AMT Netherlands Olympus HP User manual

Olympus HP
copyright
©
AMT Netherlands
Serial number
Manual & ENGINE LOG (V 2.17)
N L
Air start engine
Electric start engine
Phone
Fax
Email
(int [phone]
(int [phone]
[email protected]
Spaarpot 34
Geldrop5667 KX

Copyright by B.J.J. van de Goor, AMT Netherlands all rights reserved.
This manual may not be reproduced, in whole or in part, by photocopy or print or any
other means, without permission from the publisher.
Write for information to: AMT Netherlands b.v.
Spaarpot 34
5667 KX Geldrop
the Netherlands
Webside : Http:// www.amtjets.com
E-mail : [e-mail]

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page :1
Table of contents Revision: 2.17
The table of contents serves as a means to check the completeness and validity of this
owners manual. With each update of this manual, the revised pages will be sent to the
owners, if necessary.
Each page can be recognised in the header by:
- chapter number and description
- page number in the chapter
- revision number
Text pages have been included as right-facing pages.
Pages with drawings have been included as left-facing pages and have been inserted
opposite the relevant text, when possible. Pages with drawings have a reference to the
matching text page in the header.
Page Revision
Table of contents 1,2,3 2.17
1. Introduction Advanced Micro Turbines 2.07
1.1 Profile of Advanced Micro Turbines 1
1.2 Description OIympus HP E-Start 1
1.3 Technical data of OIympus HP E-Start 2
2. Contents OIympus HP E-Start set 2.05
2.1 Turbine 1
2.2 Electronic Control Unit (ECU) 1
2.3 Fuel pump 1
2.4 Owners Manual 1
2.5 Sundries 1
3. Extra requirements 2.07
3.1 Fuel 1
3.2 Starting gas 1
3.3 Compressed air 2
3.4 Ignition 2
3.5 Fire extinguisher 2
4. Safety 2.05
4.1 General 1
4.2 Assistance 1
4.3 Handling the turbine 1
4.4 Danger zones 1
4.5 Noise production 1
4.6 Liability 1

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page :2
Table of contents Revision: 2.17
5. Electronic Control Unit (ECU) 1.2
5.1 Description ECU 1
5.2 Which radio sysytem, PPM or PCM are you going to use. 1
5.2.1 Using a PCM system 1
5.3 Definition of input channels 2
5.3.1 Temperature input A 2
5.3.2 RPM input B 2
5.3.3 Reg. channel input D 2
5.3.4 CTF input E 2
5.3.4.1 CTF input E (Dual channel operation) 2-3
5.3.4.2 CTF input E (Singel channel operation) 4-5
5.3.4.3 CTF input E to operate Automatic Startup Unit (air start) 5
5.3.5 Switch channel input C 5
5.4 Definition of output channels 5
5.4.1 Fuel valve connection output A 5
5.4.2 Glow plug connection output B 5
5.4.3 Gas valve connection output C 5
5.4.4 Electric starter connection output D 6
5.4.5 Fuel pump output E 6
5.4.6 Serial output F 6
5.5 Buzzer 6
5.5.1 Buzzer beeps 6,7
5.5.2 Resetting the error beep 7
5.6 Analog ECU and control box 7
5.7 Extra features 8
6. Installation of the OIympus HP E-Start 2.07
6.1 Dimensions OIympus HP E-Start 1
6.2 Position of turbine 1
6.3.1 Inlet shape & dimensions 1
6.3.2 Air inlet duct 1
6.4.1 Exhaust duct & dimensions 2
6.4.2 Exhaust duct cooling 2
6.4.3 Installing exhaust duct 2
6.5 On-board fuel pump 2
6.6 On-board propane container 3
6.6.1 Installing the gas container in the model 3
6.6.2 Gas container connections 3
6.7 Mounting the thermo-couple 3
6.8 On-board ECU 4
6.9.1 Hard fuel tank installation 4,5
6.10 Fueling up the model 5
6.11 Alternative method for fuelling 6
7. Operation 2.07
7.1 Fuelling up the model 1
7.1.1 Fuelling the kerosine 1
7.1.2 Fuelling the propane 1
7.2 Powering up the system 2
7.3 Starting the OIympus HP E-Start 2,3
7.4.1 Stopping the engine 3
7.4.2 Switching off in case of an emergency 4

