Gaspar Xicoy X45H User Manual Download

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Features and Functions

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Tiny 60mm case 2 stage engine developing up to 5kw of shaft power

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Very low installed weight and bulk

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Heli gearbox outline and shaft matches standard 90 size heli glow engine

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Turboprop version comes complete with bulkhead mounting

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Turboprop option of two reduction ratios: Hi = circa 6k and Lo = circa 8k

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2nd stage rpm feedback to ECU for constant speed governor function (heli)

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Gearbox over-speed protection function

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Gearbox output rpm and temperature included in telemetry feedback

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Accommodates wide presettable range of helicopter reduction ratios

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Peak power user presettable

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Valves and ECU installed on-engine

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Internal kero burner and thermocouple for clean exterior

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Compatible with diesel and kerosene

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Incredible start to idle of less than 25secs

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Fast spoolup to flight rpms

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Automatic cooldown after run, even with receiver power turned off

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Automatic battery disconnection after cooldown

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Brushless high speed starter

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Tiny intelligent brushless fuel pump

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High speed digital control of all components

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Gearbox uses lubrication from engine, no separate oil required

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Choice of display options, on and off board and Bluetooth Android/iPhone

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Telemetry options available for most modern transmitters

New options and features are being added from time to time,

keep watching on:

www.Xicoyturbines.com

for details

Page 5

Summary of Contents for Xicoy X45H

Page 1: ...Xicoy X45Helicopter X45TurboProp Two Stage Gas Turbine Engines User Manual Version 1 1 Aug 2020 NEW NEW For 2020 For 2020 X45H X45TP ...

Page 2: ...elp you set up and safely operate your engine in your chosen airframe If you encounter any problems operating the engine then please consult this manual first and if you cannot find a solution please get in touch with us If your problem is with a helicopter installation or operation of your chosen helicopter then please get in touch with your install kit supplier Here is a contents list for this m...

Page 3: ...Setup 40 Heli Radio Special Notes 40 Turboprop radio setup 41 Pre setting Radio to ECU 41 Aligning transmitter with ECU 42 Failsafe 43 Preparing the engine for running 43 Priming purging the fuel system 44 Starting Notes 44 Starting the engine 45 Helicopter engine running 45 TurboProp engine running 46 Engine shut down procedure 46 Adjusting the engine maximum power 47 AutoRestart function 47 What...

Page 4: ...and we recommend this route see the Xicoyturbines com webpage for details of kits and supported airframes and brands Conversion kits alleviate the requirement to adapt components and airframe and install this unique gas turbine power unit as all have already been resolved and included Step by step instructions plus access to help and support from like minded helicopter people greatly simplify the ...

Page 5: ...ios Peak power user presettable Valves and ECU installed on engine Internal kero burner and thermocouple for clean exterior Compatible with diesel and kerosene Incredible start to idle of less than 25secs Fast spoolup to flight rpms Automatic cooldown after run even with receiver power turned off Automatic battery disconnection after cooldown Brushless high speed starter Tiny intelligent brushless...

Page 6: ...Servo type cable 300mm x 2 Aluminium filter 4mm tubing 1mtr USB memory card with instruction manual TurboProp engine Engine unit inc mounting and fod screen Fuel pump Hub Lite colour display 300mm signal cable OR Compact Hub Engine cable 500mm Battery cable Servo type cable 300mm x 2 Aluminium filter 4mm tubing 1mtr USB memory card with instruction manual Page 6 ...

Page 7: ...er Manual are copyright Xicoy Electronica SL Canet de Mar Barcelona Spain All rights are reserved This User manual pictures and data are the property of Xicoy Electronica SL and cannot be used or reproduced in any way with written permission from Xicoy Electronica SL Disclaimer This engine is a very sophisticated piece of machinery Great care should be taken at all times when using the engine It s...

Page 8: ...ndition of rotor without which the engine may not run without sustaining damage to the rotating assembly This warranty is voided if any one or more of the following conditions apply In such a case Xicoy Electronica SL will accept no responsibility for any damage or other consequence caused by engine operation 1 The product has been subject to operation using incorrect fuel oil or fuel oil mix 2 Th...

