Turbine engine user manual. ATJ SV series turbine

Welcome! Congratulations on the purchase of your new ATJ gas turbine engine. ATJ Turbines are dedicated to the design and production of engines to the highest standards of quality and reliability that is very latest next generation engine designs. ATJ Turbine is our gas turbine engine product line brand name. Leading Jet Turbine Co., Ltd. Is our company name. PLEASE READ! The Leading Jet Turbine Co., Ltd responsibility is limited exclusively to the repair of the engine and accessories which are outlined in the conditions of warranty. Please read these instructions carefully after receiving your turbine and before the first operations. Keep this manual for later consultation and check for the latest update on our web site. Customer satisfaction is important to Leading Jet Turbine Co., Ltd. Technical support or your local dealer Leading Jet Turbine Co., Ltd Web site: www.atj.com.tw Legal and Disclaimer All contents are copyright by Leading Jet Turbine Co., Ltd All rights reserved. This manual, the pictures and data are property of Leading Jet Turbine Co., Ltd and cannot be used or reproduced in any way without written permission from Leading Jet Turbine Co., Ltd. Disclaimer The ATJ Turbine engine is a sophisticated piece of machinery. Care should be taken at all times when using the engine. It should only be operated by those with the appropriate skills and knowledge to do so. This engine is not a toy. Incorrect operation or misuse can cause damage to property and bodily harm operators, spectators and animals. ATJ Turbines accepts no liability for any kind of damage which may occur. ATJ Turbines assumes no responsibility for any errors contained in this document and is not liable for any damages resulting from such errors. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 2

Warranty The warranty period for the ATJ Turbine engine is 3 year and electronic parts 1 year from the date of purchase. 25hr service charge contact us for quotation.warranty is valid solely for the original owner and is non transferable upon resale. Warranty is limited to manufacturing and material defects only. Damage or defective operation covered under the warranty terms will be repaired and tested at no cost the original owner (other than postage and packaging). Repairs not covered under the terms of warranty will be carried out by ATJ Turbine, or their appointed agents after agreement of costs. Before returning the engine or ancillary equipment for service of repair, please contact ATJ Turbines or a ATJ Turbines approved agent to agree action and costs. Please do not disassemble this engine. You will breach your warranty agreement and you will find it is a precision assembly which you will be unlikely to re-assemble without considerable difficulty and specialist equipment. Simply slackening the spinner nut of the rotor will immediately lose the delicate balance condition, without which the engine may not run without damage to its rotating assembly. You are permitted to access the fuel and gas connections under the black cover in event of replacement of the fuel or gas pipes. Access may also be gained to the magnetic rpm pickup if repair or replacement is required. You may not dismantle the engine further. Any further investigation may only be undertaken by ATJ Turbines. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 3

Warranty contents This warranty is void if any one or more of the following conditions applies. In such a case ATJ Turbines will accept no responsibility for personal damages, loss or any other consequences caused by the ATJ turbine engines 1. The engine cover is dismantled except for the removal of the front cover to access service connections and the speed sensor. 2. The engine has been subject to any form of operation whilst containing incorrect fuel, oil, or fuel/oil mix. 3. The engine is crash damaged 4. Unauthorized maintenance or modifications have been made to any part of the product 5. Parts have been damaged by ingestion of foreign objects (e.g. wires, sand, water etc). 6. The engine has been operated incorrectly. 7. The product has been misused, neglected or inadequately maintained. 8. Damage to the engine where blockages in the fuel system have occurred by unfiltered or contaminated fuel. 9. Don't use the engine cables of other brands on ATJ turbine engine,it s damaged ECU and RPM sensor no warranty Terms and conditions may change without notice. Buyers are to accept the latest terms and conditions with no exceptions, which is to be found at:www.atj.com.tw LEADING JET TURBINE Co., Ltd. ATJ TURBINES 4

Contents Contents list Safety Notes...6 Warning...7 Before starting the engine...8 After shutting down the engine...8 Installation turbine engine...9 Turbine engine connection... 10 Aligning transmitter with ECU ( Learn R/C )... 16 First Turbine Operations (starting engine)... 20 Using and Programming the ECU... 22 Fuel tank ( fuel system )... 26 Battery & by pass nozzle extension... 28 Maintenance and repair work... 29 List of ECU STATUS message codes... 30 List of ECU Warning message codes... 31 ATJ Turbine Log... 32 LEADING JET TURBINE Co., Ltd. ATJ TURBINES 5

