with a small tie wrap.
The SMC type connector is small, therefore delicate in assembly. Mount this connector first when mounting the 302 (more space available to do a careful job), and remove last when taking the instrument out of the panel. The connector must be fed onto the coupling in the 302 perfectly in line, to avoid bending or pressing the tiny inside connector pin into the coaxial cable. The locking nut should be locked hand – tight only (not too much!). The GPS antenna mounting position can also be below an instrument panel cover, since these are mostly made in Glass fibre (carbon fibre structure blocks GPS reception!) Alternative: Cut a matching hole into the panel cover to allow the antenna to “see the sky“, but fasten the antenna below to the actual instrument panel.
The minimum distance to other active GPS Antennas (also the radio antenna from the FLARM) is 20, better 25cm.
Remember: Testing all GPS based instruments after the assembly may come out positive, but it can always be that in flight sometimes the GPS all of a sudden quits due to antenna disturbance!
The CAI bus (RJ12 6 wire cables) to connect the 303 and 306:
Basic rule when adding the connectors: On all RJ type cables the connector has to be mounted in a „twisted” position. So, the little tongue of the connector faces the other way on one cable end. The flat cable has a groove on one side, which helps indicting the correct position to each cable end. Add a ferrite towards one cable end before, if the glider has an intensive electronic installation. This precaution avoids “sparks” in dataflow, and also possible radio noise, although the 302 is well shielded against RFI noise. To split the cable for a 303 and 306, the 3 hole coupling RJ12-6/6 must be used.
Mounting an Audio loudspeaker outside the 302:
Powered gliders require an ENL (Engine Noise Level) sensor in the flight recorder. According to IGC rules the loudspeaker inside the 302 had to be removed for motorglider ENL detection. Therefore it is located outside the 302 now, although the enl Microphone is looking for low frequencies such as the ones of a propeller. It is recommended to also mount a second loudspeaker close to the pilot’s head in a pure glider. This brings the audio noise level setting down in the cockpit. We deliver an aluminium mounting plate, which has the cut out and stainless net cover for the Visaton speaker. Also here we recommend: Do not mount on a glider part such as the panel cover that sometimes is being removed.
Mounting of a PDA: (example: all Compaq and HP models):
Mount a PDA always on the right side of the cockpit, ideal place on the right end of the panel on a stalk (gooseneck). Length of the stalk: This depends on the panel and pilot position, and clearance for the stick handle. Stalk length is available in 10, 15, and 20cm. Mount a PDA holder only, not loose cables ending from below into the PDA. For further tips on his issue see special instruction by TEKK
Mounting of a NK ClearNav display:
See separate instruction.
Mounting of the optional sub-D 9 pin serial Cable from the 302 into the Panel:
This cable (length 20 to 80cm) is specially produced by TEKK. Best place is near the 10mm hole drilled for the PDA stalk. Cut the hole for the sub-D-Adapter accurate, (or use our special supporting plate in aluminium into a 30mm round hole in the panel). The cut out in the panel has to be as big as the outlines on the connector part, that slides over the coupling, the cable end. Cutout size: 10,8 x 19,2 mm. Hole distance for the 3/16“ srews: 25,4 mm. These come with the cable. Into this coupling one plugs in the PDA or the Laptop for data Xfer.
Mounting of the „PEV“button (Pilot EVent, or GPS- Position marker)
Install PEV in the instrument panel besides the 302. Mark GPS-PEV
Mounting of the STF (Speed to Fly / Vario mode) switch
Install STF in the instrument panel besides the 302. Mark with Sollfahrt Automatic
or STF auto or Speed to fly auto
The 302 does not need a STF/vario mode switch on the flaps or on the stick handle.
Why? 2 G-Meters in the 302 sense the moment one enters into climb position = circling.
Together with the GPS V-ground data the 302 switches fully automatic into vario mode and later back to STF. This switch one only needs when trying to climb flying alongside a slope. Normal switch position is: In up position where the label Sollfahrt Automatic is. Control: When in vario mode, on the 302 screen right besides the pointer centre appears a label showing a circle.