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Wren 44 Gold Helicopter Owners Manual

Page 1

Front cover, Ian Erskines beautiful TRex 800, Wren 44Heli power, hmmmmm!

WREN 44

i

Turbine Helicopter Manual

Congratulations on your purchase of the latest version of our miniature Wren44 Helicopter
gas turbine engine. The new 44”i” means your heli engine now has the Wren kero burner

internal

to the engine, no pipes or wires to get in the way of your installation!

This manual has been prepared to help you set up and safely operate your engine in your
airframe. If you encounter any problems then please consult this list first and if you cannot
find a solution please get in touch with us. The engine is simple to prepare and use but
certain precautions must be observed for your safety and others by you – see

safety notes

.

Included in the manual is a

problem checklist

to help solve any problems you may encounter

in  operation.  Please  remember,  although  small  and  seemingly  harmless  the  engine  is
definitely  not  a  toy  and  must  be  treated  with  utmost  care  and  consideration  to  your  own
safety  and  others  around  you.  The  manual  also  contains  sections  on  the  individual
components of the installation and operation, refer to these for more detailed information.

Contents

:

3

Introduction

5

Package contents

5

Weights and measures

6

Specifications

7

Fuel consumption

8

General description

13

Ancilliaries

16

Safety notes

19

Installation

21

Autostart system

21

Radio setup

24

Failsafe function

25

Services schematic

26

Starting the engine

27

Setting a throttle curve

29

Problem checklist

31

Maintenance

32

Storage

33

Warranty

Precision CNC machined gearbox- fully 3D modelled for perfect
alignment and trouble free operation.

Too good to hide!

I’ve got my engine, which heli should I choose?

A question we are often asked is which is the ideal heli to use with the Wren 44Heli unit? It’s not an
easy  question  to  answer  as  much  depends  on  your  skill  as  a  builder  and  your  idea  of  the  perfect
machine. One fact is, the Align TRex 700 + 800 is by far the most popular choice of helicopter and is
very  easy  to  get  spares  with  endless  upgrade  opportunities.  It  is  well  supported  with  at  least  four
different  conversion  kits  available  to  convert  to  the  Wren  Heli  engine  and  lots  of  body  options  too.
Which to choose from, or to do your own is your choice.

See the Wren website for more details on the options and contacts:

www.wrenturbines.co.uk

https://www.facebook.com/pages/Wren-Turbines/154656198069224

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Содержание 44i Kerostart

Страница 1: ...gas turbine two stage engine fully internal automatic starting no gas req d kerosene fuelled precision gearbox Up to 7hp 5 2kw of output shaft power up to 20k rpm for superb performance in sport scale or 3D aerobatics Gearbox matches OS91H dimensions and accessories Many airframe conversions available ...

Страница 2: ...mponents of the installation and operation refer to these for more detailed information Contents 3 Introduction 5 Package contents 5 Weights and measures 6 Specifications 7 Fuel consumption 8 General description 13 Ancilliaries 16 Safety notes 19 Installation 21 Autostart system 21 Radio setup 24 Failsafe function 25 Services schematic 26 Starting the engine 27 Setting a throttle curve 29 Problem ...

Страница 3: ... a first model Turbines are NOT toys and anyone building or operating a turbine helicopter must have suitable skills and experience FIRE There is a small but real risk of fire when operating turbine powered models Hot kerosene ignites readily and it is almost impossible to put out the fire without a fire extinguisher Only carbon dioxide C02 extinguishers are suitable as powder types will ruin the ...

Страница 4: ...y built to withstand many hours of operation and is designed for lubrication with a fuel take off from the engine All this is automatic and the user need only put fuel clean into the tank charge battery and go fly We have tried hard to produce a compact high power to weight engine capable of filling the gap currently occupied by the noisy and smoky 90 size heli I C engines and yet keep the package...

Страница 5: ...with the c of g issues this presents Importantly the engine is already well established so you are not buying an unproven design Parts and service is readily available and the hundreds of Wren 44 Gold customers across the world will testify to the longevity and ease of use of this world beating engine Above all Be Safe and enjoy Special thanks to Lucien Gerard a good friend and colleague of all at...

