JetCat P1000-PRO Operating Instructions Manual Download Page 1

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05/2019

Operating instructions

JetCat PRO Engines

Summary of Contents for P1000-PRO

Page 1: ...05 2019 Operating instructions JetCat PRO Engines ...

Page 2: ...NNECTION OVERVIEW PRO INTERFACE 20 Battery and engine connection 20 GSU LED s and expansion connectors 20 RC Servo PWM inputs Telemetry output Airspeed input 21 Power on via RC signal 21 CAN Bus Serial port connectors 22 SYSTEM CONNECTION DIAGRAM WITH PRO INTERFACE 23 Connection diagram A Direct battery connection 23 Connection diagram B Battery connection via PRO Interface 24 GROUND SUPPORT UNIT ...

Page 3: ... 39 PREPARING FUEL AND FUEL SYSTEM 39 PRIME THE PUMP AND SYSTEM 40 RUNNING THE ENGINE FOR THE FIRST TIME 41 INITIAL ADJUSTMENTS 41 THE CHECKLIST 41 Before Running the engine 41 After Stopping the engine 41 Starting and stopping the engine 41 After the start process is initiated the following occurs 42 Automatic Cooling Process 42 GSU RUN MENU DEFAULT DISPLAY SYMBOLS 43 INITIAL DEFAULT DISPLAY SCRE...

Page 4: ... and its operating procedures equipment and accessories Study the material step by step and ascertain how to install operate and maintain your jet engine If you are unsure about anything re read it again or contact JetCat for further support DO NOT OPERATE THE JetCat ENGINE BEFORE YOU HAVE READ THE MANUAL AND FULLY UNDERSTAND EVERY PROCEDURAL DETAIL Should you still have doubts or questions do not...

Page 5: ... upon request JetCat PRO engine features Integrated Engine Components ECU electronic control unit Electric starter motor or brushless starter generator depending on engine type Brushless fuel pump Fuel Kerosene start Solenoids Fuel filter Direct kerosene startup Barometric altitude pressure sensor for automatic engine tuning upon operation altitude 4 pin Molex expansion connector e g for smoke pum...

Page 6: ...eature allows to connect multiple engine to same serial interface 1x analogue voltage control sensor input 1x JetCat Bus interface e g for connection of GSU and or other JetCat accessories LCU flow sensor BMS system etc CAN Bus interface for control and data reporting Customer specific data connectors including customer specific pinouts are possible on request JetCat PRO Interface Option By using ...

Page 7: ...areas WARNING The construction and operation of the model and or engine under the influence of alcohol drugs medicines etc are strictly forbidden These activities must take place only in the best physical and mental health condition This applies to both the operator and any assistants WARNING The JetCat engines were designed exclusively for model aircraft and are NOT suitable for any other purpose...

Page 8: ... when working with the engine Before operation make sure there are no lose parts or debris near the engine Objects being sucked in can cause severe damage If your installation allows we highly recommend using a Jet Net to protect the intake WARNING Never run the engine in a closed room or an area near any kind of flammable matter Do not fly engine powered aircraft near flammable materials nor in f...

Page 9: ...ese safety areas are kept free of persons during operation Always wear safety glasses when operating a jet engine Make sure intake area is free of any parts obstacles possibly being sucked in by the compressor FOD The engine will produce an immense suction able to aspirate unsecured parts in quite a large radius Keep fingers away from intake area Make sure that fire extinguishing equipment is pres...

Page 10: ...pperer GmbH 49 7634 5056 800 Wettelbrunner Straße 6 sales jetcat de 10 79282 Ballrechten Dottingen www jetcat de GERMANY Instruction manual JetCat PRO engines 1 7 V12 01V Hazard areas on engine idle 20 to full power operation ...

Page 11: ...cated mounting brackets are available for mounting of the engine Place the brackets around the engine as shown in the pictures below Do not over tighten the fixing screws not to deform the engines casing P300 PRO Versions P400 PRO Versions P1000 PRO P550 PRO Versions Best rotation orientation position of the P550 engine is to rotate the engine such that the fuel input is located around the 4 o clo...

