Behotec Turbines Manuals - Click Here
Transcription
Behotec Turbines Manuals - Click Here
JB130 - JB220 BEA JB130-JB220 - Version 05/2013 1 Dear R/C model making enthusiast! Congratulations for the purchase of the Behotec JB jet engine. This is the ultimate engine for your R/C jet plane. Please read these instructions carefully after receiving your jet engine and before the first operation. Keep this manual for later consultation. 1.Directions for safe operation 1.1. 1.2. 1.3. 1.4. 1.5. General safety instructions Warning Before starting the turbine During operation After shut off 1.Mounting of the engine 1.6. Mounting options 1.7. Safety rules for the attachment of the jet engine 1.8. Assembly of the complete system 2.Operation of the jet engine 1.9. 1.10. 1.11. 1.12. First operation First testing Control functions Tuning options / electronics 3.Legal disclaimer 3.Maintenance instructions 1.13. Maintenance 1.14. Repairs 4.Warranty 5.Technical data 6.Wiring plan 7.Illustrations 8.Accessories / Replacement Parts 2 1. Directions for safe operation 1.1. General safety instructions Even though jet engines are different from piston engines, it is easy to safely operate and fly them when you follow some basic safety rules. With this goal, the Gas Turbine Builders Association GTBA has created a Code of Practice, which can be found as an attachment to this manual. It is available in multiple languages and can be found on the GTBA website (www.gtba.co.uk/codes/german.htm). It is mandatory to read this Code of Practice before mounting the jet engine and follow the recommendations when mounting and operating the engine. The operation of any jet engine can be dangerous. This also holds true for the JB130-JB220. During operation, the jet wash and parts of the jet nozzle become very hot; the nozzle can reach up to 700 °C. In addition, the turbine fans do reach very high rotary speeds, which leads to extreme tensile loads and temperatures. Therefore, it cannot be excluded that parts of failing turbine fan wheels and broken fans will strike through the housing which can lead to damage and even injury or death. Study the operation mode and the dangers of operation before using a jet engine. In case you have no experience with the operation of gas turbines and jet engines, instruction by an experienced person, especially before initial operation, is mandatory. Errors in mounting and operation of a jet engine can lead to damage, injury, or death. Follow national laws concerning aircraft, the operation of jet engines, and the handling of combustible liquids and gases. You are exclusively responsible to have sufficient insurance when operating aircraft. You are also responsible to protect other persons from injury and danger. Operating personnel and their assistants must be in best physical and mental condition and pay full attention to the operation. This engine must only be used for unmanned operation in R/C aircraft. The instructions in this manual must be exactly followed. 3 Follow the Safety Rules! Non-adherence of the following safety rules can be fatal! This device was manufactured to the highest current technological standards. It must only be used for the purpose it was designed for. This device can, however, be a danger to people, animals and things when • not operated according to the purpose it was designed for • the instructions in the manual are not correctly followed • it is changed or rebuilt This manual introduces you to a safe operation of the device. Therefore, careful reading and thorough understanding of the manual is vital before operation the device. Every person who is involved in the operation of this device must read this manual, especially the instructions for safe operation. Furthermore one has to follow the laws and general rules of • the avoiding of accidents • technical safety, as generally valid and accepted • the country one wants to operate the device in Moreover, • jet engines and turbines in general must only be operated with the highest diligence • ear protection must be worn during operation to avoid hearing damage • indoor operation is forbidden • a fire extinguisher (CO2) must be within reach! 4 1.2. Warning Consider the basic differences between gas turbines and piston engines. Turbines will deliver power only at high rotation speeds. Then there will be a lot of power (see diagram). Higher loads occur when driving an R/C aircraft model with a turbine compared to equally powerful drives like propellers or impellers. This is a result of considerably higher air speeds caused by jet propulsion. Maximum speeds under jet propulsion can exceed 400 km/h, depending on the model. The resulting loads effect the whole structure, not only the rudders or the installation of the servo wires. Models have to be constructed with jet aircraft specific stability. Please ask manufacturers about the current level of production standards for the models in question. Meanwhile, a large array of models built for jet propulsion is available by different manufacturers. Servos should be at least 1.5 times as strong as for comparable models with conventional engines. During installation, seal the intake and nozzle, as well as propane and kerosene joints to keep dust and debris out of the engine. Really make sure to: • first inform, then buy • have the fitting size model for your turbine • select servos that are powerful enough • construct servo wiring and rudder joints very carefully and reinforced • seal the turbine during the installation process 5 1.3. Before starting the engine • Tank system, pump, shut-off kerosene valves and turbine must be checked for correct alignments. • Loose parts in the intake area must be fixed in a way they can never be sucked in. Loose parts or dirt can damage or destroy the turbine. We recommend the use of a protection screen. • Have a fire extinguisher (CO2) within reach! • The kerosene system must not be leaking. • Use only kerosene or Diesel with a 5% fraction of lubrication (fully syntethic 2-stroke mix oil or turbine oil). • Take off must be against the wind. • Hold the turbine with the nozzle facing downwards right before take off so excess fuel can run off to avoid a hot start of the engine. 