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page :3
Table of contents Revision: 2.17
7.5 Recommended refuelling/charging sequence 4
8. Maintenance 2.08
8.1 Preventive maintenance 1
8.1.1 Visual inspection of turbine and gear 1
8.1.2 Checking of bearings 1
8.2 Storage and Lubrication 2
8.3 Removal of front cap and prelubrication procedure 2
8.4 Returning motor for service or repair 3
8.5 P2 Pressure fitting installation 3
8.6 Looking after your gasturbine 4
9. Log OIympus HP E-Start 2.05
9.1 How to complete the log 1
9.2 Log 1
10. Warranty conditions 2.04
10.1 Warranty conditions 1
10.2 Completing the Warranty card 1
10.3 Warranty 1
11. Engine Data Terminal 1.2
11.1 Description Engine Data Terminal 1
11.2 On Off switching 1
11.3 Charging the EDT 1
11.4 Startup screen 1
11.5 Screen 1 2
11.6 Screen 2 2
11.7 Screen 3 2
11.8 Additional Text 2,3
11.9 Error messages 3,4
Engine log 2.05

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page :1
1. Introduction Revision: 2.07
1.1 Profile of Advanced Micro Turbines
Advanced Micro Turbines develops small gas turbines for the propulsion of radio-
controlled flying airplanes, remote heat/power generators, and auxiliary power units.
The company originates from Jet Team Holland, which has been giving flight
demonstrations with jet propelled models since 1987, both in the Netherlands and
abroad.
Our first turbojet, the Pegasus MK-1, which was developed in 1991 and 1992 had a
thrust of 90 Newton at 90,000 rpm. In 1995 the Olympus was developed with a thrust of
170 Newton and further refined specifications. AMT’s latest version of this engine the
Olympus HP now provides a thrust of 230 Newton at 108,000 RPM.
The production version of the Olympus HP turbojet has been developed from
knowledge gained during design and operation of the Mercury HP, Pegasus HP and
Olympus motors, and it has specifications and performance which have never been
achieved before in a motor of this size.
In 2004 the Electric Start version of the Olympus HP was developed together with a
new type of ECU capable of fully automatic start with our own newly developed electric
starter.
All materials used in all AMT's turbojets are carefully selected according to extensive
calculations and operational tests, and our stringent quality controls.
1.2 Description of Olympus HP and HP ES
The Olympus HP has been constructed from a single radial compressor and an axial
flow turbine. The Olympus HP owes much of its excellent performance and superb
power/weight ratio to this turbine wheel which was designed by AMT staff especially for
our motors. The time required for the turbojet to spool up and down is also positively
influenced by the low mass of the axial turbine wheel, taking less than 4 seconds and
from min. to max. rpm and only 3 seconds from max. rpm to min. rpm.
The combustion chamber is of the annular type, which is fitted with a unique "low
pressure" fuel system, also developed by AMT Netherlands. Both the front and the rear
hybrid bearings are also lubricated and cooled by the fuel system, and therefore the
motor requires no separate lubrication system or oil tank.
The turbine is protected from misuse and accidental damage by means of a
microprocessor based controller (ECU) which regulates the maximum performance
within preprogrammed software limits. The ECU is fully automatic and needs no
adjustment by the operator.

maximum distance 170 mm
minimum distance 160 mm
rear engine mount
front engine mount therm sensor mount
front view
Olympus HP
374 mm
267 mm
130 mm
figure 1.1
figure 1.2
1. Introduction Page : 2
Rev. : 2.07
side view Olympus HP ES
mounting slots
MANUAL Olympus HP ES Advanced Micro Turbines
compressed
air (starting)
fuel input
start gas connection
mounting ( M-3)
top mounting strap
Glow Plug
bottom mounting strap
mounting slot
mounting slot
mounting ( M-3)
thermo sen.
mount
Front cap mounted, starter not shown.

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page :2
1. Introduction Revision: 2.07
1.3 Technical data for Olympus HP and HP ES* (*Electric Start)
All data at S.T.P: 15°C and 1013 mBar (59°F and 29.91 in)
Diameter 130 mm 5.1 inch
Length (Air start) 267 mm 10.5 inch
Length (Electric start) 374 mm 14.7 inch
Weight turbine (Air start) 2475 gr 5.4 Lbs
Weight turbine (Electric start) 2850 gr 6.3 Lbs
System airborne weight *(Air start) 3150 gr 6.9 Lbs
System airborne weight * (Electric start) 3795 gr 8.35 Lbs
Thrust @ max. RPM 230 N 51.7 Lbf
Thrust @ min. RPM 10 N 1.8 Lbf
Pressure ratio @ max. RPM 4:1 4:1
Mass flow @ max. RPM 450 gr/sec 0.99 Lb/sec
Maximum RPM 108,000 108,000
Maximum allowed RPM 112,000 112,000
Exhaust temperature 700 °C 1290 °F
Maximum exhaust temperature 750 °C 1382 °F
Fuel usage @ max. RPM 640 gr/min 22.5 oz/min
Fuel type kerosene/paraffin/A-1/white spirit
(* System airborne weight: engine ECU,pump,battery,solenoid valves,thermosensor,mounting straps)
For general turbine dimensions see half size drawings (figures 1.1 and 1.2) on opposite page.