Страница 6: ...ne extension cable 8 Gearbox access plug removal tool Weights Power unit complete with cables 1320g 2 9 lbs Fuel pump 88g 3oz Valves 45g 1 6oz ECU Engine Control Unit 35g 1 25oz LiPo battery 7 4v 1500mAh 80g 2 75oz Airborne weight 1570g 3 45Lbs Typical total heli weight 5 2 5 3kg 11 5Lbs Principle Measures Output shaft diameter 3 8 5 16 UNF threaded portion as per OS 91Heli Mounting dimensions gea...

Страница 7: ...rmance specifications Practical rpm range 4 000 to 18 000rpm 3 24Nm 7hp 5 3Kw engine to max 195k rpm Peak torque output 4 05Nm 13300 rpm 7 53hp 5 62Kw Peak rpm output 18 700rpm torque 2 15Nm 5 65hp 4 2Kw Gearbox ratio 2nd stage turbine to output shaft 4 285 1 Nominal recommended maximum engine rpm for normal flying 90 size heli 175 000rpm Nominal recommended maximum engine rpm for aerobatic 3D fly...

Страница 8: ...l oz to Engine RPM 0 0 40 0 80 0 120 0 160 0 5 5 1 0 0 1 3 0 1 6 0 1 8 0 1 9 5 F u e l c o n s u m p t i o n i n m l m i n Engine RPM x 1000 Fuel Consumption in ml min to Engine RPM Charts showing the fuel consumption used for the unit in fl oz min Charts showing the fuel consumption used for the unit in ml min New heli for the Wren 44 unit by Chris Bergen of Bergen Helicopters the Bergen Magnum 4...

Страница 9: ...at a higher torque level The energy given up by the gas driving the 2nd stage turbine drastically reduces the velocity of the exhaust gas with the result than only a small residual thrust remains from the exhaust outlets What happens if I stall the output shaft in a bad landing In a situation that causes the output shaft to stall the gas generator will continue to function normally with little ill...

Страница 10: ...provided for securing the shaft accessories clutch etc The gearbox housings are anodized to resist corrosion and maintain their lustre The gears are fully hardened and are able to run with long life using just a small amount of engine fuel bled off the gas generator fuel system The oil percentage in the fuel should be 5 to ensure satisfactory lubrication A hole up the middle of the tool enables th...

Страница 11: ...elopment testing It is most important the black washer supplied is fitted before the clutch unit so the clutch cannot foul the top bearing on the gearbox What is the effect of forward airspeed on the engine Once the helicopter is in the air and traveling forwards the rotor rpm will increase as its load reduces with forward speed An rpm increase of 10 15 can be expected in the air so choose a pitch...

Страница 12: ...ed with ease The mounting should support the engine at the approximate centre of gravity to withstand all normal loads such as might be subjected to during flying maneuvers Aren t gas turbines more dangerous than I C engines No Turbine fuel has a high flashpoint which means at normal ambient temperatures it is extremely difficult to ignite unlike gasoline or glow fuel which is a low vapour tempera...

Страница 13: ...on detre for this type of model flying On shutdown excess remaining fuel in the gearbox will be blown into the exhaust area and can make quite a lot of smoke but treat this as a confirmation of lube present Can I use the transmission supplied with my heli kit Yes In all cases we have looked at so far the transmission components are modelled around the standard 0 90cu in 15cc heli engine and there ...

Страница 14: ... from suffering heat related damage at least 5mm all round Fuel tanks are often increased in size from the standard supplied and these larger tanks need careful positioning and secure mounting safely clear of the engine exhaust heat This Align T Rex 700 tank was ok at the standard 630ml and was retained Virtually standard practice in heli installs is the use of Velcro type fastening to hold critic...

Страница 15: ...ery ECU Engine Control Unit The ECU and ancillaries are identical to the thrust engine variant and use similar programmed settings although a reduced maximum rpm setting is supplied which users may adjust after flight trials It is very important however that users do not change other settings from those set without referring back to Wren Turbines The ECU is the new V10 Xicoy type supplied by Gaspa...

Страница 16: ...rstage casting and attached to the engine It senses the exhaust temperature of the engine and feeds this information back to the ECU Temperature information is used to detect sufficient pre heating at the engine start phase and correct operation during normal running On shutdown the temp probe indicates to the ECU when the engine has cooled sufficiently during the cool down phase It is attached to...

