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Range Testing: Engine On
Preparation: Remove the main and tail rotor blades from your Ergo Z230 before
initial Engine On Range Tests are performed.
PCM Fail Safe Preparation
It is suggested that for these initial Engine On range tests, your PCM Fail Safe
positions be set so that the engine throttle will return to an idle position if a fail
safe situation occurs. Please refer to your specific radio system’s instructions for
information on PCM Fail Safe adjustment.
Range Testing: Engine On
Turn on your radio system first and verify that the PCM setting brings the throttle
to the idle position before starting the Zenoah G23 engine.
Start the engine and perform an antenna down range test using the same
positioning/path as the previous Engine Off Range Test.
Before beginning the walk, set the throttle stick to approximately 1/3 throttle so
that when you reach the end of the range test and the system goes into PCM fail
safe, you will hear the engine change from 1/3 throttle to idle. This will
accurately establish the engine on range test distance. To verify that the Engine
On Range Test is acceptable, compare the Engine Off and Engine On Range Tests
maximum distances. If acceptable, the Engine On Range Test should be no more
than 20% less than the Engine On Range Test. Due to the additional RF
interference generated by the Zenoah G23 engine, it is normal to note this slight
reduction in range. If your range test comparison shows greater than a 20% loss
of range, recheck your engine and coil installation to make certain that the engine
and coil are properly grounded and retest. If the same results are achieved,
contact your radio manufacturer for further instructions.
Engine Tuning/Initial Test Flights
Once the Engine On Range Tests have been performed and approved, it is now
time to reattach the main and tail rotor blades and begin initial test flights and
tuning.
As gasoline engines operate and tune differently than glow engines, it may take
some time to become familiar and comfortable with the tuning procedures of the
Zenoah G23.
Although the Zenoah G23 is a 2 cycle engine, the smoke levels emitted by the
exhaust are much less than with most common 2 cycle glow engine. Therefore, it
is nearly impossible to tune the engine by the volume of smoke it produces.
Another factor in tuning is the increased operating temperatures that a gasoline
engine operates, as compared to a glow engine, and also the amount of time it
takes for the Zenoah G23 to reach its constant operating temperature.
Engine Tuning: Hover
In most cases, the Zenoah G23 engine will need to operate for between 2-4
minutes in an initial Hover before the final operating temperature is achieved.
During this time, the Zenoah G23 needs to be adjusted so that it starts off in a
“rich” condition, since as the engine temperature increases, the fuel mixture
setting will continue to “lean” and will not stabilize until the engine operating
temperature also stabilizes.
Given this information, a properly tuned Zenoah G23 engine will actually start
off “rich” and slowly transition to the correct fuel mixture after 2-4 minutes of
sustained hovering. How do you tell if the fuel mixture is set properly? Here’s
how:
If the Zenoah G23 is adjusted to a “rich” condition, the engine will occasionally
sound as if it has a “miss.” This “miss” indicates that the fuel mixture is rich and
the engine is going into a “4 cycle” condition momentarily. A properly-tuned
Zenoah will “4 cycle’ during the initial 2-4 minutes of flight until the engine
reaches the final operating temperature. Once this temperature is achieved, the
engine should run smoothly with no “miss” or “4 cycle”. If the engine continues
to 4 cycle after 4 minutes, land the helicopter and turn the low speed needle in
1/16th of a turn and retest. Continue this until smooth operation is achieved. As
mentioned previously, the low speed needle valve of the carburetor sets the fuel
mixture for hover and below. Adjustment of the high speed needle valve will not
remove the “4 cycle” condition if the low speed needle valve is adjusted to rich.
Zenoah G23 Engine Break In
Once the low speed needle valve has been adjusted correctly, it is suggested that
one full tank of fuel be “hovered” through the engine to insure proper piston ring
seating before initial High Power Forward Test Flights.
Engine Tuning: Forward Flight
As mentioned previously, since the volume of smoke created by the Zenoah G23
is much less than a standard 2 cycle “glow” engine, forward flight tuning relies
more on “power output’ than smoke or engine sound.
To set the high speed needle valve, transition into forward flight to a safe altitude.
Next, while in forward flight, move the throttle stick to and sustain full power. If
rotor RPM appears low, either reduce main rotor blade pitch (not below 9
degrees), or lean the high speed needle valve slightly. Repeat this procedure until
the proper RPM and power output is established.
Once this has been achieved, continue to fly the Ergo Z230 in forward flight
while monitoring the engines power output levels. If during the flight the engine
begins to loose power or “sag”, land the model immediately and richen the high
speed needle valve. Continue this procedure until the engine runs consistently,
with no loss of power.
Warning: Use caution during these tests as if the Zenoah G23 is set to an extreme
lean position, it is possible for the engine to stop abruptly at high power with
little or no warning. Also, an extreme “lean” condition such as this can cause
severe damage to the internal components of the engine due to excessive heat and
lack of lubrication.
ZENOAH G23 ENGINE INITIAL START UP AND TUNING/RANGE TESTING (continued)
Summary of Contents for Ergo Z230
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