Page 9: ...n 4 see text for breakdown Overall length 280mm 11 320mm 12 6 Width across exhausts 120mm 4 75 120mm 4 75 Width main body 60mm 2 35 72mm 2 83 mounting Firewall to rear of prop distance n a 160mm 6 3 Gearbox output shaft Clutch portion 9 5mm 3 8 Dia 10mm plain portion threaded threaded 5 16 UNF M8x1 25 internally for M8 cap bolt Gearbox mounting holes 4 off dia 4 1mm 4 off dia 5mm W86 90mm x H50mm ...

Page 10: ...he clutch supplied for the piston engine for the airframe It enables the engine to start and run to idle without powering the rotors It also provides a valuable slipping point in event of rotor being overloaded or forcibly stopped in a crash or the helicopter being blown over by strong gust of wind Keep gearbox cool The gearbox unit must be cooled in operation Being connected to a gas turbine prod...

Page 11: ...ck the output shaft Do not attempt to do this by jamming the 2nd stage turbine 2 Remove the four M3 screws from the bottom cap of the gearbox to reveal access to the lower output shaft nut which you can hold stopped using an 11mm socket wrench or ring spanner Be extra vigilant not to allow grit or dirt to enter while the cap is removed Be aware there may be some loose fuel in the gearbox so best n...

Page 12: ...for any reason the 6mm gland nut on the gearbox should be unscrewed to allow the pipe and gland to be removed as one Note there are two small Orings fitted onto the pipe which the gland nut presses down upon to provide the seal When refitting ensure the Orings are in position and the gland nut gently nipped up don t over tighten it not needed 9 The engine section should be supported by its special...

Page 13: ...but rigid framework provides a lot of engine protection in event of a nose over or crash however this stress will be passed directly to the firewall so must be a secure point in the airframe Without such a system any significant prop strike or nose over could banana bend the 2nd stage a very expensive repair A template is provided to place over and position mounting holes and cutout for the firewa...

Page 14: ...itioned to place the propeller shaft in the centre of the cowl the engine clearance hole and bolt mounting holes can be cut out using the template Protect any exposed wood using fuel proofer Allow a small clearance between the end of the cowl and the back of the propeller Add a spacer to the mounting position on the firewall if required do not add a washer behind the propeller Exhaust extensions A...

Page 15: ...ner backplate fit this 1st For spinners Xicoy recommend Truturn prop backplates and spinners for their accuracy and careful balance bob truturn com They have a wide range of adapters to suit the unit just mention you have an M8x1 25 prop bolt and they should be able to help Important No attempt should be made to add material lead shot or coloured sticky tape to balance the prop as this is sure to ...

Page 16: ... 655ft sec Above this the tips start to make that familiar howling noise This can be just in a dive or most of the time if a prop with shallow pitch is fitted to a fast airframe with a powerful engine A rough guide to optimum tipspeed is calculated by 3820 prop dia in mtrs So for example a 610mm prop max rpm would be 3820 0 61 6262rpm For imperial measures 12 510 prop dia in feet or 150 100 prop s...

Page 17: ...ad quickly and can approach any preset rpm limit more easily so best is to set it slightly on the high side For example a prop on the ground might give 5000rpm you could set the limiter to 10 above this 5 500 as the prop is sure to gain 10 in the air it will be more like 20 Experience will be your guide here Maximum forward speed is mainly a function of forward thrust against airframe drag A sleek...

Page 18: ...if the FOD screen should be displaced for any reason This is 250mm 10 on the Heli and 500mm 20 on the Turboprop Please do not modify it if not quite right ask for a longer or shorter one if required Avoid placing the cable close to the engine rpm sensor which is located at approximately 4 O clock when viewed at the intake of the engine with the cable entry plug at 12 O clock A cable too close can ...