1.4. During operation • Always keep in front of the turbine (intake facing), never to the side or in the exhaust area of the turbine. • Also make sure that no other persons or animals are present in the mentioned dangerous areas. • Keep your hands and every kind of object out of the area within 20 cm of the compressor (intake). The enormous suction can grasp everything within reach lead as quickly as a flash and lead to severe injury or damage. • Never look into the jet exhaust. Severe burns can be the result. 6 1.5. After shutting off the engine • Place model with the nose facing the wind. Wait until the cooling down process is completed. • Be aware of the cooling process after engine shut down. During this process, the electric power supply of the receiver and the ECU must not be turned off. The cooling down process takes 1 – 2 minutes, depending on outside air temperatures. • Do not touch the turbine during the cool-down because the danger of burning still exists. • All tube connections must be inspected for leakage. The fuel tanks must be emptied in case of extreme outside temperatures or when there is no early operation planned (danger of explosion!). 7 2. Installation of the turbine 2.1. Attachment Options • The attachment points of the bracket to the frame must be parallel (check before attachment). Otherwise bad tensions can lead to damage of the engine. • Attach the turbine only with the provided bracket, screws und bushings (see picture). • The turbine must be attached with the front, near the screws. • Attach the turbine with the hole of the glow plug centered in the slot to avoid a forward shifting of the turbine (see picture). • The temperature probe must be put into place outside the bracket (see picture). • The glow plug dummy has to be facing upwards, at twelve o’clock when seen from the turbine front end (see picture). • Should you have deviating wishes concerning turbine installation, contact the manufacturer. 2.2. Engine mounting rules • The engine must be installed in a way that the glow plug dummy is in the 12 o’clock position. This is absolutely vital for a kerosene start of the JB Engines. Else, the start, i.e. the ignition, would fail and might even lead to engine damage. • There must not be any combustible objects near the turbine. The turbine must not be touched by combustible objects. • The nozzle and the whole area within reach of the jet exhaust must be clear of any objects. 8 • In case of a housed in installment of engine the rear end of the installation area and any parts which affected by the jet exhaust should be protected with non-combustible materials (danger of fire!). When an extension of the nozzle is necessary, it must be constructed and installed to the manufacturer’s specifications (overheating!). • The turbine must be installed in a way that it can be cooled by a bypassing air stream. • Combustible liquids and gases as well as tanks and tubes must be kept or installed in safe distance of the engine. • The intake area (impeller / compressor) must be kept clear. Any wires, tubes, etc. must be installed and fixed in a way they cannot be sucked into the turbine. In general, there should not be any objects or installations close to the front end of the turbine. • The intake section of the model should have at least twice the area of the impeller/compressor wheel. • You must make sure that no objects, e.g. rocks, dirt, screws, etc., can be sucked into the turbine. It is a good idea to protect the turbine intake with a close meshed screen (accessories). • The intake area must be absolutely kept clear. 2.3. Assembly of the complete system • Please look at the installation scheme on page 22-23 • The optimum size of the fuel tank depends on the model but should be at least 1.5 liters. The optimum size for the JB Turbines is 3 - 5 liters, which is enough for an average air time of 6 – 8 minutes, depending on your style of flying. For further information please see technical data, fuel 9 consumption (p. 16). There must be a felt pendulum in the tank. Use only the included felt pendulum. The tank set up can be realized with a so called Hopper tank (please see installation scheme “engine fuel supply”. The felt pendulum must only be installed in the Hopper tank; there must be free passage from the other tanks of 3 mm (minimum). Use yellow, highly flexible Tygon tube and attach it to the pump with a cable connector. Tank accessories, pendula, etc. can be found in the Behotec line up • The Type P7-2 fuel pump must be installed directly after the tank. Be careful to install the pump correctly (brass fitting = draw side). The electric wiring of the pump hast o be done with the correct polarity (+ / -). If the pump is not wired correctly, it will not work right and will transport no fuel • Install the fine filter in the pressure tube after the Behotec fuel pump (out). After that, a Festo Y quick connector should follow; red and blue tube with 4mm diameter should be used there. There the kerosene supply is divided; the connection to the fuel valves is next. The flow direction is very important, it is marked with an arrow. The electric connection is done at the ECU at the “KEROVALVE” input. The fuel supply is connected to the turbine through the Fuel connection (picture on pages 22 – 23). The electric connection to the kerosene burner is done at the ECU at the input “PROP-VALVE”. The fuel supply is connected to the turbine via the Burner input (picture on pages 22 – 23). • All FESTO quick connectors (blue head) are self-locking. They are connected and disconnected like this: Insert tube strongly. There is no resistance for the first 6mm but for the next 6mm (approximately) resistance can be felt. Only then the tube is perfectly locked in. For release, push the blue 10 cap in the direction of the metal piece and remove the tube by pulling. • Now the turbine should be electrically wired to the ECU: Connect the turbine via high voltage wire to the ECU at the Glow / Starter output. Also connect the black data cable to the turbine and the Sensors input of the ECU. • Then connect the I/O Interface with the ECU at the “Terminal“ connection. Later the EDT (operation terminal) can be connected to the I/O Interface. The I/O Interface serves as control interface; it features acoustic and optic control. The control interface needs not necessarily be installed in the model. • Power supply: Rechargable batteries of at least 2500mAh - 4000mAh and with 3 cells must be used. For kerosene starts, we recommend a Lipo 3S and a maximum of 12 volts. Connect the battery to the “BATTERY” input of the ECU. Disconnect the battery from the ECU when not in use to prevent discharge. Mind the right polarity at the high voltage plug! Longish battery wires should be twisted! • At last, connect the receiver to your ECU. Now the cable is readily prepared. Only use original adaptor cables if other receiver plugs are necessary. The ECU is only operated by one input channel (engine power limiter). 