Page : 1
Rev. : 2.05
2. Contents
MANUAL Olympus Advanced Micro Turbines
Example

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page : 1
2. Contents Revision :2.05
2.1 Turbine
The kit consists of a turbine, manufactured with the utmost precision and care, and it is
important that you, as a user, treat the motor as a precision instrument.
Each new motor has undergone 3 test runs before delivery, during which the running
capacities and performance have been checked.
2.2 Electronic Control Unit (ECU)
The ECU is a control unit, controlled by a microprocessor, which is powered from the
fuel pump battery. The control unit has two inputs which are connected to your radio
control system, and also inputs for the Exhaust Gas Temperature (EGT) and the RPM
of the motor which are used to make sure that the motor cannot exceed the maximum
design RPM or EGT.
2.3 Fuel pump
The fuel pump is a type built from two gear-wheels running in a high-precision chamber.
Therefore it is very important that you use a fuel which is absolutely clean and pure, in
order to prevent blockages in the fuel system. Taking the pump apart can lead to
irrepairable damage.
2.4 Owners Manual
It is very important that you study this manual closely before installing or starting the
motor, in order to understand the Olympus HP (ES) and its systems properly.
If there are updates of this manual which are important for safety or operation, then
AMT will make sure these are sent to you.
2.5 Sundries
The kit also contains a number of additional items such as tubes, Festo connectors,
battery charging cables etc. We recommend that you only use tubing from "FESTO" to
fit onto the motor and pump connectorions, as this guarantees that everything fits
properly. If the availability of FESTO components is a problem for you, then please
contact AMT NL or your AMT dealer for supplies.
The total quantity of the delivered goods is to be found in the packing list.

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page :1
3. Extra requirements Revision: 2.07
3.1 Fuel
Several types of fuel can be used. However, AMT NL recommends that you stick with a
fuel type once it has been chosen. It is important to get information about the local
availability of your choice of fuel before making this decision.
Fuel types
1: JP-4/Kerosene This fuel type is used in the military aviation.
2: Paraffin This fuel type is mostly used in oil stoves.
3: Jet A-1 This fuel type is used in commercial aviation.
The Olympus HP and HP ES also uses the fuel for lubrication, so the fuel must be pre-
mixed with 4,5% Aeroshell 500 turbine oil before use. This oil takes care of the
lubrication during start-up and power-down sequences. When a power-down is
activated the fuel flow stops and each of the above fuel types will vaporise in the hot
turbine. At that moment the oil takes care of the lubrication. This remaining oil also
lubricates the turbine during the next start-up sequence.
Important: Be sure that you use clean fuel, and always use a fuel filter in the tube
between the external fuel supply container and the fuel tanks for the motor.
3.2 Starting gas
The starting gas used for the pre-heating of the motor is propane. This gas type is often
used for hobby blowlamps and has a pressure of approx. 4 Bar at a temperature of
10°C. Starting using a mixture of butane/propane gas is not so reliable, especially in
colder climates.
The external gas bottle has to be provided with a regulator valve that needs at least
three full turns to be completely open. This is necessary so that you can control the
amount of gas supplied when using it for starting the motor, and also during the filling of
the internal gas container.
When you do not use the internal gas container, and use an external one for starting,
make sure that the gas container is stable enough and cannot fall over during start-up,
as the propane must be supplied to the motor in gaseous form for starting.
(NB: If the external propane container falls over it will supply liquid gas, which can be
dangerous.)