Страница 17: ... order to try to use a single battery for ECU and receiver Experience shows this does not work The fuel pump needs high current pulses to operate correctly and a regulator cannot handle this Keep the batteries separate Only charge using a charger which includes a balancer to keep all cells equalized The battery includes a balancing lead you must charge through this to ensure the balancer can work ...

Страница 18: ...s possible between the fuel tank and fuel pump take great care to ensure a totally fuel tight pipe run from tank to UAT hopper and then onto the fuel pump Purge all air bubbles from the UAT or hopper before use Monitor the remaining fuel level in the UAT hopper as this is a good indication of air getting into the system If this level drops noticeably during a flight and there is still fuel remaini...

Страница 19: ...aces as the engine exhaust contains gases which can cause asphyxiation and nuisance from smells The exhaust gases are very hot over 400 C on leaving the engine and can cause burns to skin or damage to objects close to it keep exhausts clear of anything which is affected by such heat This engine must not be used near flammable gases liquid or materials Always keep a CO2 or similar fire extinguisher...

Страница 20: ... falling over someone Never allow someone to hold onto the model while you start the engine always stand well clear Accordingly NEVER ever attempt to start or run an installed heli engine in an enclosed space such as a garage workshop or small back yard Quite apart from the exhaust dangers it is not possible or safe to attempt to restrain the heli safely and if anything happens you may not be able...

Страница 21: ...eed sensor to transmit incorrect rpm information to the ECU The fuel pump should ideally be mounted with the spindle in the vertical position with the motor uppermost and the black cap downwards alternatively mount the pump horizontally Note the pump is supplied fitted with built in suppression to reduce radio frequency noise The centre of the fuel tank should be mounted laterally as near to the c...

Страница 22: ...ned so can only be used with care and in wide open spaces Suitable turbine oils are Aeroshell 500 Exxon 2380 Mobil Jet Oil Castrol TTS Certain low ash mineral based 2 cycle oils are also suitable Some of these leave a sticky gummy deposit on the bearings and inside the exhaust casing so are not good Many are synthetic and do not stay mixed to the fuel so are also not good Some sold for lawn mowers...

Страница 23: ...el injectors in the engine or blockage of the engine lubrication system and subsequent bearing damage Don t cut the fuel line between the filter and the engine as this can allow debris to enter the engine fuel system which can cause severe damage to bearings and combustion system Do not try to run the engine without rotors fitted The head can easily overspeed in a couple of seconds and the excessi...

Страница 24: ...not plugged in The fuel pump fuel and propane valves need to be connected into the socket positions shown on the ECU label Note the fuel valve label is on the side of the ECU not obvious from the front The plug polarity for the valves is not important The rpm and temperature cables from the engine should also be plugged into the ECU be careful to locate the plug brown wire to brown end of the sock...

Страница 25: ...the radio setup screen You should then see this screen On your transmitter place the throttle stick and trim to maximum and press the button to set the value into the ECU The screen will now change to Move the throttle trim or switch the engine cut switch to on and throttle stick back to zero and again press the button The display will now change to Leaving the throttle stick in the minimum positi...

Страница 26: ...total running time of the engine in minutes Tot the time in seconds of the last engine run Last the total number of starts cycles CY Use this screen to keep track of your total running time and starts Basic ECU Settings These are the initial settings used in setting up the Fadec AU107 ECU to the engine These are then optimised to suit each engine Max rpm 175 000rpm user adjustable up to a maximum ...

Страница 27: ...gine control will return PCM IPD systems The user should program the failsafe function of the radio to send a signal lower than the normal stop signal ie if normal stop is 100 then program the failsafe to output 125 When the receiver enters into failsafe mode it will issue a signal to the FADEC of 125 that is outside the valid command window between STOP 100 and Full power 100 In this case the FAD...

Страница 28: ... fuel used for the burner is very small and the fuel pump is unable to run this slowly in a reliable way so the solenoid valve supplying the burner switches on and off rapidly to help regulate the flow The longer the valve stays open the more fuel passes and this is how the ECU controls the flow The setting for this is important as too little flow and there will only be a small flame but too much ...