11 3. Beginning of Turbine Operation 3.1. Initial Operation • Fill the fuel tank with kerosene. Ensure a 5% fraction of oil. • Make sure the tank breather is open! • Filter your fuel already when filling up through the preceding fine filter. • Make sure the electric power supply battery and the receiver battery are charged. • Test the reach of your remote control with and without the ECU turned on. • Place the model always with the nose against the wind so the direction of the jet exhaust equals the wind direction. • Turn on the sender and the receiver unit. • The Pro-Jet ECU is mostly pre-adjusted and tuned to your turbine. Nevertheless, you have to adjust the ECU to the remote control unit. To do this, follow the ProJet instructions on page 16, activate manual point 2.1 accordingly, Trimmung und Gas hinten – Enter, trim forward – Enter, Throttle forward – Enter. Sender is now adjusted. Make sure that no sender functions like Dual Rate, Expo, distance limit, etc. are programmed! • It is necessary to de-aerate the fuel tube before the first operation in a new model. That means the fuel tube must be filled with kerosene. Do this manually (throttle back, trim back). This must be done carefully to prevent the turbine from being flooded with kerosene. So let kerosene flow until it can be seen that it has reached the turbine. Never pump kerosene into the turbine. Press the button on the I/O platine circuit board. 12 • This measure must be taken before the virgin operation as well as after emptying the tank through engine operation. • Should the turbine have been flooded, place the model with the nozzle facing downwards to allow excess kerosene to leave the turbine. Thus you avoid a hot start, which can damage the turbine. 13 3.2. First Test Run of Your Turbine • Be sure to have a fire extinguisher (CO2) within reach. • The ECU does an automatic calibration routine to adjust to all turbine and weather parameters as well as tube lengths. The Hornet III, unlike the Hornet II, does this routine at every start. • After the factory adjustment of the temperature probe and the pump’s starting voltage, you can start the turbine. Throttle forward - trim forward – turbine standby. Set throttle to a minimum and within three seconds to full. Now the starting procedure happens. See Pro Jet instructions (pages 24 – 27). Attention: there the turbine adjusts to the factory set rotation speed of ca. 60.000 rpm. Hold or adjust your model for this procedure. The procedure can be interrupted any time with emergency stop by setting trim and throttle in the back position. • After that, the turbine can be controlled with the throttle. • All parameters necessary for operation are now controlled. Failure of the turbine or the system are now excluded. • Conduct a test run of your turbine, preferrably by testing the range of your model. • Shut off the turbine at a medium rotation speed. This is done by setting the trim back all the way and then setting the throttle back from a middle setting. An engine shut-off at a medium rotation speed benefits a gentle cool down of the spindle ball bearings and the whole system. • Put the model against the wind and wait until the after cooling process is over (around 2 minutes). After that you can turn off the receiver unit. • Check the model’s fuel supply connections and de-fuel, if necessary. 14 3.3. Control Functions • In case of error, check the ProJet manual. From p. 15 on you will find concise error descriptions and explanations. • Sender signal: Shut off happens if the sender signal fails. Attention! With PCM receivers, the fail safe function should be programmed to idle in order to avoid emergency stops at short receiving errors. This, however, is within the decision range of the pilot. 3.4. Tuning Options / Electronics • We do not want to elaborate on the electronic control because it is explained in detail in the Pro Jet manual. You should study the latter carefully. • Avoid a system reset!!! As a result, the ECU may have to be updated at the Behotec factory. • The ECU features a CODE controlled menu system. Every number features an individual menu point. From these menu points you have options of changing different pre-set parameters. This should, if at all, be done very carefully because the factory setting of the parameters is optimal already. • The following parameters are to be controlled, i.e. changed, also after a system reset (see attached sheet). 3.1 2.3 2.2 2.1 1.4 Battery voltage Adjustment of the temperature probe Glow voltage Pulse width of the sender signal Pump starting voltage 15 4. Disclaimer (Liability, Damage) Behotec GmbH cannot supervise a compliance of the rules for turbine installation and operation. Therefore, Behotec GmbH will not assume any liability resulting from damage, loss and costs resulting from operation. Behotec GmbH is excluded from compensation of any kind unless regulated differently by law. This includes injury, death, material damage, loss of profit or business, interruption of business and other directly or indirectly resulting consequent loss. Full liability is in every case limited to the sum paid for the turbine. Behotec GmbH has not granted any pledge, contract or accord in terms of functionality and operation of the model with the turbine. Set up and operation of the model and the turbine take place under full liability and responsibility of the operator. 