Page 19: ...ging as the usual pulse type charger can easily destroy the ECU and is in any case a sensible precaution with rechargeable batteries 10 The centre of the fuel tank should be located as close to the centre of gravity CofG of the model as possible This will minimize the effects of the CofG shifting as the fuel is used during the flight 11 The fuel tank should have an effective fuel pickup like a fel...

Page 20: ...g from fuel tank push on a short 12mm 1 2 length of the supplied 4mm pipe onto the pump suction port and push the Tygon over the top to provide a tight leak free fitting A double wrap of lock wire will ensure secure connection Otherwise use the 4mm piping supplied DO NOT use tie wraps anywhere on the fuel system Be aware Tygon gradually softens in use so should be replaced annually 17 DO NOT use T...

Page 21: ...st flights 22 Do not under any circumstances try to run the fuel pump by plugging it into any other FADEC brushless pump control or similar type 3 phase driver It does not work like that and you will destroy it in the process The supplied FOD screen is essential to protect the engine USE IT Page 21 ...

Page 22: ...gine Do not use a powder extinguisher unless of last resort as the abrasive powder will ruin the engine if it is used Just before starting perform a visual check to ensure the immediate area is clear of spectators and that anyone nearby knows of your intention and to stand clear Safest place to stand to start the engine for either heli or turboprop is to the rear Be especially aware this engine is...

Page 23: ...r This is an Authorised Dealer and or Service Agent replaceable component as the engine must be opened to access it Note unauthorised opening of the engine will void the warranty The burner has been designed that the rotor is not disturbed during this process so the balance is retained The engine also features an internal thermocouple This avoids the danger to this delicate component being outside...

Page 24: ...om flight the Hub unit will ensure the cooldown continues until the end The Hub will then disconnect the battery after the end of the cooldown When the receiver is turned back on the Hub unit will reconnect the battery At the end of the flying day it is good practice to disconnect the ECU battery just in case Fuel The engine can be run using Kerosene or Diesel fuel Kerosene is the recommended fuel...

Page 25: ...ial brands like Mobil DTE Llte Shell Tellus 32 Igol 32 Cepsa Turbine 32 etc plus 1 of 100 synthetic 2 stroke oil Plenty of commercial brands are available locally just check in the bottle that the oil is JASO FC or JASO FD compliant Commercial turbine oils like Kingtech oil Jetcat oil Jackadofsky oil Fuchs Deluxe can be used It is allowed to use a 5 of oil contents for compatibility with other eng...

Page 26: ...power turbine and the spider The interstage and spider are high temperature stainless and the power turbine is of Inconel and is blown round at high speed by the gas flow which is angled in direction by the interstage vanes The spider holds the power turbine bearing in the centre The power turbine is mounted on a shaft with substantial ceramic bearings and drives the gearbox to which it is connect...

Page 27: ...nent Description ECU Engine Control Unit The ECU and indeed the whole system used on this engine is totally new and unlike any previous version of Xicoy ECU The ECU is a powerful new design using a completely new architecture so represents not an upgraded version of anything before but a new system completely This new platform allows us to break from the limitations of older technologies to make u...

Page 28: ... and signals to and from the outside world to the ECU a small component which we call the Hub is provided There are two types the Hub Lite is a small shrink wrapped flat board the Compact Hub is housed in a small box and includes a small integrated LCD backlit display Both Hubs form the connecting point for The receiver throttle signal max voltage 10v ECU battery volts 7 4 9 9v Fuel pump ECU on th...

Page 29: ...le with socket but a small plug built into the pump which enables a regular high quality JR type servo cable to be used as the pump cable socket at both ends This way its easy to get just the right length you need without cutting or extending the wire Note the three wires are NOT for the 3phases usually used for a brushless motor The three wires are for the plus and minus power supply and a single...

Page 30: ...ble just get the right length you need ECU Display There are two display options with the X45 engine depending on which package you select Compact or Lite The Compact Hub is a Hub and screen combined in one box It has its own buttons and is backlit This type does not record flight data It weighs 22g 0 77oz The Lite option includes the small shrinkwrapped Hub and separate colour display connected v...

