Wren Turbines MW54 Mk2 Kit Assembly And Instruction Manual Download Page 1 | Manualshive

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Summary of Contents for MW54 Mk2

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Page 2: ...a company formed by Roger Parish John Wright Mike Murphy and Terry Lee Wren Turbines Ltd was formed initially to launch the MW54 gas turbine design and to manage the design and production of cast turbine wheels and ngv s for the engine This brief has now been very much widened to incorporate the production and supply of a wide range of parts and accessories for the turbine enthusiast The company h...

Page 3: ...6 27 28 32 33 41 35 47 40 34 42 48 44 43 45 12 41 6 6 8 8 38 49 7 4 4 2 51 52 Note O ring not used M MW W5 54 4 G Ge en ne er ra al l A Ar rr ra an ng ge em me en nt t r re ef fe er r t to o i it te em m n nu um mb be er rs s t to o a ai id d i id de en nt ti if fi ic ca at ti io on n s se ee e l li is st t o on n p pa ag ge e 4 4 ...

Page 4: ...nnel 34 Gas Injector Pipe 51 Bearing Circlip 12 Shaft 35 Nozzle Guide Vane NGV 52 Circlip Shim 13 Combustion Chamber assembly 38 Pre load Tube Additional items required for completion of this kit We have tried hard to ensure the highest state of preparation for this kit enabling it to be quickly built up and run We have assumed certain basic tools are available to the constructor as would be found...

Page 5: ...uisher to hand when running flying CO2 or BCF is ideal dry powder foam or water is not recommended This engine must not be used near flammable gases liquid or materials In the UK it is suggested that you join the BMFA to take advantage of their insurance cover even if you do not wish to fly the engine Wear ear defenders when standing in close proximity of a running engine This engine must only be ...

Page 6: ...rains Ifchecking glow plugoperation keepfingers or bareskinaway from possible burnfrom theglowingelement usea metaltoolor appropriate insulation As operator it is yourresponsibility toensureany spectators especially smallchildren orhelpers arekeptwellaway fromtheengine whilst it is operating Thesafestposition tooperate theengine is directly in front The area inline and tothe rear oftheturbine is t...

Page 7: ...wpoint will note several changes have been made to facilitate ease of assembly over the original design although the basic design remains the same It is not intended to change the plan for the foreseeable future The extras listed above and the balancing options following also apply to the homebuilt version of the engine All components of the engine are available separately as spares enabling you t...

Page 8: ...ountless other builders to build and run good engines which run smoothly and quietly All that is required is a short length of tube and a hand held grinder such as the Dremel and a 30mm 1 1 4 grinding disc With option 2 for which there is an additional charge for Mk2 kit builders the turbine is factory balanced on the shaft to a high degree below 50mg mm at balance ring Due to the need to have the...

Page 9: ...CU etc and connect them all up on the bench The engine can be mounted using a suitable mounting system such as the Wren two part mount and secured firmly into place All pipe work must be suitable for kerosene and we recommend Tygon type soft tubing for tank feed to pump and 3mm Festo type fittings for the pressure side of the pump to the engine We suggest you use a good quality felt filter clunk f...

Page 10: ...0 000 Self sustain rpm 28 000 Max case pressure 1 65 Bar 24 5psi Idle case pressure 0 07 Bar 1psi Fuel consumption 200ml min Mk2 210ml min Mk3 approx max thrust 50ml min idle thrust Fuel Kerosene or Jet A1 with 2 5 oil 40 1 mix Fuel pressure max thrust 2 6 Bar 38psi Fuel required for average 6 min flight 1200ml 40oz Oil mix required 25ml per 1Ltr fuel 1oz per 40oz fuel Oil Turbine oil such as Exxo...