Page 12: ...customer specific connector Connector B XT60 power connector Or customer specific connector Fuel inlet fuel pump is inside of engine Do not use a filter in the suction line just an UAT air trap or large felt clunk Bleed air output port OPTIONAL Can be used to pressurize fuel tank for high altitude operation Inside of the engine there is a one way valve fitted which prevents reverse flow into the e...

Page 13: ...AUX PWM input RC PWM Signal AUX 8 Safety Shutdown input engine kill signal Safety shut down input This is an input for additional flight termination systems This input pin should not be used to stop the engine under normal conditions Needs to be connected to GND to allow engine to run This signal is only present on P1000 engines or engines with ECU hardware setup V2 0 or higher Connect this pin to...

Page 14: ...ures that a running engine cannot be accidentally shut down even if there should be glitches on the power on signal ECU will only power down if the engine is not running and cool down has finished 3 cooling With this option the ECU will stay powered on as long as the engine still is in cooling mode even if the control voltage on pin 9 is removed As soon as cooling is finished the ECU will turn off...

Page 15: ...rived from one of the RC control inputs Thr Aux In this case the system powers on automatically when the receiver is switched on Attention Fire A LiPo LiFePo battery can explode if incorrect charge parameters are used You should therefore always refer to the manufacturer s charger instructions NEVER charge the batteries unattended Do not exceed the batteries maximum allowed charging current READ A...

Page 16: ...GERMANY Instruction manual JetCat PRO engines 1 7 V12 01V Expansion connector C The 4 pin Molex expansion connector on the front side of the engine provides data and switched power to other optional JetCat accessories like Smoker pump Bus Type Light control unit LCU GSU via special bus adaptor Expansion connector C 4 pin Molex connector ...

Page 17: ...mmended due to possible generation of cavitation air bubbles Fuel Connection Diagram Standard Do not use a filter in the suction line to the engine just an UAT air trap or large felt clunk On engines above 400N thrust two felt clunks in parallel might be needed not to restrict flow or one high flow felt clunk from JetCat The fuel demands are high especially on larger engines and require large tubi...

Page 18: ...p to 3 5 bars can be reached In case bleed air is not required used please block the outlet by a piece of crimped tubing Typically bleed air is used to pressurize the onboard fuel system to avoid degassing bubbling of the fuel on high altitude operation of the engine 5000m For full operation of this feature an additional pressure relief valve needs to be fitted in front of the fuel tank in order n...

Page 19: ...Adapter if desired Furthermore the PRO Interface allows for an easy access point to connect other accessories such as One or two channel RC control from receiver Telemetry output for Jeti Graupner Hott Multiplex M BUS and Futaba SBUS 2 RJ12 jack for connection of GSU Air Speed sensor header 6 and 8 pin ERNI flat cable connectors e g for connection of LCU Mini GSU RS232 header for computer control ...

Page 20: ...ection Overview PRO Interface Top view Battery and engine connection Side view GSU LED s and expansion connectors 3x Status LED s 8 pin ERNI connector expansion connector e g to LCU 6 pin ERNI connector expansion connector For connection of e g Mini GSU Expansion connector GSU connector To engine battery Input for charging of engine battery Power output to engine connects to engines data connector...

Page 21: ...Power on via RC signal Besides the control function the positive supply voltage on the servo inputs THR AUX is used to power up the ECU engine This means the ECU engine will switched on as soon as the receiver is powered up or when a voltage on the pin of the servo inputs is supplied to the PRO Interface S AUX AUX auxiliary servo PWM input channel Can be used for engine ON OFF control or for contr...

Page 22: ...as two serial interfaces COM1 COM2 COM1 is the main control interface COM2 is used for special tasks as e g synchronizing two engines cross checking feature Signal level on COM1 2 is 3 3V TTL per default COM1 signals are also fed out on the GSU connector Protocols for the CAN interface as well as the serial communication protocol can be obtained from JetCat on request CAN Bus connector CAN H CAN L...

Page 23: ...4 5056 800 Wettelbrunner Straße 6 sales jetcat de 23 79282 Ballrechten Dottingen www jetcat de GERMANY Instruction manual JetCat PRO engines 1 7 V12 01V System Connection diagram with PRO Interface Connection diagram A Direct battery connection ...