Page 31: ...u Button HDT to visualize fadec data HDT Screen Button Back x to go initial screen Data from FADEC Buttons to navigate through FADEC menus Tools Screen ButtonBack x to go initial screen Button Player to go Player Radio Check to go Radio Check Button Last Shutdown to go Last Shutdown Button File to go File Player Screen ButtonBack x to go initial screen Button Play Last Run to visualize last run Bu...

Page 32: ... in from left You will then see a screen showing 4 items the radio signal Pulse 0 xxxx uS the throttle stick percent x the battery voltage vb x x V and the current draw Ib x x A x any number Press the button again You now see the four main menu root choices Start Info Radio Run Press the button beneath the START label You now enter the stream which covers the starting functions Press the button to...

Page 33: ...start and white smoke from exhaust In this case adjust upwards by 0 2v Having too high a setting shortens the life of the glowplug There are no more functions to adjust in this branch so exit by pressing until you return to the opening screen Press the button twice to get back to the main navigation Menu Press the button under the INFO option Timer screen TimerServ shows the total runtime on the e...

Page 34: ...me can appear at the exhausts if any residual fuel left Again use only a few seconds Test Prime Pump screen Use this function to fill the fuel line on a new installation of after the feed pipe has emptied Disconnect from engine and prime into a rag to clear any particles then connect Do not prime into the engine it is not needed and can make a flame on startup Test Gas Valve We don t use gas any m...

Page 35: ...tons to toggle Default is OFF For Helis you can select Off or Manual For TurboProps you can select Off Manual or Automatic Read the section on Restart carefully before enabling this function Return now to the main navigation menu and choose RUN RUN Menu This menu is used to access all adjustable settings used for when the engine is running Full Power Screen This shows the maximum power setting cor...

Page 36: ...to ECU decides optimum for current conditions In case of acceleration problems the setting can be switched to manual preset of Cold Mild Warm or Hot Each is a slightly longer deceleration ramp Governor The next screen is for the Heli and shows the governor setting for rotor head RPM Default is 0 meaning OFF The governor is disabled with a setting of 0 when rotor speed will track the throttle stick...

Page 37: ... one click equalling 25 Default is 125 Replacement pump preset In event of pump needing replacement for any reason the user can set the new pump to the default setting 100 and see the heating effect on the engine on a start If slow to heat up then the value can be raised to the next level until a satisfactory setting is found There are a limited range of values with jumps of 25 between each so the...

Page 38: ...wer without adding rotor pitch until you reach the governor rpm set where it should lock Further increases in throttle setting should now have no effect on rotor rpm which should be held at the value set Lowering the throttle should also have no effect until you reach a value equivalent to 130k where the governor will drop out and you regain normal engine control After flight and landing the rotor...

Page 39: ...s available in many outlets Be careful to select JR type compatible leads as the pin sizes for Futaba can be smaller thus making a looser and troublesome connection It s always best to use those supplied in the engine package which have been used in setting the engine up for its factory tests Please don t give in to temptation If you don t have the recommended type battery please obtain one of the...

Page 40: ... to power many servos at once and its supply voltage will vary considerably as the servos are driven It would be so easy for the varying supply to subsequently cause what is known as a brown out a short dip in supply voltage that causes the ECU to suspend operation or reset itself In either case it will shut off the engine which is very bad news for heli fliers in particular as an impromptu autoro...

Page 41: ...tch curve in transmitter and maximum power may correspond to maximum pitch As the Xicoy X45H heli engine does have a governor function a manual control is needed to be able to raise rotor rpm from idle to flight speed on the ground without adding rotor pitch so as not to generate lift This knob slider switch control is also used to set the radio to the ECU as it fulfills the necessary function of ...

Page 42: ...tton from left once to show an information screen Note at top left a number showing the received radio signal shown as Pulse xxxxuS It should be between 900 1050uS at ENGINE STOP position It should be between 1100 and 1300uS at IDLE position And between 1800 and 2200uS at Full Power position Ignore the reading to the top right for the moment Please note these readings are measured directly from th...