Safety Notes Please remember the turbine engine is not a toy and has the potential to cause bodily harm to you and others if misused. The following guidelines should be read carefully and adhered to. 1. Always keep a CO2 or similar fire extinguisher close when starting and operating the engine 2. Always protect eyes and ears during the starting procedure. 3. Be aware of the extreme intake suction hazard, we advise the use of a suitable commercial wire mesh Foreign Object Damage guard to protect the engine intake. Ensure you have no loose items of clothing (ties, etc.) or equipment which can readily be sucked into the engine intake, even from adjacent to the engine. 4. Always operate your engine in open air away from confined spaces as the engine exhaust contains gases which can cause asphyxiation and nuisance smells. 5. Do not touch the engine whilst it is running. Turbines rotate at a very high rpm and the engine casing and exhaust can reach very high temperatures. Ensure anything affected by heat is kept well clear of the engine and exhaust during operation. 6. Never use the engine near to sources of flammable gases, liquids or materials. 7. Keep unauthorized persons, spectators, children and animals well away from the starting area (at least 30ft or 10 metre away). 8. Always handle turbine fuel and oil with care as they are highly flammable. Store them in appropriate label containers. Never dispose inappropriately. We recommend the use of suitable disposable protective gloves for the mixing of turbine oil/fuel. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 6

Warning Higher loads occur when driving an R/C aircraft model with a turbine engines compared to equally powerful drives like propellers or impellers. This is a result of considerably higher air speeds caused by jet propulsion. Maximum speeds under jet propulsion can exceed 200 mph, depending on the model. We would like to remind you that the AMA has issued strict rules regarding maximum speed for operating turbine powered RC models. Please refer to the AMA regulations from the link posted above. During installation, seal the intake and nozzle, as well as kerosene joints to keep dust and debris out of the engine. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 7

Before starting the engine 1. Fuel and fuel tank, pump, shut-off kerosene valves, all cables and turbine engine must be checked for correct. 2. All loose parts in the intake area must be fixed in a way they can never be sucked in. Loose parts or dirt can damage the turbine engine. We recommend use of a FOD screen. 3. Have a fire extinguisher (CO2) within reach! 4. Use only Jet A-1 or kerosene or Diesel with a 5% ratio of oil ( fully Synthetic turbine oil). We recommend Mobil Jet Oil II 5. The Fuel system must not be leaking. 6. Start engine must be into the wind. always keep the turbine with the nozzle facing downwards right before starting. 7. Charge engine battery. After shutting down the engine Move jet model with the nose facing the wind. Wait until the cooling down process is completed, it will take few minutes depending on the outside air temperature. The cooling process after engine shut down. During this process, the electric power supply of the receiver and the ECU must not be turned off. Do not touch the turbine during the cool-down because the danger of burning still exists. All tube connections must be inspected for leakage after each flight. The fuel tanks must be emptied in case of extreme outside air temperatures or when there is no further operations planned for the day (danger of explosion!). LEADING JET TURBINE Co., Ltd. ATJ TURBINES 8

Installation turbine engine 1. The engine should be mounted using the ATJ engine mount or an approved equivalent. The securing strap should be tightened gently so as not to mark the engine casing. 2. Fuel FASTO fitting should be routed similarly clear of the intake. 3. The fuel pump should be mounted at least 300mm away from the front of the engine. The pump can emit electrical pulses that cause the speed sensor to transmit incorrect rpm information to the ECU. The fuel pump should be mounted with the spindle in the vertical position with the motor uppermost. In the event of any fuel seeping from the pump this will not pass through the electric motor. Note the pump is supplied fitted with built in suppression to reduce radio frequency noise. 4. The centre of the fuel tank should be mounted laterally, as near to the centre of gravity (CG) of the model as possible. This will minimize the CG shift as the fuel is used during flight. 5. Any air ducting to the inlet of the engine must have a minimum area of 95mm square. 6. If an extended exhaust duct is required, it should be approved by ATJ turbine. We have found that an exhaust over 90 mm diameter gives optimum engine performance, base on turbine engine thrust and size. 7. Extreme care should be exercised to ensure that no foreign object, loose parts of the model. Or debris is allowed to enter the compartment where the engine is installed. We recommend testing the engine on a test stand prior airframe installation. You should have a clear idea of how to arrange the components needed to run the engine. The main issue is the fuel tank, you will need to arrange the CG in the centre of the tank and adjust the receiver and ECU batteries to achieve the correct location. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 9

Turbine engine connection Over all connection 1. Turbine engine core 3 port connector A: RJ45 8pin for EGT & RPM signal with Valves power control B: 3 wire power cable for starter and preheat burner power control C: 4mm FASTO fast fitting for main fuel in to the engine 2. Fuel pump power cable one side to ECU (green 6pin ) the other side to battery (T connector), Fuel tube 4mm to engine, fuel filter,fuel tank, fuel hand cut off valve. 3. GSU JR connector to ECU LEADING JET TURBINE Co., Ltd. ATJ TURBINES 10