Page 24: ...6 sales jetcat de 24 79282 Ballrechten Dottingen www jetcat de GERMANY Instruction manual JetCat PRO engines 1 7 V12 01V Connection diagram B Battery connection via PRO Interface This way of connecting the battery allows for easy charging of the battery via the Pro Interface ...

Page 25: ... even when the engine is running Connection of GSU There are different ways to connect a GSU to the JetCat PRO engine A GSU connects to engine sided 4 pin Molex connector A GSU can be connected to the engine sided 4 pin Molex connector via Interface adaptor This 4pin Molex connector also allows to connect e g a smoke pump or LCU It supplies switched battery power and data to the devices attached I...

Page 26: ...Runs starter motor for testing or together with Set key to direct start stop engine from GSU Starter LED yellow Ignition LED red Pump running LED red OK LED green Change value key for altering engine parameters in conjunction with the or keys 4 Hotkeys Directly enters the menu named on the corresponding blue key SET Enter parameters for several functions or together with Set key to direct start st...

Page 27: ...value is admissible to change a small arrow appears in the display before the value If the indicated value cannot be changed e g current RPM or temperature the display will indicate that the Value Item cannot be changed Description of LEDs on the GSU Please take the time to understand the table above especially the descriptions for the Select Menu and Change Value Item keys These are often used fo...

Page 28: ... ensure safe engine operation in a very high altitude band If selected there are further options to simulate dry run the engine This allows e g to test the serial communication without hot running the engine Industrial operation mode High altitude B with altitude controlled low rpm governing Same as previous mode in addition this mode will engage a governor system which will make sure that the com...

Page 29: ...al 4 14V GND DC 4 14V Connector A optional switch 20mA max When using the JetCat PRO interface this can be accomplished like this Power on via RC signal from receiver Whenever a voltage is applied to at least one of the RC PWM inputs between the and pins the engine will power up In a typical RC model configuration this will happen automatically whenever the receiver system is turned on S AUX AUX a...

Page 30: ...g keys Action Buttons to be pressed Comment Engine Start Stop Press and hold Set and additionally press Spool If engine is Off engine will be started If engine is running engine will be shut off Increase Rpm Press and hold Spool and additionally press Only if engine is running and green OK LED is on Decrease Rpm Press and hold Spool and additionally press Only if engine is running and green OK LED...

Page 31: ...is no longer available A suggested typical wiring of e g a potentiometer for engine thrust control to this input would then look like this 10 kOhm Potentiometer to airspeed sensor input 1 8 kOhm Switch engine OFF when closed 10 kOhm 5V GND 5V ECU internal GND 220 kOhm analog input 0 3 3V 3 3V Potentiometer Position Switch Position Action Resulting approx control voltage Left min position Closed En...

Page 32: ...he key scroll through the selections until AUX channel func is displayed There are three selections in the AUX channel func menu While pressing the Change Value key use the or key to scroll through these selections ON Turb Ctrl ON Aux channel enabled for engine control enabled ON Turb Ctrl OFF Aux channel enabled for speed limiter functions and or Smoker Turbine control disabled You still need to ...

Page 33: ...safe Keep it in hold mode only The auxiliary channel is always designed to stop the engine instantly if commanded to do so For spread spectrum radios there are two different ways to set the failsafe It is either accomplished by the transmitter s failsafe menu or by binding the receiver to the transmitter Refer to your transmitter s manual on how to set the failsafe To set the failsafe you must exe...

Page 34: ...ually disable the auxiliary channel in the limits menu 2 While pressing the Select Menu key on the GSU switch on the receiver engine Note Instead of the Select Menu key on the GSU the small button switch on the LED I O board may be pressed instead This key can also be used to advance through the learn R C sequence described below This feature is useful when the GSU is not available Keep in mind th...

Page 35: ... turn off and the yellow Standby LED will illuminate The GSU screen will display Throttle channel Full Power position 6 Advance the throttle stick to maximum Press Select Menu or the LED I O board button switch again to store the R C system s pulse width for the engine full power position The yellow Standby LED will turn off If your ECU is set up for single channel operation skip to instruction nu...

Page 36: ...by LED will turn off 12 The green OK LED will flash and the display will briefly show SAVING SETUP DAT and then return to the normal default RUN screen Return the throttle stick and trim to the minimum position and the auxiliary channel if used to Off and the green OK LED will turn off This completes the programming The ECU will now permanently store the data Repeating this procedure is only neces...