16 5. Maintenance Instructions 5.1. Correct Maintenance of Your Turbine Behotec turbines need only little maintenance under normal operation conditions. However, some points must be considered to guarantee a faultless function of the engine. This includes regular cleaning and inspection. • Dirt and grease deposit can cause slippage of the starter unit clutch. If this happens, clean the tappet rubber und the impeller nut with a grease-dissolving agent like acetone or liquid gas. • The felt pendulum built into the tank should be cleaned or changed after 10 hours of operation. • The upstream fine filter between pump and turbine should be cleaned every 5 hours of operation. Do this very carefully and make sure no particles will enter the fuel supply tube. Destruction of the turbine could be the result! Make sure the o-ring is in the correct position when screwing the filter together. Check for leak tightness! • Cover the intake and nozzle areas when the turbine is not in use. • Keep the turbine in a dry and dust-free place when it is not used for a longer time. We recommend a dehumidifier to prevent corrosion. • Check battery condition regularly. • Your turbine’s maintenance interval is at 40 – 50 hours (about 300 flights). After this time as well as after a special event (crash, etc.) the turbine should be returned to the factory. 17 5.2. Repair Work Repair and maintenance work which include the disassembly of the turbine must only be performed by professional personnel. Address your Behotec dealer with all service questions. Returning of warranty cases can only carried out by your professional dealer. Only use original Behotec replacement parts. When ordering replacement parts, engine type and serial number of the turbine must be specified. Maintenance and repair work performed by non authorized personnel will lead to expiration of the warranty. Warranty The warranty includes free repair and replacement of parts with manufacturing or material faults 24 months from the date of purchase. Further liability is excluded. Any costs caused by transport and packaging have to be paid by the customer. There is no liability of the Behotec company concerning transport damage. Before sending, please contact Behotec GmbH. An explanation of the error or damage has to be included as well as a valid receipt of purchase with the date of purchase. Any kind of warranty will expire in case of unauthorized opening, disassembly or removal of the housing locking device. When returning the turbine to the factory, the ECU must be included so we can check the operation hours and other operation parameters. When a defective turbine which does not feature any faults in terms of the warranty, examination and repair will be invoiced (also see terms and conditions in your invoice) 18 6. Technical Data Diameter Length Weight Max. thrust Min. thrust Fuel consumption Exhaust temperature Glow plug Fuel Acceleration 35123.000 U/min Acceleration 60123.000 U/min Maintenance interval Diameter Length Weight Max. thrust Min. thrust Fuel consumption Exhaust temperature Glow plug Fuel Acceleration 35125.000 U/min Acceleration 60125.000 U/min Maintenance interval JB130 113 mm 325 mm 1500 g – 3,20 lbs 130 N – 29,25 lbs @ 123.000 rpm 8,0 N – 1,60 - 1,75 lbs @ 35.000 rpm 480 ml/min bei 100% thrust 560 - 680 °C Burner Jet A1, Diesel (with 5% Oil) ca.3 seconds ca.1 second every 50 hours, earlier in case of bearing noise or other reasons JB165 113 mm 310 mm 1520 g – 3,30 lbs 165 N – 37,10 lbs @ 123.000 rpm 8,0 N – 1,60 - 1,75 lbs @ 35.000 rpm 550 ml/min bei 100% thrust 560 - 700 °C Burner Jet A1, Diesel (with 5% Oil) ca.3 seconds ca.1 second every 50 hours, earlier in case of bearing noise or other reasons 19 Diameter Length Weight Max. thrust Min. thrust Fuel consumption Exhaust temperature Glow plug Fuel Acceleration 35123.000 U/min Acceleration 60123.000 U/min Maintenance interval Diameter Length Weight Max. thrust Min. thrust Fuel consumption Exhaust temperature Glow plug Fuel Acceleration 35123.000 U/min Acceleration 60123.000 U/min Maintenance interval JB180 113 mm 320 mm 1585 g – 3,50 lbs 180 N – 40,50 lbs @ 125.000 rpm 8,0 N – 1,60 - 1,75 lbs @ 35.000 rpm 620 ml/min bei 100% thrust 560 - 730 °C Burner Jet A1, Diesel (with 5% Oil) ca.3 seconds ca.1 second every 50 hours, earlier in case of bearing noise or other reasons JB190 113 mm 320 mm 1585 g – 3,50 lbs 195 N – 42,70 lbs @ 123.000 rpm 8,0 N – 1,60 - 1,75 lbs @ 35.000 rpm 700 ml/min bei 100% thrust 650 - 750 °C Burner Jet A1, Diesel (with 5% Oil) ca.3 seconds ca.1 second every 50 hours, earlier in case of bearing noise or other reasons 20 Diameter Length Weight Max. thrust Min. thrust Fuel consumption Exhaust temperature Glow plug Fuel Acceleration 35123.000 U/min Acceleration 60123.000 U/min Maintenance interval JB220 113 mm 310 mm 1640 g – 3,62 lbs 220 N – 49,46 lbs @ 123.000 rpm 8,05N – 1,81 lbs @ 35.000 rpm 730 ml/min bei 100% thrust 650 - 780 °C Burner Jet A1, Diesel (with 5% Oil) ca.3 seconds ca.1 second every 50 hours, earlier in case of bearing noise or other reasons 21 7. System Installation Plan 22 23 8. Pictures When the turbine is not used or returned to the factory, the kerosene and propane joints must always be sealed. Please use included plugs. Miniscule particles can clog kerosene tubes and fault free operation of the turbine cannot be guaranteed. Repair costs of up to 360 Euros can be the result. Tank size must be determined by the user. See technical data, fuel consumption. Usually 3 – 5 liter tanks are used with JB turbines. Drill a 6mm hole in the fuel tank cap of your choice. 24 Use the included tank pendulum device and screw it together with the tank cap. Check for tightness. Cut a piece of Tygon tube with a length of ca. 120 – 150 mm. This is the ideal length for the typically used 1.5 liter and 2.0 liter Coca Cola bottles. The length of the tank pendulum, however, depends on the type of tank used. We recommend to choose the length the way that the felt pendulum lies at around 75% of the tank length. Now place a 6 mm flat washer on the felt pendulum and connect it with the Tygon tube. This will prevent slippage of the felt body. 25 Then secure the Tygon tube connections with wire. Again, check for leak tightness. Braze the battery cable to your chosen battery. Red = plus, black = minus. We recommend batteries with a capacity of at least 3000mAh and 12 V maximum have proven to be ideal for turbines of type JB180 Gold Edition. Energy consumption is roughly at 450 – 550 mAh, dependent on your style of flying, for 8 minutes plus after flight cool down period. The use of 3S Lipos has proven of great benefit. These should feature max. 10 – 30C de-charging current max. 12 V. Lipos with a higher de-charging rate can destroy the ECU due to the higher current situation. 