Fuel pump connection 1. Use good quality 4mm fuel tube for turbine engines. 2. Install fuel filter between fuel pump and fuel tank (low presser side). 3. Change fuel tube every year and keep the fuel tube soft no leaking. 4. Always keep the fuel filter clean. 5. Install hand cut off valve between fuel filter and air trap tank. (You feed fuel from carry tank into aircraft main fuel tank, close this valve stop fuel into the engine) LEADING JET TURBINE Co., Ltd. ATJ TURBINES 11

Turbine signal cable and power cable connection 1. 3 wire power cable with 6 ping connector to the engine 2. RJ45 8ping plug for signal and electronic valves control *** Important note *** Don't use the engine cables of other brands on ATJ turbine engine,it s damaged ECU and RPM sensor no warranty LEADING JET TURBINE Co., Ltd. ATJ TURBINES 12

Signal cable connection 1. 4 pin connector have GV symbol aim at ECU Gas valve 2. 6 pin connector have EGT symbol aim at ECU Thermocouple 3. The Signal cable connection very important, double check connection before running the turbine engine. *** Important note *** Don't use the engine cables of other brands on ATJ turbine engine,it s damaged ECU and RPM sensor no warranty LEADING JET TURBINE Co., Ltd. ATJ TURBINES 13

Throttle signal JR cable connection (to ECU Throttle input ) GSU or System Analyzer connection (to ECU Data T/PC) LEADING JET TURBINE Co., Ltd. ATJ TURBINES 14

Engine 3 wire power cable connection Main power cable and pump cable connection LEADING JET TURBINE Co., Ltd. ATJ TURBINES 15

Aligning transmitter with ECU ( Learn R/C ) RE: below show old type GSU or new type System Analyzer the same function Turn on the 7.4V main engine battery power, then Transmitter and Receiver power, you can view this screen changes to the first main monitor each 2 seconds pressing the second button from the left (Menu Up) the second informative screen is shown. In the first line you have the measure of the pulse width received from your RC system, and the relative stick position. Second line is show the voltage of the battery and the software version. If the current drawn from the battery is higher than 0,5A, then the ECU display the battery voltage and the battery current in Amp. Next menu let you to choose in four submenus, selected by pressing the button under of each option. Start: Jump to the parameters used on startup Info: Information and test menus Radio: Adjust the radio throws Run: Set the parameters used during engine run. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 16

Turn on the transmitter and receiver. Using the menu up and (-) buttons move to the Radio menu. First screen will be this one: If you are sure that you want to modify the radio settings then press the right hand button (+) and the screen will change to: On your transmitter, raise the throttle stick and trim to full. Ensure stick is firmly against the stop. Now holding the stick against the stop, press the right button (+) to set the value into the ECU. IMPORTANT NOTE: Pressing any other button the setting WILL NOT be stored. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 17

The screen will now change to: Move the trim (or switch the engine cut switch to on) and throttle stick back to zero and again press the right hand button (+). The display will now change to: Leaving the throttle stick in the minimum position, raise the throttle trim to the full up position or switch Engine Cut switch to off, and again press the + button. The ECU will store the current position as IDLE. If you have done all steps correctly the green LED located directly above the data terminal socket will light up in the ECU when the Idle command. (Trim and throttle stick set to idle positions on the transmitter). LEADING JET TURBINE Co., Ltd. ATJ TURBINES 18

Lower your throttle trim and the green LED will go out indicating correct reading of The transmitter engine shut off signal by the ECU. On rare occasions, usually when using a Futaba transmitter, it has been found that the throttle channel sense of movement may require reversing (Servo reverse) and repeat the transmitter alignment. Correct reading of throttle % by the ECU can be verified in the second screen, percentage of the throttle position is shown on, 0% in the position of engine stop (trim and stick down), 100% with stick/trim full up and between 10% and 30% at idle. This now completes your radio setup and should only need doing again if the radio settings in the TX are changed. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 19