Page 37: ...esult gives a slight logarithmic relation between throttle command and effective engine thrust For most applications this gives a good handling of the engines response versus throttle command In case a perfect linear relation between throttle position and engine thrust is desired the Throttle curve parameter can be set to a value of 2 0 see example 2 below Examples In the following examples the tr...

Page 38: ...Y Instruction manual JetCat PRO engines 1 7 V12 01V Example 3 Parameter throttle curve set to 1 0 gives the following relation linear throttle to rpm curve Example 4 Parameter throttle curve set to 0 50 gives the following relation exponential throttle to thrust curve Example 5 Parameter throttle curve set to 15 0 gives the following relation ...

Page 39: ...il or when operating fueling defueling etc never handle near an open flame Please do not spill or empty fuel to the ground The JetCat engine can use deodorized kerosene 1 K kerosene or Jet A1 for fuel Fuel must be mixed with 3 5 synthetic engine oil Example formula 1 quart of oil in 5 gallons of fuel JetCat recommends low toxicity JetCat oil with anti static additive or Aeroshell 500 engine oil al...

Page 40: ...select menu key and select the Test Functions menu Press the Change Value Item key to run the pump If you want to change the voltage the pump runs at press either the or while pressing the Change Value Item key It is best to lower the pump voltage back down to the 0 5V default amount when finished The priming function on the PRO engines should typically only be used to fill the fuel lines after in...

Page 41: ...e wind Stop engine During the cooling process the receiver switch can be shut off at any time When the cooling process is complete the ECU will automatically shut off After each flying session defuel the tanks before storing WARNING In case of a mishap fire extinguishers should be on hand at all times JetCat recommends the CO 2 variety Powdered extinguishers will corrode the precision components i...

Page 42: ...engine to a constant speed and then starting fuel pulses into the engine until the combustion chamber rises above 120 degrees C The yellow Standby LED will illuminate when the starting motor engages Should ignition not occur after a 30 second period the process is aborted and the green OK LED will blink 3 Turbine RPM will progressively increase until achieving stable speed When the engine speed su...

Page 43: ...ction manual JetCat PRO engines 1 7 V12 01V GSU Run menu default display symbols Initial default display screen after power up After power up error condition display screen Exhaust temperature in C Battery voltage Turbine RPM In 1000 units Battery icon shown full Last Off Condition none indicated Igniting plug defective Failsafe active transmitter off ...

Page 44: ...Cat PRO engines 1 7 V12 01V Engine starting display screen Engine running display screen Flashing E EGT sensor defective Last Off Condition Low RPM shut off from previous run Exhaust temperature in C Current pump voltage Started directly from GSU explained in advanced section Current state only during startup Set RPM commanded from transmitter Actual RPM in thousands ...

Page 45: ...d by injecting kerosene into the Kerosene Igniter The pump and the internal starting fuel solenoid will begin pulsing MainF On Main fuel solenoid opens and kerosene is modulated into the engine AccelDly Delay while combustion chamber is preheating Waiting for a rise in EGT Ker Full Starting fuel solenoid closes and all the fuel is now directed to the main injectors The red Pump running LED turns o...

Page 46: ...attryLow Battery pack is dead Cell voltage is 1 0V 9 Auto Off Turbine shut down via the AutoOff sequence using the AUX channel 10 LowTemp EGT dropped below the minimum value A dislodged EGT sensor can trigger this shut down 11 HiTempOff EGT exceeded the maximum range 950 C 12 GlowPlug Defective kero glow plug 13 WatchDog ECU processor was locked out usually from static discharge or voltage spike i...

Page 47: ...river problem 30 LowRpmFB Rpm measurement subsystem error 31 Clutch Clutch of Starter motor does not disengage 32 EngMatch Not applicable for PRO engines 33 CAN Error Engine has been started up via CAN Bus but then the CAN Bus has been disconnected no commands received 34 NoRcPuls Engine has been started up via THR channel but then the THR signal has been disconnected 35 RotorBlck Rotor of engine ...