Page 11: ...into correct hole in Diffuser and position feed end at cut out Step 4 Shaft Tunnel Insert front bearing this way round printed arrow points out Step 5 Shaft Tunnel Check thick side of inner ring faces out other side is thin Step 6 Shaft Tunnel Fit Shaft Tunnel into rear of Diffuser and align fixing holes Note Tunnel is supplied as a complete assembly Step 7 Shaft Seal Shaft Tunnel Align Shaft Seal...

Page 12: ...tep 12 Aligning Case Front Holding the shaft in against the pre load spring insert the front spacer small diameter downwards Do not press hard as you might pop the bearing apart Step 13 Aligning Case Front Slide on Compressor and secure with Compressor Nut note it has a left hand thread Step 14 Aligning Case Front Fit the Intake Cone onto Case Front be careful to align the service cut outs correct...

Page 13: ...ont from the inside Step 19 Fitting Chamber stand offs Slip one of the short metal tubes onto the screw holding the screw in place with the hex key Step 20 Fitting Chamber stand offs Using a pair of side cutter pliers crimp the tube onto the screw to retain it Step 21 Fitting Chamber stand offs Crimped tube shown here Repeat for remaining two tubes Step 22 Fitting Combustion Chamber Align and inse...

Page 14: ... now be eased onto the end of the Shaft Tunnel and Combustion Chamber Step 29 Preparing to fit case Apply a small smear of silicon grease or petroleum jelly to the O ring to help it slide into the Outer Case Step 30 Making up Mk2 Outer Case Find the WREN mark on the case this indicates front end top Now rotate it 180 and locate the hole at the bottom of the rear end the hole by the seam Step 31 Ma...

Page 15: ...nto place by loosening each in turn as before Step 36 Sealing Mk2 Case Rear Seal in place with a small fillet of high temperature sealing compound Holts Firegum shown here Step 37 Sealing Mk2 case seam Finally finish off with a light smear along the welded seam inside the case Step 38 Fitting Mk2 case Align the two glowplug holes with those on the Combustion Chamber and gently slide case on Step 3...

Page 16: ...e Mk3 case is installed in the same way after carefully pressing on pull NGV into position and secure with eight M3 x 4 screws as before Step 45 Fitting Outer Case Mk3 Fit the six Outer Case securing screws once NGV has been secured Step 46 Preparing the glow element Prepare the glow plug by carefully teasing out plug element with a pin Make the bend gently to not break the fine wire Step 47 Fitti...

Page 17: ... fixing holes vacant this is to allow fitting of the RPM pickup Pic shows earlier style of connectors Step 52 Prepping the RPM sensor Press the brass tube spaces into the rubber grommets on the sensor Wire should protrude at r h side Step 53 Fitting RPM sensor Fit the RPM sensor to the two vacant holes above the Inlet using the two M2 5 x 20mm cap screws Step 54 Fitting lube feed pipe The Lube fee...

Page 18: ...s 280BB with Wren miniature clutch Step 58 Assembling pod starter Solder suppressor capacitors to the motor brush terminals one each 47nF from brush to case and one 100nF brush to brush Step 59 Wiring pod starter Thread starter wire through cap and solder to terminals check polarity is correct using battery Step 60 Fit starter pod to cowl Align pod legs to cowl and insert 3 off M2 5 x 5 screws usi...

Page 19: ...eration be connecting switch start lead and battery Action should be clean and snappy Ease pod position if clutch sticks at all Step 65 Completing pod starter Once correct operation is confirmed the black cap can be eased into place A filter screen cover can also be fitted to engine Provides mounting for on board starter Suits direct switching 7 2V or Autostart ECU Pipes exit at bottom Fit as for ...

Page 20: ...to the gas supply port on the engine Connect ECU signal lead to receiver and set up radio as described in next section Secure fuel tank and connect to fuel pump A fuel on off valve may be connected in the fuel pressure line The ECU readout should also be secured sticky pads are suitable for quick testing Once secured it can be plugged in and you are ready Connect a 6 cell charged nicad to the hand...