Page 43: ...throttle position should read 0 at the position of engine stop trim and stick down 100 with stick trim full up and between 10 and 30 at idle Note the setting seen in the Thrust Curve above could be Half Expo Full Expo or Linear Will change depending on what has been set up This now completes radio setup and only needs doing again if the radio settings are changed Page 43 Trim Low T 20 C RPM 00000 ...

Page 44: ...ired and can only be carried out by Xicoy Electronica SL or your authorized dealer or service agent Preparing the engine for running Important notes for kerostart engines PLEASE READ The kerostart system used on this engine is a reliable and well tested system that produces very smooth and trouble free starts However extra care and attention must be paid when starting a kerostart engine With keros...

Page 45: ...tart Double check that the engine is not flooded An extra security measure is to place a manual valve between the pump outlet and engine so during the process of filling the tanks or during storage fuel cannot arrive to the engine After a failed start or whatever condition that could cause that fuel be collected inside the engine ie accidental priming ALWAYS empty the engine of fuel by placing a r...

Page 46: ...r some clicking coming from the engine this is the valves pulsing 8 Once this phase is finished the RPM rises to 10 000RPM and the reading will be FUEL RAMP In this phase the ignition system is switched off The fuel flow and starter power will be increased automatically to increase the RPM quickly up to idle at 60 000RPM At arriving to idle the ECU will automatically disconnect power to the starte...

Page 47: ...er rpm is now handed back to the transmitter and controlled by the position of the throttle stick Initially Increase decrease the throttle slowly verifying that the engine accelerates decelerates following the throttle command Take special care and maintain a safe distance from the rotating propeller Engine shut down procedure To shut down the engine lower the trim and the stick It is recommendabl...

Page 48: ...ther startup cycle Engines are supplied in this mode from factory Manual Restart Heli and TurboProp User can normally shutdown the ECU through the transmitter by lowering the stick and trim The ECU will execute the normal shutdown and post run cooling cycle Once the cooling is finished temperature below 100ºC the ECU will return to power up state allowing the engine to be restarted through the nor...

Page 49: ...own was caused by any fault other than a typical flame out caused by air in the fuel system It will not monitor and confirm flight conditions are optimum for a restart Leaving the restart to progress is the pilot responsibility and decision depending on each particular case When should AutoRestart function be enabled Auto Restart is fast but still takes an average time of 10s to establish restored...

Page 50: ...he transmitter in the STOP position The engine could restart and go to full power on its own the ECU does not know when or if the plane is on the ground Can I use the restart function many times NO Restart function is an emergency procedure and places a high stress on the engine ancillary components The starter and ignitor are fed with extra power that is not used in normal startups this places co...

Page 51: ...just the power at low settings HALF EXPO An intermediate setting between the other two modes Throttle stick position chart Stick Position MODE 0 Idle 25 50 75 100 FULL EXPO Idle thrust 6 25 56 100 of total thrust HALF EXPO Idle thrust 16 38 66 100 LINEAR Idle thrust 25 50 75 100 Throttle curves can be changed while the engine is running so you can leave the throttle at a given position and switch ...

Page 52: ...tes that the throttle stick is in a position above IDLE the engine will not start with the stick in this position 4 Glow Test Verification of glow plug continuity 5 StartOn Test of the starter and rpm sensor 6 Ignition Ignition phase 7 SwitchOver Phase of heating of the combustion chamber after detecting the ignition 8 FuelRamp Phase of acceleration until idle speed 9 Run Idle Engine working corre...

Page 53: ...h cycle of operation the ECU stores the last cause of shut down and the values of RPM temperature and pump power In order to access these measures it is necessary to shut down and power up the ECU Set the trim down TrimLow and push the left button on the display The ECU will show the cause of last shutdown and the parameters value at the moment of shut down These are as follows Diagnosis messages ...

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Gaspar Xicoy X45H, User Manual

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