26 When using a nozzle extension with your model, the diameter of the extension pipe and the distance from nozzle to nozzle extension must be correct. With JB130 - JB180 turbines the entry diameter of the extension pipe should be around 85mm while the end diameter should measure around 80mm. With JB190 - JB220 turbines the entry diameter of the extension pipe should be around 100mm while the end diameter should measure around 95mm. The shorter the nozzle extension the smaller the loss of power. When using Behotec nozzle extension pipes for JB type turbines, the distance from the end of the aluminum turbine housing to the aluminum hopper should be 3 – 4 cm. The extension pipe must be securely attached to the model. Fuel Valve - Burner Valve 27 9. Accessories / Replacement Parts order number identification price € picture TP3 Tank pendulum heavy for Tygon tube diameter 19 mm 7,90 TP2 Felt pendulum for Tygon tube diameter 14 mm 7,50 FG1 Fine filter – kerosene filter large for tube diameter 4 mm 9,50 Z-11-R Kerosene tube (per meter) red outer diameter 4 mm 1,10 Z-11-B Kerosene tube (per meter) blue outer diameter 4 mm 1,10 TS1 Tygon tube (per meter) (tank pendulum tube) 7,50 TPA Tank pendulum device for Tygon tube 10,50 28 TPA-0001 Tank pendulum device for tube 4 mm TPA-0002 Tank screw connection for Tygon tube 7,50 TPA-0003 Tank screw connection for tube 4 mm 7,50 Z-0016 Screw connection short for Tygon tube / M5 for use with P7-2 pump 3,30 Z-0017 Screw connection long for Tygon tube / M5 for use with P7-2 pump 3,90 Z-0006 Y Festo connector for 4 mm tube P-7-2 Kerosene pump JB130 – JB180 ready-to-operate (shielded, wire and plug) 29 10,50 96,50 TH-4 Turbine bracket split 33,50 AS1-1-2 Electronic unit single Hornet III AS1-2 GSU - programming device 53,50 AS1-11 I/O circuit board 21,00 AS1-B Connector wire 500 mm 3,50 AS1-B-750 Connector wire 750 mm 4,00 AS1-B-1000 Connector wire 1000 mm 30 215,00 4,50 AS1-8 Connector wire high current 500mm 10,00 AS1-15 Akku connector wire for brazing connection 5,50 AS1-16 PC – Interface for USB adaptor and cable 55,00 AS1-17 Telemetry system TelJet 2,4Ghz by request AS1-18 Air speed sensor by request Maintenance at the Behotec 60,00 € Factory (price includes no and up replacement parts) Replacement parts are invoiced separately according to effort and supply. 31 Prices fixed to the date of the order! Please contact us if you have further questions. Behotec GmbH Heisenbergstrasse 9 85221 Dachau Germany Fone 0049(0) 8131-80400 Fax 0049(0)8131-80405 e-mail: [email protected] web: www.behotec.de Business hours Monday - Thursday 8-12 o‘clock and 13 – 16 o‘clock Friday 8 -13 o‘clock 32 33 34 35 LIST OF CONTENTS INTRODU CING EXCLUSION OF LIABILITY AND COMPENSATION CONNECTION DIAGRAMM PROPANE INGNITION/KEROSENE IGNITION KOM P ONEN TS POWERSUPPLY FUELSUPPLY SENSORS ELEK TR CAL CONN E CTI ON STARTER GLOWPLUG VALVES IO-B OARD G RU N D SU P P OR T U N I T (G SU ) FUNKTIONS STATUSDISPLAY ERROR MESSAGES MEN U ES 1-SETUP 2-ADJUSTMENTS 3-SYSTEM 9-EXPERT MODE FUNKTI ONS & R UNNING ST ATES AUTOSTART AUTO-CALIBRATION AUTOMATIC MODE EMERGENCY OPERATION SAFETY FUNKTIONS R AD IO C ON TR O L THROTTLE CHANNEL AUXILIARY CHANNEL APENDIX THE FIRST START – NECESSARY ADJUSTEMENTS TECHNICAL DETAILS ACCESSORIES 3 4 5 5 5f. 6 6 7 8 9 11f. 12f. 14 15 16 16f. 18 19 19 19 19 20 21 2 21 22 2 INTRODUCING The HORNET-III is a modern engine control unit for model aircraft turbines to controll and regulate the engine in a safety operation area. Additional all important engine data are observed and the engine is shut down if an error occures, i.e. overtemperature or rc-signal failure. Description of error conditions look at apendix. ATTENTION !!! A perfect running engine is required for unproblematic operation. Bad running engines could not be operated successfully and reliable by an electronic control unit. LIABILITY By using this product, you agree to hold ProJET electronic components GmbH free from any type of liability either directly or indirectly while using this product. WARRANTY This product is warrantied for 24 months. ProJET electronic components GmbH, Buchäckerweg 27, 95689 Fuchsmühl, Germany guarantees this product for a period of 24 months from date of purchase. The guarantee applies only to such material or operational defects wich are present at the time of purchase of the product. Damage due to wear, overloading, incompetent handling or the use of incorrect accessories is not covered by the guarantee. The user´s legal rights and claims under guarantee are not affected by this guarantee. Please check the product carefully for defects before you are make a claim or send the item to us, since we are obliged to make a charge for our cost if the product is found to be free of faults. 3 CONNECTION DIAGRAMM PROPANE IGNITION 4 CONNECTION DIAGRAMM KEROSENE IGNITION COMPONENTS Listed accessories are needed for engine operation: HORNET ECU GSU I/O BOARD (with LED and buzzer) Sensor – amplifier pcb Sensors (rpm and temperature) Fuel pump Power supply battery POWER SUPPLY Al components are supplied by one battery. The capacity should be at least at 2500 mAh. If the ecu is not operated more than a week, the battery must be disconnected. 5 FUEL SUPPLY The whole reliability of the running engine system depends on a perfect fuel supply. Using a high quality fuel pump Using high quality valves Hopper Tank No filter before fuel pump Largest cross-section of the fuel pipeline ELECTRICAL CONNECTION DIAGRAM STARTER To start the engine you can use a fan or an electrical motor. GLOWPLUG Propane ignition A modified conventional (hot range, non-idle bar) glow plug (Rossi #3) is appropriate. The glow plug is installed on the engine without a washer. The glow plug is modified, so what to turns of the element extend beyond the bottom of the plug. Using a pin, turn out two turns of the element. Make sure the plug glows brightly red. The glow plug voltage is adjusted at Menue „Adjustment“. Kerosene ignition The glow plug voltage has to be adjusted to the burner-plug voltage. 6 VALVES To realize the automatic start you could connect a propane /kerosene valve. Further there is the opportunity to plug in a smoker valve. IO-BOARD: To lengthen the in-and output port and the serial port the io-board could be plugged in between the ECU and GSU. The board should be mounted on a good accessible position. Buzzer: Short signal : Power on message – GSU connected Long signal : Begin autostart (open propane supply) Short interrupted signal : Battery power alarm/Temp.-Sensor fault/Glow plug fault (Symbol at GSU) Status-LED: Green Orange Red : OFF : READY : Engine in auto-mode Button: By pressing the button in OFF-mode the pump is turned on manually. 