Page : 2
Rev. : 2.07
2 - 2,5 mm
glow plug for ignition
use only cold type
Note: The glowplug in the Olympus HP engine is fitted with a brass “glowplug
extender”, when the glowplug needs to be changed, replace the glowplug
extender using a HEX wrench of 1.5 mm in size.
2.5 - 3 turns out
figure 3.1
scale 3:1
3.Extra requrements
MANUAL Olympus HP ES Advanced Micro Turbines

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page :2
3. Extra requirements Revision: 2.07
3.3 Compressed air
For the air start version of the Olympus HP you need compressed air with a pressure of
10-12 Bar, and starting will use approx. 50 litres per 5 seconds. The simplest way is to
use a high-pressure air bottle (scuba diving tank) with a capacity of 10 litres, fitted with a
1st stage regulator set to 10 – 12 Bar. Normally these bottles are filled to a pressure of
200 Bar. Therefore with a 10 litre bottle you have 2000 litres of air, which is enough for
10-15 start-ups and cool-downs.
3.4 Ignition
The Olympus HP uses a normal model glow plug (type "cold") for ignition (Rossi R8
supplied). These are available in most hobby stores and must be modified as shown in
figure 3.1. The easiest way to do this is by using a piece of bent 1mm steel wire, or a
pair of tweezers.
These glow plugs are lit by connecting the right voltage. This is often indicated on the
package, and is normally 1.5 or 2 volts. It is of the utmost importance that you are
absolutely sure that the glow plug is functioning properly before you begin with the start-
up procedure. With a defective glow plug you run the risk of too much gas in the motor,
which might lead to a fire. When you have problems starting the engine, please check
the glow plug first, it should be glowing very bright yellow.
Note: From ECU software version V23 and higher you will not get “start clearance” on
the EDT display when the glowplug is faulty. However, when all other conditions for
start clearance are OK (ie: EGT below 88 deg C, charged pump battery, shaft rpm less
than 500) the ECU will still allow you to start the engine, using an external ignition
source (such as a cigarette lighter). When you put the 3 position switch in the ‘start’
position the ECU will still try to start the motor, and proceed with the normal start-up
sequence.
This is a useful feature in an emergency, such as during a competition when you only
have a certain time to commence your scoring flight.
Warning: When using an external ignition source, like a cigarette lighter, please be
extremely careful of the exhaust heat at ignition. Of course, this method is not
recommended by AMT Netherlands, expect in emergency cases.
3.5 Fire extinguisher
Safety is of the utmost importance, so please make sure that you have a properly
functioning fire extinguisher within reach, and take care that at least one of your
assistants is able to handle it.
A fire extinguisher filled with CO2 or Halon is preferred, because these do not leave
harmful residues in the turbine.

4. Safety Page : 1
Rev. : 2.05
Top view danger zone Figure 4.1
turbine and danger zone not
drawn on same scale !
area within dotted line is
minimum danger zone
behind turbine minimum 12 m
side turbine minimum 15 m
inlet danger zone
(sucking in of dirt)
min. 1 m
turbine
top view
MANUAL Olympus HP ES Advanced Micro Turbines

MANUAL OLYMPUS HP E-START AMT NETHERLANDS
Page :1
4. Safety Revision: 2.05
4.1 General
A turbine is a type of motor that needs more safety precautions than the average
propulsion system, such as a ducted-fan unit.
Therefore it is of the utmost importance that the safety precautions mentioned below
are taken into account.
4.2 Assistance
Make sure that you have at least one assistant when starting up the turbine. This
assistant has to get acquainted with the turbine, just like you.
4.3 Handling the turbine
It is advisable to make a test stand to learn about starting and handling the turbine,
before installing it in a model. You should make enough test starts in a "clean" space, or
better still "outside", until you can handle the turbine properly and with confidence.
4.4 Danger zones
Figure 4.1 indicates which areas your assistant, and also bystanders, need to avoid.
In any case, do not start the turbine if there are people in these danger zones.
4.5 Noise production
A turbine mainly produces noise in the high frequencies. Often these noises are not
experienced as annoying, but prolonged exposure may still harm your hearing, and
especially as an operator you are intensively exposed to this noise. Therefore please
wear sufficient hearing protection when running the turbine.
4.6 Liability
AMT Netherlands is not liable in any way for whatever damage or injury, resulting from
the use of the Olympus HP and Olympus HP ES turbine.

5. Electronic Control Unit Page : 1
Rev. : 1.3
SERVO
position @ 100%
throw on idle side of
throttle channel.
Failsafe
50% throw
on idle side
of throttle channel.
100% throw @
full throttle side
of throttle channel.
Centre of throttle
channel.
If possible at your
RC system; switch
“off ” trim when using
dual-channel operation.
figure 5.1
figure 5.2
Version 2 ECU.
MANUAL Olympus HP Advanced Micro Turbines
Note:
The servo shown is a “JR”
type servo. This type of
servo goes anti-clockwise
at an input with a pulse with
of 1.0 milli second.