Страница 29: ...outlet to 4mm pump inlet tube Position Y connector close to valve inlets and connect pump outlet to Y inlet with 3mm tube If you prefer to fit a manual fuel shutoff fit it in this fuel pressure line not in the pump suction side Accessory available from Wren Connect Y outlets to each valve with 3mm tube Connect one valve output to engine fuel pipe clear with 3mm tube Connect the other valve output ...

Страница 30: ... brief them what to do and where to point the extinguisher You should be the one to decide if the extinguisher is to be used and where Position fire extinguisher if you get into trouble place trim down stick down immediately to halt the start Then energise the starter by raising the stick to full in blips to spin the engine up to clear A little tiny flame is not a concern but big ones are If you h...

Страница 31: ... is freshly charged and connected up Go into the 2nd screen of the display where you will see the battery voltage indicated confirm you have 8 2v or more to indicate a charged LiPo Go back to the opening screen on the display Confirm there is an ambient temperature reading on the HDT Starting the engine Display shows Trim Low To initiate the start raise trim to full blue led in ECU lights and scre...

Страница 32: ...tube to the gearbox in regular droplets At any time the start can be terminated by lowering stick and trim to zero The throttle stick can then be used to switch the starter to clear cool the engine If this is your first flight test ease the throttle stick forward gently at first no rapid slams to allow the clutch to start to grab and then hold while the transmission picks up Be aware of the swing ...

Страница 33: ... set up the throttle curve for our turbine helicopter we need to remember that turbine engines respond to throttle changes in a different way from their IC counterparts Whereas an IC engine will speed up and slow down relatively quickly a turbine engine takes longer to make RPM changes at the low end of the throttle range but much faster at the high end so your throttle curve needs to reflect this...

Страница 34: ...0 2000rpm is about right with 690mm main blades Less is needed with 700mm blades Try to allow the rotors to run freely with gentle pitch and plenty of rpms too much pitch and it will become twitchy and bog down Stunt modes are very similar but you need more rotor energy for the snappy manoeuvres so you might dial in a higher max rpm setting to the ECU to raise your head speed a little Raising the ...

Страница 35: ...when unloading the main rotor after a hefty dose of power so use the best you can get and set up carefully The best way to determine what is achievable is to fly the model The model may be nose heavy with the engine out front but you can offset this with the battery over the tailboom and it s not hard to get a good overall balance you can feel this when you are flying You will get a feel for what ...

Страница 36: ...ll solve your problem quickly Please use the checksheet before calling us it is there to help you to save time trouble and expense The most regular problem is failing battery voltage under load so check this first If you find something not covered then of course mail us with a description and we will try to help you info wrenturbines co uk Please note we can only help users with a Wren engine ECU ...

Страница 37: ...nected to ECU Plug in Temp reading shows lower or negative figure after ignition Thermocouple plug inserted wrong way round Ensure connector matches the label on the ECU No rpm indicated when engine is spun or shows start bad Rpm sensor plug inserted incorrectly Ensure connector matches the label on the ECU Rpm sensor lead broken chafed Contact Wren and remove source of chafing Rpm sensor malfunct...

Страница 38: ...elivered Fuel not reaching tank pick up Check clunk for blockage Ensure fuel like is not kinked Pump fault Contact Wren Burner solenoid not opening Check wiring to ECU No or little rpm increase as fuel enters Insufficient revs on starter motor Recharge ECU battery Clutch slipping Replace O ring Air in fuel line Air will disappear after several seconds Excessive flaming 20k Trim down shut off fuel ...

Страница 39: ...by a fuel air mixture fed from the front of the engine No maintenance is required The helicopter airframe rotating components must be well balanced Out of balance forces from the rotor shaft and blades can cause rapid fatigue damage to the engine and we will not warranty the engine for this Ensure the engine and transmission are aligned accurately within the frames Always report back to Wren if yo...

Страница 40: ...on the wall with its nose at the bottom as the lube can run out into the exhaust area and can cause a large cloud of smoke on the next start or a mess in your store If you absolutely have to hang the heli on a wall keep it nose up Horizontal storage is best if you have room Place a small polythene bag over the vent on the fuel tank to prevent your workshop dust getting into the fuel tank and clogg...

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