7 GROUND SUPPORT UNIT (GSU) OPERATION All important settings are transmitted from the GSU to the ECU. The following diagram shows a menu overview. The input is done by four buttons UP( ), DOWN( ), ESC( ) and Enter( ). The GSU can be connected during operation to change or show adjustments. With -button the menu is scrolled up and down or adjustments are in/ decreased. With –button inputs can be escaped, without saving adjustments. With -button adjustments are saved. 8 ADDITIONAL FUNCTION – STARTING ENGINE If you operate two engines simultaneously, it could be necessary to start the engines manually. Push the throttle stick and trim to maximum position - by pressing [ESC] and [UP) buttons at the same time the autostart is executed. ATTENTION !The GSU must not be mounted inside the model aircraft, because of electric magnetic disturbances! POWER ON MESSAGES After connecting the GSU to the ECU two messages appear. HORNET-III V1.4a HOMEBUILDER ECU-Version SENSOR: OPTIC IGNIT : KEROSENE RMP sensor (optical/magnetic), Ignition System (Propane/Kerosene) 9 STATUSDISPLAY With -bottons the different status displays could be showed. STATUSDISPLAY 1 – ENGINE STATE The status display appears with following information : Temperature 26°C OFF – RMP x 1000 – Throttle position (%) ---/--†0.0V Operation state - pump voltage Temperature : current egt RMP : RMP x 1.000 Operation state : current state (OFF, READY, AUTOMATIC etc... Pump voltage : current pump voltage ) Display Symbols • Battery full § Battery normal ¶ Battery weak ¢ Glow glug faulty † Pump running/pump voltage If an error condition occurs (Battery weak, glow plug faulty…)an alert tone sounds. 10 STATE MESSAGES OFF engine off, standby STANDBY standby – waiting for start sequence (throttle stick to 0% and next to 100%) PROP IGNIT Start engine– propane ignition BURNER ON Kerosene ignition– Burner plug on FUELIGNIT Kerosene ignition FUELHEAT Heat – Engine will be heated with constant rmp and pump voltage RAMP DELAY Starter will accelerate slowly without increasing pump voltage RAMP UP Increase engine to idle rpm WAIT ACC Waiting for acceleration gets steady STEADY Waiting for stabilize rpm CAL IDLE Teach in idle rpm CALIBRATE Teach in calibration rpm GO IDLE Stabilize idle rpm AUTO Engine in automatically operation AUTO-HC Engine in automatically operation – max. rpm is teached in – Necessary for carry out emergency programs 11 EMERGENCY Emergency program – engine will be regulated over pump voltage SLOW DOWN Engine turned off – waiting for still stand COOL DOWN Cool down engine with constant starter rpm DEV. DELAY The engine speed could not follow the increasing pump voltage – Acceleration ramp too fast! 12 STATUSDISPLAY 2 - KEROSENE Status display 2 informs about kerosene consumption and remaining fuel. STATUSDISPLAY 3 - POWERSUPPLY Status display 3 informs about battery state. STATUSDISPLAY 4 – ERROR MESSAGES Status display 4 show last turn off reason. ERROR MESSAGES START-PHASE: RPM < 2.000 DURING HEAT REASON: Engine felt short of 2000rpm during heating time EXPLANATION: Starter voltage to low(Menu 9.16), Starter broken, Stucking engine RPM < 5.000 DURING INCREASING REASON: Engine could not reach 5000 rpm during ramp-up to idle rpm EXPLANATION: Starter voltage to low(Menu 9.16), Starter broken, Stucking engine FLAMEOUT DURING HEAT REASON: Temperature felt of short 200 degree during heating time EXPLANATION: Starter voltage to high (Menu 9.16), Fuel intervals (Menu 1.8) to low FLAMEOUT DURING INCREASING REASON: Temperature felt of short 200 degree during ramp-up. EXPLANATION: Starter acceleration to high (Menu9.19), Fuel supply interrupted 13 ERROR MESSAGES AUTO-CALIBRATION FLAMEOUT DURING CALIBRATION REASON: Temperature felt short of 250 degree during calibration-run. EXPLANATION: Fuel supply interrupted -> User error FELT SHOR T OF MIN. CALIBRATION RPM REASON: Necessary rpm felt short of to ramp up engine EXPLANATION: Disturbance at speed sensor (Light, electrical error), Fuel supply interrupted (Bubbles) -> User error ERROR DURING CALIBRATION REASON: Calibrations rpm could not stabilized EXPLANATION: Calibration time to fast (Menue 9.4), Fuel supply interrupted -> User error CALIBRATION VOLTAGE EXCEEDED REASON: Max calibration voltage was exceeded EXPLANATION: Max. calibration voltage to low (Menu 9.5), Fuel supply interrupted , Pump broken (Loosing power ) -> User error Calculated fuel pump voltage too high REASON: Necessary pump voltage exceeded the max. permitted voltage of the ecu to reach the max. rpm (Menu 1.6) EXPLANATION: The max. allowed fuel pump voltage exceeds the adjusted volte in pump max volt (Menue 1.6) ERROR MESSAGES ENGINE RUN FAILURE GASTHROTTLE PULSE REASON: Break down throttle pulse during engine run, EXPLANATION: Disturbance at input signal of PPM receivers, Loosing contact at connection receiver/ecu, Broken throttle-channel FAILURE SPEEDSENSORSIGNAL REASON: Speed-impulse fail EXPLANATION: Bright light, Broken speedsensor,Disconnected speedsensor MAX. RPM EXCEEDED REASON: Exceeded max. rpm EXPLANATION: Wrong settings at control loop -> Overshot, Disturbance at speedsensors (Light, electrical error,losing contact) MIN RPM UNDERRUN REASON: Minimum rpm felt short of 14 EXPLANATION: Disturbance at speedsensor (Light, electrical error,losing contact), Fuel supply interrupted (Bubbles) FAIL TEMPERATURE-SENSOR REASON: Incorrect temperature measurement EXPLANATION: Temperature-sensor broken, Disturbance at sensors(electrical error, losing contact) MAX. TEMP EXCEEDED REASON: Max temperature of 800 degrees was exceeded EXPLANATION: Mechanical problem of engine FLAMEOUT DURING RUN REASON: Temperature felt short of 200 degree during run. EXPLANATION: To fast delay, Bubbles at fuel supply, tank empty MENU Access main menu by the – button. 