Page 21: ...then controlled by the switch Note the switch must short the motor on release of the switch to snap the starter clutch out of engagement The same setup can also be used for the FOD screen starter mounting This setup is usually utilised for helicopter and turbo prop installations Note picture shows Mk2 version Mk3 version uses same setup and accessories NB Indicates accessories available from Wren ...

Page 22: ...e Optional Optional 2 volt glow battery Switch Starter battery On board or Hand starter Starter switch Manual start ecu schematic hand starter Manual start ecu switched pod starter Eco ECU schematic Engine lubrication Eco E C U Fuel pump Rx Batt RPM pickup Gas tap Gas Quick release coupling Filter Fuel tank Shut off tap Glow plug Fuel to engine Temp probe Optional Optional 2 volt glow battery Swit...

Page 23: ...tructions Jun 2004 Page 23 Autostart ecu schematic Fuel to engine Temp probe Engine lubrication Fuel Solenoid Gas feed in Gas Solenoid E C U Fuel pump Rx Batt RPM pickup Gas tap Gas Quick release coupling Filter Fuel tank Shut off tap Glow plug Starter motor ...

Page 24: ... need securing or tying back so nothing is allowed to roll about or more importantly get sucked into the engine Ensure nothing flammable fuel or gas is located in the plane of ie in line with the turbine wheel as in the unlikely event of a blade failure these would be at risk so better to play safe If you wish to perform thrust tests as well as general start and running practice then your test sta...

Page 25: ...ommended A tank capacity of 1Ltr should be sufficient for a run of 6 8minutes Oil should be added to the fuel to a ratio of 3 oil to 100 fuel that s 33 1 or 30cc of oil to 1Ltr of fuel Use oil to grade TCW3 or alternatively turbine oil can be used If you opt for turbine oil be careful not to breathe the fumes as they can be harmful to health A propane butane or pure propane bottle is connected to ...

Page 26: ...t too fast or you will blow out the gas say about 8 10 000rpm You should see the ECU showing a temperature rise and once over 100 C it will then start to ramp up the fuel pump and fuel should then start flowing to the engine Keep blipping until you hear the engine note change to indicate the fuel has arrived at the engine and it will start to accelerate quickly Switch the starter full on at this t...

Page 27: ...he rotor is out of balance If the engine makes a high pitch whistle whilst running carefully touch the outer case with the metal part of a screwdriver and feel the shank with your fingers Again if you feel a vibration the rotor is out of balance Any penetrating noise that appears greater at the front of the engine is likely to be a compressor rub Stop the engine and check immediately this fault ne...

Page 28: ...adio set up not completed correctly reads StickLo Temp reading incorrect or missing Thermocouple not connected to ECU ECU problem Thermocouple failure Temp reading shows lower or Thermocouple plug inserted wrong way round minus figure when heated No rpm indicated when engine is Rpm sensor plug inserted incorrectly spun Rpm sensor lead broken chafed Rpm sensor malfunction return to dealer ECU probl...

Page 29: ... open open fully Pump battery low recharge Air in fuel line air will disappear after several seconds Tank feed problem see above Excessive flaming Trim down shut off fuel gas immediately Residual fuel in engine spin engine dry for 10 seconds to clear There was air in fuel system restart Insufficient revs on starter recharge starter battery Starter removed too soon hold on until 32 000rpm minimum S...

Page 30: ...ted to be minimal and is likely to be at its highest whenever the engine is reassembled and first run as the bearings have to settle back in onto their seating For this reason it is advised to not do this unless any unusual noises are noted in which case immediate investigation is required Do however check the various screws and fittings for tightness and note any apparent leaks The O ring seal at...

Page 31: ... the aircraft unfortunately straight into the engine intake At Wren we had an engine brought in which refused to start On investigation it was found to be full of sponge which had been used in the model to restrain batteries This had become detached and sucked into the engine and shredded on its way in completely blocking the diffuser and preventing air getting through the engine It can and has ha...

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