First Turbine Operations (starting engine) Initial steps 1. Fill the fuel tank with jet turbine fuel, include 5% turbine oil mix. 2. Make sure the tank breather is open, no bubbles in fuel system. 3. Filter your fuel when filling up using a line filter on your carry fuel tank. 4. Make sure that both the ECU battery and the receiver battery are charged and in good conditions. 5. Test your remote control range with and without the ECU turned on. 6. Always place the jet aircraft with the nose into the wind and make sure that the jet blast will not be set in the direction of persons or equipment. Prime the Fuel Pump feed the fuel into engine first time.( page 21 ) Turn the transmitter and the receiver ON. Turn the engine main power ON Set the throttle stick down and the trim up. Idle - Confirm that the LED in the ECU is illuminated and the screen shows "Ready" -! Move the stick to 100% and then back to idle again. Do not leave the stick at 100% more than 3 seconds. The ECU will automatically check the glow plug circuit and if OK energize it, wait 10 second then apply power to the starter and open the gas solenoid. In the screen of the ECU it will show the word "Ignition" The gas will ignite. You will hear a "flame sound" confirming this, the temperature indicator in the screen of the ECU will begin to up. When the ECU detects an increase in temperature of 80~100ºC from the temperature read at the moment the start is initiated, the screen will change to "preheating". The fuel pump will begin to operate and power to the glow plug will be disconnected. Next the screen will change to "Fuel ramp". In this phase the ECU will be gradually increasing the starter power and fuel flow. When 18.000 RPM is reached the ECU will automatically disconnect power to both the starter and LEADING JET TURBINE Co., Ltd. ATJ TURBINES 20

gas solenoid valve. When the rotor speed reaches idle, the screen will change to "running" and the engine speed stabilized. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 21

Using and Programming the ECU All the programming and measures are done trough the data terminal. Once the FADEC is programmed, it is not necessary its use and it is not recommendable to leave it inside the airplane to minimize the risk of interferences. The data terminal has a 16 character LCD screen and 4 buttons. The first two buttons on the left side allow moving to the menus, and the two buttons on the right side allow changing the data. Main screen, as shown in the picture, give to the user that main readings from the engine. These are the FADEC status, the EGT (temperature), RPM and pump power. In the case of an error, this screen changes to the error screen each 2 seconds Pressing the second button from the left (Menu Up) the second informative screen is shown. In the first line you have the measure of the pulse width received from your RC system, and the relative stick position. Second line shows the voltage of the battery and the software version. If the current drawn from the battery is higher than 0,5A, then the FADEC display the battery voltage and the battery current in Amperes. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 22

Next menu let you to choose in four submenus, selected by pressing the button under of each option. Start: Jump to the parameters used on startup Info: Information and test menus Radio: Adjust the radio throws Run: Set the parameters used during engine run. Throttle curves FULL EXPO: Mean linear RPM, it is the default setting and the mode used for all previous software versions. Thrust develops exponentially, and it is the recommended curve for big engines or/and high thrust/weight ratio planes, as it ease the control in low power used during taxi. HALF EXPO: An intermediate setting between the other two modes. Stick position LINEAR: Mean that the thrust develop linearly with the throttle setting. Could cause difficult taxi, as it would be difficult to fine adjust the power at low setting. MODE 0% (Idle) 25% 50% 75% 100% FULL EXPO Idle thrust 6% 25% 56% 100% HALF EXPO Idle thrust 16% 38% 66% 100% LINEAR Idle thrust 25% 50% 75% 100% Throttle curves can be changed while the engine running, so you can leave the throttle at a given position and switch between the curves to see the LEADING JET TURBINE Co., Ltd. ATJ TURBINES 23

difference. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 24

Test menus The Fadec provides several menus to test the starter motor, glow plug, pump and solenoid valves. These test screens are only available when the Fadec is on Trim Low status, that is to say, recently powered up and receiving a STOP signal from the TX. Pressing the (-) button (under the ON reading on the screen) will energize the selected device and pressing (+) will shut down. Special care should be taken when testing the pump, as it is possible that some fuel be pumped in to the engine, flooding it, and causing a hot start on next startup RUN menus: On these submenus the parameters used for the engine during normal run can be modified. Note that some of these menus could not be available in your unit if your ECU belong to a production engine where the engine manufacturer have set these values at factory and restricted to the users to modify them. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 25

Fuel tank ( fuel system ) Use high quality air trap tank Air trap tank is recommended, between the main fuel tank and the engine. Always use a filter between the fuel pump and fuel tank. Engine fuel and oil ATJ turbine engines use only Jet A-1 or kerosene or Diesel Mixed with 5% ratio of oil ( Fully Synthetic turbine oil). About turbine jet oil we recommend Mobil Jet Oil II, BP 2380 LEADING JET TURBINE Co., Ltd. ATJ TURBINES 26

Main Fuel tank tube Main fuel tank breath tube recommend inside diameter 4~5mm Main fuel tank brass tube recommend inside diameter 4~5mm Prime the Fuel Pump To prime fuel pump and fuel lines or for fuel pump test purposes, it is run fuel pump manually to feed fuel into the turbine engine. For this operation, go to the INFO menu and use the Test selection, Prime pump. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 27