Page 48: ...battery Check ECU s battery connection Replace defective glow plug Check cable Check for proper connection from ECU to the engine ECU doesn t follow full commands from the throttle stick Programming alteration in R C transmitter Check alignment with RC Check menu Re align ECU to the R C system Turbine ignites but the start process is discontinued Air in fuel feed lines Fuel pump not running Air le...

Page 49: ...ttery was disconnected or was intermittent or if the receiver power goes lower than 3 volts In this case the data in the system would be for the previous run Sample of displayed values Tim Time 4 0 R RPM 0 S Set RPM 0 EGT Temp 0 Pmp Pump V 0 0 Sta State 0 Th Thr pulse 0 Au Aux pulse 0 Bat Batt volts 0 AirS Air Speed 0 SetS Set Air speed 0 See the Explanation for Turbine Shut Down for a description...

Page 50: ... if the AUX Switch 3 Pos switch is brought into the lower position OFF Position and the engine is running To be able to use this function it is necessary that the AUX channel is activated this is the parameter AUX channel func see below must not be adjusted to NOT USED Open if AuxSw 2 Smoke pump is activated if the AUX Switch 3 Pos switch is brought into the upper position AUTO OFF Position and th...

Page 51: ... GSU Menu Selections RUN menu MIN MAX menu RC Check menu INFO menu STATISTICS menu LIMITS menu TEST menu Selecting a Menu The corresponding buttons hot keys can directly select the Run Info MIN MAX or Limits menus An alternate method is to press and hold the Select Menu button and use the buttons for selecting Note this method is the only access to all menus Change Values Items To change an indica...

Page 52: ...his readout is usual for function check of the speed sensor Note This readout is only supported by connected airspeed sensor Set Speed Target state air speed km h This readout is for checking at the speed control mode the set target state airspeed of throttle stick Note This readout is only supported by connected airspeed sensor The Min Max Menu The Min Max menu is used primarily for diagnostics p...

Page 53: ...nal purposes only and will vary in accordance with R C input Value Explanation Throttle StickPulse Position of the throttle stick by percentage 0 100 Position units of the throttle stick AuxInp AuxPulse Position of the 3 position AUX channel by percentage 0 100 Position units of the AUX channel Aux Position Position of the AUX channel control 0 Off 1 Start Standby 2 AutoOff Fail Safe Count F Indic...

Page 54: ...splayed Starting the engine is not possible until the battery is recharged If the engine is running it will be immediately shut off to avoid a malfunction of the ECU Current voltage of the battery Displayed on bottom line Baro Temp Indicate the current barometric pressure Temperature indicator C in range of ECU Last Run Time Last engine run time Last Fuel Count Quantity of fuel consumed during the...

Page 55: ... show the results of the last flight even if the ECU is switched off in the meantime These results kept stored up to the next run of engine The Statistic Menu Value Explanation Totl Run Time Total engine running time excluding startups Runs OK Number of successful engine runs without errors Runs aborted Number of engine shut downs caused by the ECU s safety system Ignitions OK Number of successful...

Page 56: ...to get back to the common idle speed can take 2 5 seconds according the used engine type Ignition Mode Version of ignition type Kerosene N JetCat kerosene start This parameter is for informational purposes only and can t be changed Battery Type Kind of connected Battery NiCd LiPo 2Cell 7 4V LiPo3Cell 11 1V recommend by JetCat for PRO engines LiFePo 3Cell 9 9V Pb 12V lead battery Barom Auto Tune En...

Page 57: ...he maximum speed of the plane This safety function can t be disabled AUX SW0 Action Only if the parameter AUX channel func see above has been set to ON TrbCtrl OFF this option is visible In this case the AUX channel 3 step switch can be used for optional controls or can be disabled This option defines the action taken if the 3 step switch is be set to the SW0 position backwards position DISABLED N...

Page 58: ...or the 3 step switch The ECU can directly control a smoke valve or a Smoke pump for injection of smoke fluid into the exhaust blast to generate smoke You can use the shut off valve Part 61106 00 as smoke valve For smoke pump you can use any Jetcat Smoker pump AUX channel programming for smoke function 3 step switch Settings DISABLED Smoke solenoid is not used valve is constantly closed Open if Aux...