1-SETUP 1.1 1.2 1.3 1.4 1.5 1.6 1.7 MAX. RMP Setting the max. rmp of the engine IDLE RMP Setting the idle rmp FLOWDYNAMIC Setting of acceleration and delay – FAST – MIDDLE - SLOW, it depends on the weather how to adjust the acceleration and delay ramps. Fast response characteristic results in overheating or exhausting engine. STARTING PUMPVOL TAGE Min necessary voltage to start pump. If pump voltage is too high it could result in a flame formation during starting engine, is the value entered to short fuel could not be ignited. PUMPVOLTAGE IDLE RPM After ignition engine pump voltage will be ramped-up to reach idle rpm. The ECU teaches in the idle rmp autonomous. For inquiring start ramp must entered only an estimated value. MAX. PUMPVOL TAGE Not to confuse with pump voltage at max. rpm. The entered voltage is for detection some errors at pump. Is this value exceeded, engine will immediately be stopped ! The voltage should be entered a little higher than the voltage at max. rmp. Pleas note: If voltage is too less, engine will not reach max. rpm ! PROPANE-VALVE PULSE Quantity of propane to start engine depends on ambient temperature and propane pressure . If fuel ignition is used, valve will be smooth pulsed. 15 1.8 1.9 FUEL-VALVE PULSE After successful ignition, the fuel supply will regulated with the entered value. Engine will exhaust with less values. GAS-EXPO Setting of throttle stick – RPM-Curve. 0% = Linear (no EXPO) 100% = max. EXPO. 1.10 TEST GLOWPLUG Glow plug test can be switched on or off during starting phase. 1.11 COOL DOWN TEMPERATURE Engine will be cooled down to the entered temperature. 2-ADJUSTMENT 2.1 TEACH IN TRANSMITTER The ECU has to learn the used transmitter. Listen to the following instructions: 1. THRO. LO/TRIM LO (THROTTLE/TRIM MINIMUM) Throttle-Stick and trim to minimum -> 2. THRO. LO/TRIM HI (THROTTLE MINIMUM/TRIMMING MAXIMUM) leave throttle-Stick at minimum, Trimming to maximum -> 3. THRO. HI/TRIM HI (THROTTLE MAXIMUM/TRIMMING MAXIMUM) push Throttle-Stick to maximum, leave trimming at Maximum -> Ready. If AUX-Channel is active (plugged in), the aux channel positions must be tea ched. The plausibility will check up after adjustments. If an error message with a sound signal appears, solve the problem and carry out the procedure again. The reason is mostly a wrong programming of the transmitter. 2.2 ADJUSTMENT GLOW PLUG Setting the voltage of the glow plug 16 2.3 ADJUSTMENT TEMPERATURE Adjustment of the temperature element 2.4 FUEL CONSUMPTION To use the fuel gage the characteristic pump curve is necessary. Set in the fuel-flow at 1 Volt (FUEL-FLOW @1.0V) and 2 Volt (FUEL-FLOW @2.0V) pump voltage. For calculating the remaining fuel set in the size of the fuel tank. 3-SYSTEM 3.1 BATTERY VOLTAGE Set in the min. and max. voltage of battery. 3.2 LANGUAGE Choose your language . 3.3 COUNTER Shows the effective running time of engine 3.4 FAILSAFE FUNKTIONS Necessary if receiver fail safe or error impulses arises (see chapter distance control) 3.5 SWITCH CHANNEL FUNCTIONS If a switch channel is used, the functions must be filled in. Choosing possibilities : Without function : Switch channel is not used ON/OFF Switch : Switch channel replaces trimming SMOKER VALVE : A Smoker valve can be used. Notice, that the output will switched off not before egt exceeds 300°C Notice, the channel has to be teached in before using. 3.6 WIRELESS TELEMETRIE Activating a telemetry transmitter (TRX-2400). The count of data is specified (OFF/1x/2x/3x) and channel (COM-CHANNEL 0-10) and the address of telemetry-Terminal (0-10000). More detailed information see on telemetry-system instructions manual. 3.10 SETTING RES ET ATTENTION! Choice sets the ecu in condition of delivery date! 9-EXPERTE MASTERMODE The menu 9 can only be used in a self-build version, in a producer version this menu is not available. ATTENTION ! Setting of all necessery parametres for the runnig behaviours of engine. Settings must be carried out by an expert! 9.1 MAXIMUM UPM INPUT Max. adjustable speed (MENU 1.1) 9.2 MINIMUM UPM INPUT Min. adjustable speed (MENU 1.2) 17 9.3 CALIBRATION SPEED This speed will reached for calibration run after starting engine. This speed fix a crossing point between slow /fast acceleration resp. delay(Menu 9.8 – 9.11) 9.4 CALIBRATION RATE Input of pump voltage increasing rate during automatically calibration. If voltage is too high, flaming results and calibration speed could be exceeded (9.3). This should be avoided! Is the adjusted value too low, the automatic calibration is delayed. 9.5 CALIBRATION MAX. VOL TAGE This max pump voltage must not be exceeded during auto. calibration. Engine will shut down -> see error messages 9.6 CORRECTION FACTOR MAX. To calculate the desired pump voltage at max., set in a multiplication factor. ATTENTION ! Is this value to low, the max rmp will be reached verry slow at first attempt, overshoot if the value too high. 9.7 CORRECTION STEP MAX Are the differences in normative-actual state rpm the pump voltage will re-adjusted with this value. The input happens in volt/sec. ATTENTION ! If this value is choosen too low, the re-adjustment happens verry slow, is this value too high, the closed loop regulator can swing, turbine could be shut down. 9.8 ACCELERATION SLO W Time to accelerate engine from idle to calibration speed (Menu 9.3). 9.9 ACCELERATION FAST Time to accelerate engine from calibration speed to max. rpm (Menu 9.3). 9.10 DELAY SLOW Time to delay engine from calibration speed to idle (Menü 9.3). 9.11 DELAY FAST Time to delay engine from max. rpm to calibration speed (Menu 9.3). 9.12 ACCELERATION / DELAY TEMPERATURE If temperature rise per 1/10 per second is higher than the declared value, the fuel injection is delayed to avoid overheating engine. 9.13 SPEEDSENSOR Used sensor optical/magnetic – one or two pulse/rotation 9.14 IGNITION Choice fuel or gas ignition 9.15 STARTER-V IGNITION Starter Voltage to ignite engine 9.16 STARTER-V HEATING Starter voltage during heating time 9.17 STARTER-V MAXIMUM Max. starter voltage. 9.18 SPEED STARTER OFF Rpm to decouple starter. 9.19 STARTER ACCELERATION Value which starter voltage will increased per second, too high values could blow out engine. 18 9.20 HEATING TIME After fuel ignition the combustion chamber will be heated up for this adjusted time. 9.21 FUEL DELAY After heating the starter will rise up slowly in adjusted time, without increasing pump voltage. (STATUS: RAMP DELAY) 9.22 RAMP-UP TIME Engine will increased to idle rpm in adjusted time. Thereby pump voltage will increase. Menu 1.5 P UMP VOLTAGE IDLE 9.23 RAISING PUMP VOLTAGE To ignite fuel, the pump voltage will increased with this value. 9.24 PROPANE/BURNER SWITCH OFF SPEED After exceeding the adjusted rpm the propane resp. the fuel supply will stop. 9.25 ACCELERATION CURVE Choice of an acceleration curve (chapter functions and program flow). 9.26 DELAY CURVE Choice of a delay curve (chapter functions and program flow). 9.30 RESET OPERATING COUNTER Reset operating counter. 