Battery & by pass nozzle extension 1. Turbine engine main battery Xicoy V10 ECU only accept 7.2V Lipo battery, full charged 8.4V We recommend use over 5000 mah and over 15C good quality Lipo battery. 2. By pass nozzle extension The entry diameter of the extension pipe should be around 90~100mm while the end diameter should measure around 95mm. The smaller nozzle extension it s loss of power. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 28

Maintenance and repair work ATJ turbines only need little maintenance under normal operating conditions. Some points must be considered to guarantee faultless operations of the engine. This includes regular cleaning and inspection. Dirt and grease deposit can cause slippage of the starter clutch. If this happens, clean the O-ring and the compressor nut with a degreaser like alcohol. Fuel tube and filter between the pump and the turbine should be cleaned every 5 hours of operation. Do this very carefully and make sure that no dirt will enter the fuel supply tube. Destruction of the turbine could result! Make sure fuel system no leaking. Cover the intake and nozzle areas when the turbine is not in use. Keep the turbine in a dry and dust-free environment when it is not used for a longer time. Check the battery condition regularly. Your turbine maintenance interval is at 25 hours. After this time as well as after a special event (crash, FOD.. etc.) the turbine should be returned to the factory service. Repair and maintenance work which include the disassembly of the turbine must only be performed by professional personnel. Please contact Leading Jet Turbine Co., Ltd with all service related questions. Maintenance and repair work performed by non authorized personnel will void the warranty. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 29

List of ECU STATUS message codes Here is a list of possible messages shown on the data terminal screen and their meaning. Trim Low: Indicates that the signal received from the transmitter corresponds to the lowered trim, that is to say, engine OFF. Ready: Indicates that the engine is ready for starting, and that the transmitter signal corresponds to IDLE, (green LED lit) Stick Lo!: This indicates that the throttle stick is in a position above IDLE, the engine will not start with the stick in this position. Burner on : Verification of fuel ignition burner. Start On: Test of the starter Ignition: Gas ignition phase. Preheat: Phase of heating of the combustion chamber after detecting the gas or fuel ignition. Fuel Ramp: Phase of acceleration until speed of IDLE. Running: Engine working correctly, pilot have full control of engine power. Stop: Engine off. Cooling: Starter operating to cool the engine. Glow Bad: Defective or disconnected glow plug or fuel burner. Start Bad: Defective starter, insufficient RPM reached during start, RPM sensor failure. Low RPM: Engine speed below the minimum. High Temp: Excessive temperature Flame Out: Exhaust GAS Temperature below the minimum. LEADING JET TURBINE Co., Ltd. ATJ TURBINES 30

List of ECU Warning message codes RC SIGNAL LOST/INCORRECT: The signal received from the RX is wrong (outside calibration margin) or absent. PUMP LIMIT REACHED: The ECU have increased the pump power up to the value set on the Pump Limit parameter, but the engine hasn t arrived to full power. Causes could be flat battery, fuel restriction or anything that can cause a reduction in the fuel flow. xxxx OVERLOAD: A excessive current is detected flowing to the specified output. Diagnoses: During engine operation the FADEC measures and stores all the engine operating parameters recorded during the last the 51 minutes of operation. These measures can be downloaded later to a PC to study the behavior of the engine in flight and to diagnose any possible problems. Also, after each cycle of operation, the FADEC stores the last cause of shut down and the value of RPM, temperature and pump power at the moment of shutdown. In order to access these measures, it is necessary to reinitialize the FADEC (shut down and power-up). Set the trim down (Trim Low) and push the left button on the display. The FADEC will show the cause of shutdown and the measured values at the moment of shut down. These are as follows: Diagnosis messages: User Off: The engine has been shut down because it has received the shut down command from the transmitter. Fail Safe: The engine has been shut down because of loss of the control signal from the transmitter. Once the Ecu detects a loss or invalid RC signal for over 0,5s, it sets engine power to idle, and if after another 1,5seconds a valid signal is still not received the engine is shut down. Speed Low: The engine has been shut down because the RPM has dropped below a minimum. Cause could be lack of fuel, air bubbles, problem with the batteries, or defective RPM sensor. Flame Out: The engine has been shut down because the temperature has dropped below the minimum of (100ºC). (Usually a thermocouple failure). LEADING JET TURBINE Co., Ltd. ATJ TURBINES 31

RCPw Fail: Lack of power from the radio receiver. ATJ Turbine Log Owner Serial Number: Purchase Date Start No. Date Model Place Engine Time Remarks LEADING JET TURBINE Co., Ltd. ATJ TURBINES 32