Page 59: ...Speed Signal Engine control via analogue Signal on AirSpeed input IdleThrResponse Adjustment of the throttle response acceleration by idle up to average speed Fast default setting Normal average acceleration Slow slow acceleration for excessive warm weather or for operate more than 1000m sea level FullThr Response Adjustment of the throttle response by full throttle from average speed to full Fast...

Page 60: ...rial interface Tx2 Rx2 null modem cross over connection In this configuration every engine then knows the operation state rpm thrust etc of its partner engine and vice versa Typically this is used to synchronize two engines and or to keep their thrust differentials within a preset safe margin For this option to work correctly it must be ensured that the Slave address value see below is set to diff...

Page 61: ...rottle stick to maximum THROTTLE MAX Throttle trim and throttle stick to maximum Turbine starts if the AUX switch is set to center By Single Channel Mode devoid of AUX switch the engine starts by move the throttle stick more than 95 of maximum THROTTLE MIN Throttle trim to maximum and throttle stick to minimum Turbine starts if the AUX switch is set to center By Single Channel Mode devoid of AUX s...

Page 62: ... the operation mode is not set to RC model See also page 14 OFF run cooling cooling CAN Ctrl Address CAN control offset address See CAN bus documentation CAN Report Adr CAN report offset address See CAN bus documentation CAN Bus Mode CAN 2 0A 11Bit or CAN 2 0B 29Bit CAN Bus Speed 125kHz 250kHz 500kHz 1 MBit s RS 232 Baudrate 2400 4800 9600 19200 38400 57600 115200 Slave Address Address to be used ...

Page 63: ...ge the voltage the pump runs at press either the or key while the Change Value key is pressed Depending on engine type the fuel pump can also be run reverse Negative values for the pump voltage then result in reverse operation of the pump BurnerTest Volt By pressing the Change Value key the Burner glow with the appointed voltage The left number displays the burner voltage the right shows the curre...

Page 64: ...n GSU then switch on ECU receiver Instead of Select Menu key of GSU it s possible to press the little key on the LED board The LED s indicate the following blink sequence LED Blink Sequence Standby yellow Pump running red OK green The display of GSU indicates simultaneously Release Key to Learn RC While this sequence hold the key SelectMenu don t release it Release the key if the three LED s indic...

Page 65: ...unning red OK green The display of GSU indicate simultaneously Release Key to Learn RC While this sequence keep SelectMenu button pressed don t release it After a while approx 15 seconds the LED s indicates the following blink sequence LED Blink Sequence Standby yellow Pump running red OK green While this sequence hold the key SelectMenu don t release it Release the key not before the LED s indica...

Page 66: ...tCat USB adapter USB to serial is required First you need to install the JetCat ECU V12 Updater program for Windows PC To install the software type the following in the address line of your Internet browser http www cat ing de jetcat hexfiles JetCatUpdaterV12 htm then follow installation steps After the utility program has installed you are ready for the following steps 1 Connect JetCat USB interf...

Page 67: ... 7 V12 01V Make sure that the PC has live connection to the Internet On ECU Firmware s higher or equal 12 01S also make sure the Baudrate of the serial Interface is still set to the default 9600kbit s check settings in Limits menu Now start the previously installed application JetCat Updater V12 After some seconds the following screen should come up Press button to start programming ...

Page 68: ... Wettelbrunner Straße 6 sales jetcat de 68 79282 Ballrechten Dottingen www jetcat de GERMANY Instruction manual JetCat PRO engines 1 7 V12 01V ECU will reboot and after some seconds will be ready to run Click YES Click OK Click Abort to shut down program ...

Page 69: ...onnection by JetCat c The Model Engine is operated for commercial or institutional use d The Model Engine serial number has been deliberately removed defaced or altered 7 If a problem develops during the limited warranty period the Buyer shall take the following step by step procedure a The Buyer shall ship the Model Engine prepaid and insured to JetCat b The Buyer shall include a return address d...

Page 70: ... sales jetcat de 70 79282 Ballrechten Dottingen www jetcat de GERMANY Instruction manual JetCat PRO engines 1 7 V12 01V Ingenieurbüro CAT M Zipperer GmbH Wettelbrunner Straße 6 D 79282 Ballrechten Dottingen Tel 49 0 76 34 5056 800 Fax 49 0 76 34 5056 801 Internet www jetcat de ...

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