9.98 PUMP-OFFSET To compensate fabricating tolerances adjust a normative-actual state of voltage of the pump power amplifier. It is not allowed to change this value. 9.99 PRESETTING ENGINE TYPE Used engine could be preset. The list of types is permanently expanded, ask your producer of your engine about settings for your engine. 19 FUNKTIONS & PROGRAM FLOW RUN AUTO-START Fuel ignition 1. 2. 3. 4. BURNER ON –Burner on for 8 seconds FUEL IGNIT – Pushing burner valves– Starting fuel pump FUELHEAT – Heating time (Segue from burner supply to fuel ignition) RAMP DELAY – Slow starter acceleration with constant fuel supply RAMP UP – Increasing to idle Gas ignition 20 1. 2. 3. 4. 5. 6. IGNITION – Glow plug on / starter , gas valve open PROP HEAT – Heating with propane FUEL IGNIT – Fuel ignition FUELHEAT – Heatin time(Segue from gas supply to to fuel ignition) RAMP DELAY – Slow starter acceleration with constant fuel supply RAMPUP – Increasing to idle RUN AUTO-CALIBRATION 1. 2. 3. 4. Accelerate engine to calibration rpm Stabilize Approach idle rpm Calculation the characteristic curve of engine PROCEDURE OPERATION Characteristic features for automatically operation: Fuel supply depend on temperature and speed Controlling of speed and temperature limits Recording all relevants engine data (BLACKBOX) Telemetry transmitting EMERGENCY OPERATION The ECU disposed of an emergency program. In case of temperature or speed sensors failure a emergency program occur (State: EMERGENCY). In this modus the engine is controlled only over the characteristic curve of the pump. A precondition for activating this the AUTO-HC state must be reached one time. Restarting engine is only possible after correction the error cause. SAFETY FUNCTIONS Speed: Exceeding-fall below-failure Temperature: Exceeding-fall below-failure Power supply: Min. voltage Output fuel pump: Failure/Bypass Input receiver: Failure –Disturbance –FailSafe 21 RADIO CONTROL THROTTLE The throttle controls the engine: Initiation starting sequence Speed / Thrust controlling during flight Shut-off Before starting the engine, the radio control has to be teached in. (see Menu 2-Adjustments). STARTING ENGINE: 1. 2. 3. Triming + throttle to maximum -> STANDBY Throttle to minimum Within 3 secs throttle to full -> STARTSEQUENCE SPEED/THRUST CONTROLLING After successful start-sequence and calibration the gas throttle controls the thrust of the engine. SHUT-OFF Engine is switched off to minimum by pushing back trimming (throttle idle). RADIO CONTROL WITH DIGITAL TRIMING To react very fast with digital trimming it is recommended to mix a switcher on the throttle channel or to use a motor cut off switch. The switch replaces trimming, in this case trimming is without function and has to be left on the maximum position. FAIL SAFE The incoming throttle channel pulses are permanent checked, if they are in valid limits. Upper and lower limits will fixed in by teaching in the throttle channel. If a pulse is above or below this limits the fail safe function is working. In status display 1 the message „FAIL“ appear. 22 FAIL SAFE Settings Menu 3.4 FAILSAFE DELAY: Time between error impulses and depressing to fail safe rpm (Menu FAILSAFE THRUST). FAILSAFE TIMEOUT: Engine will shut off, if there is no valid impulse recognized or the receiver is already in fail safe modus. FAILSAFE THRUST: When „FAILSAFE DELAY“ is runned over, engine will decreased to the stored value. Disabling FAIL SAFE function: Fail safe function is disabled, if the value 0,0 sec. is entered. AUXILIARY Function as ON/OFF switch: On/Off switch (Replacement for trimming): The switch replaces trimming, switch ON = trimming ahead / switch OFF = trimming backward. Notice: using switch the trimming has to be left at the max. position. Smoker-Valve: A smoker valve can be turned on and off. The valve is activated at 300°C and is automatically shut off below 300°C. Radio control and ecu will connected on AUX-input patch cable. It is located directly below to the throttle channel cable. APPENDIX FIRST START – NECESSERY SETTINGS To use the ECU with a turbine some settings are necessary. Basic steps: 1. 2. 3. 4. 5. MAX/IDLE-speed (Menu 1.1, 1.2) Pump voltage during start (Menu1.4) Adjustment radio control (Menu 2.1) Setting burner voltage (Menu 2.2) Adjustment temperature (Menu 2.2) 23 6. Battery voltage (Menu 3.1) TECHNICAL DETAILS Efficient RISC Microcontroller Easy update by FLASH-MEMORY Modern USB PC-connection Gas-/Fuel Start Operation with only one receiver channel Starting by GSU (Models with more engines) Integrated logger: Dates will be recorded from the last 30 operating minutes. Recording resolution are 5 points per second Telemetry: Data could be transmitted to an local groundstation (Laptop ) Emergency operation: In case of an sensor error (speed/temperature) engine run can safety finished Controlling power amplifiers (Fuelpump – Starter – Burner) MAXIMUM TECHNICAL DETAILS Max. speed 175.00 RPM Pump output 6 A continuous / 10 A 200mS Starter output 6 A continuous / 10 A 200mS Burner output 6 A continuous / 10 A 200mS Output valves 250 mA continuous / 500 mA 1000mS Power supply: max 12,6 V continuous Receiver input 5 cells / max. 7,5 V / Pulse-amplitude min. 2,7 V ACESSORIES TRX-2400: 2.4 GHz Telemetry transmitter Telemetry transmitter 2.4 GHz for transmitting data to a ground station TelJET: 2.4 GHz Graphical telemetry display unit Graphical display unit with serial data output, Real-time display of all relevant engine parameters 24 ENGINE DATA – SELF SELECTION Fill in here your individual settings. 1-SETTING 1.1 MAX SPEED RPM 1.2 IDLE RPM RPM 1.3 DYNAMIC BEHAVIOUR FAST MIDDLE SLOW 1.4 PUMP VOLTAGE START VOLT 1.5 PUMP VOLTAGE IDLE VOLT 1.6 MAX. PUMP VOLTAGE VOLT 1.7 PULSE GAS-VALVE % 1.8 PULSE FUEL % 1.9 GAS-EXPO % 25 9-EXPERTE MASTERMODUS 9.1 MAXIMUM RPM RPM 9.2 MINIMUM RPM RPM 9.3 CALIBRATION RPM RPM 9.4 CALIBRATION RATE VOLT 9.5 MAX. VOLTAGE CALIBRATION VOLT 9.6 MAX. CORRECTION FACTOR X- FACTOR 9.7 MAX. CORRECTION STEP VOLT 9.8 ACCELERATION SLOW SECONDS 9.9 ACCELERATION FAST SECONDS 9.10 DELAY SLOW SECONDS 9.11 DELAY FAST SECONDS 26 9.12 ACCEL./DELAY TEMPERATURE 9.13 SPEED SENSOR 9.14 IGNITION °C OPTICAL MAGNETCAL FUEL GAS 9.15 STARTER-V IGNITION VOLT 9.16 STARTER-V HEAT VOLT 9.17 STARTER-V MAXIMUM VOLT 9.18 SPEED STARTER OFF RPM 9.19 STARTER ACCELERATION VOLT 9.20 HEATING TIME SECONDS 9.21 FUEL DELAY SEDONDS 9.22 RAMP-UP TIME SECONDS 27