GREAT PLANES ElectriFly HyperFlow User manual

WARRANTY
Great Planes®Model Manufacturing Co. guarantees this product to be free from defects in both material and workmanship at the date of
purchase.This warranty does not cover any component parts damaged by use or modification.In no case shall Great Planes’liability exceed
the original cost of the purchased product. Further, Great Planes reserves the right to change or modify this warranty without notice.
In that Great Planes has no control over the final assembly or material used for final assembly, no liability shall be assumed nor
accepted for any damage resulting from the use by the user of the final user-assembled product.By the act of using the user-assembled
product, the user accepts all resulting liability.
If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised to return this
product immediately in new and unused condition to the place of purchase.
To make a warranty claim send the defective part or item to Hobby Services at the address below:
Hobby Services
3002 N. Apollo Dr. Suite 1
Champaign IL 61822 USA
Include a letter stating your name, return shipping address, as much contact information as possible (daytime telephone number, fax
number, e-mail address), a detailed description of the problem and a photocopy of the purchase receipt. Upon receipt of the package
the problem will be evaluated as quickly as possible.
GPMZ0194 for GPMG3910/3911 V1.0© Copyright 2006
ELECTRIC DUCTED FAN INSTRUCTION MANUAL
™
Technical Data
Intake Area: 3.50 in2[22.6cm2]
Fan Swept Area: 2.71 in2[17.5cm2]
Exhaust Area: 2.70 in2[17.4cm2],
Optimum Flying Speed: 56 mph [90km/h]
Maximum rpm: 50,000 rpm
Housing Inner Diameter: 2.14 in [54.5mm]
Outer Diameter: 2.23 in [56mm]
Complete Assembly Weight (no motor): 1.3 oz [37g]
Welcome to the exciting world of Electric Ducted Fans (EDF)! The HyperFlow is a new EDF design created by Great
Planes using the latest technology to fit onto smaller EDF airplanes.The HyperFlow was created with ease of use in mind,
as well as superior performance using either a brushed or brushless motor. Great Planes offers several different motors
that you can use to tailor the fan's performance to meet your needs.This EDF can fly airplanes as small as 10oz [280g] to
airplanes as big as 35oz [990g] depending on the chosen motor. Flying speeds can vary from 55mph [88km/h] to
approximately 90mph [140km/h].You can now fly modern jets and fly them in a realistic manner– fast .

2
The following performance data has been achieved using the stock intake lip and no exhaust duct.
# LiPo Cells Voltage Current Power Static Thrust RPM Efflux Efflux
Speed Speed
Motor: Brushed Speed 370BB (meters/second) (miles/hour)
3 11.1V 10.3A 114W 240g (8.5oz) 29,000 32.40 m/s 72.48 mph
4* 14.4V 16.0A 230W 408g (14.4oz) 37,500 39.98 m/s
†
89.44 mph
†
Motor: Brushless 20-40-3500
2 7.4V 8.7A 64W 215g (7.6oz) 27,000 30.88 m/s 69.08 mph
3 11.1V 15.7A 174W 389g (13.7oz) 35,800 38.81 m/s
†
86.82 mph
†
4* 14.8V 22.3A 330W 564g (19.9oz) 43,000 48.44 m/s
†
108.36 mph
†
Motor: Brushless 20-40-4040
2 7.4V 12.0A 89W 245g (8.7oz) 28,500 32.75 m/s 73.45 mph
Motor: Brushless 24-33-4875
2 7.4V 17.2A 127W 303g (10.7oz) 32,300 40.91 m/s
†
91.50 mph
†
3* 11.1V 32.0A 355W 548g (19.3oz) 42,100 73.98 m/s
†
165.49 mph
†
Motor: Brushless 24-45-3790
2 7.4V 9.7A 72W 207g (7.3oz) 27,120 27.95 m/s 62.51 mph
3 11.1V 19.9A 221W 450g (15.9oz) 38,600 60.75 m/s
†
135.89 mph
†
4 14.8V 32.6A 482W 721g (25.4oz) 48,000 97.34 m/s
†
217.73 mph
†
HyperFlow 56mm EDF Performance
0
5
10
15
20
25
30
25,000 30,000 35,000 40,000 45,000 50,000
RPM
Thrust (oz)
0.00
50.00
100.00
150.00
200.00
250.00
Efflux Speed (mph)
Never exceed the maximum rated 50,000 rpm.
Please visit the Great Planes website (www.greatplanes.com) for performance
data on recently released motors or any other technical updates.
PERFORMANCE
*Burst Use Only Efflux Speed: Air Speed Exiting the Rear of the Fan
†
Calculated Values

The way a ducted fan works is simple: As the fan rotates and
draws air, the surrounding duct causes the airflow to
accelerate through the fan and exit out of the exhaust tube.
Because of this, fans are designed with a particular duct
profile in mind and a particular flying speed. The HyperFlow
has been designed to be most efficient while flying at 56 mph
[90 km/h]. This was done so that the fan would perform well
with an inexpensive brushed motor, but would still operate at
acceptable efficiency levels with a brushless motor.
The duct profile is extremely important for the fan to perform
well. The intake needs to be large enough to supply the
required air to the fan at both low and high speeds and at
different rpm, but if the duct profile is too large, it may increase
the airplane's drag coefficient or decrease the fan's efficiency.
The recommended intake area for this fan is 3.50 in2[22.6cm2].
This represents 129% of the fan swept area (FSA), which is
2.71 in2[17.5cm2].We do not recommend deviating from these
dimensions. Exhaust area is equally important for the fan to
perform well.Simply put, a larger exhaust will help create more
thrust but will decrease the exhaust air speed. A smaller
exhaust will increase the exhaust air speed but will decrease
thrust. The recommended exhaust area is 2.70 in2[17.4cm2]
which represents 99% of the FSA.The minimum exhaust area
is 2.40 in2[15.5cm2], or 90% of the FSA.The duct profile must
be smooth and absolutely free of obstacles (over 40% of the
thrust could be lost due to obstructions and air flow problems).
It is also recommended that the intake has a smooth, rounded
lip which helps maximize static thrust and smooth airflow.
Before starting to build, take an inventory of this kit to make
sure it is complete, and inspect the parts to make sure they
are of acceptable quality. If any parts are missing or are not
of acceptable quality, or if you need assistance with
assembly, contact Product Support. When reporting
defective or missing parts, use the part names exactly as
they are written in the Kit Contents list.
Great Planes Product Support
3002 N Apollo Drive, Suite 1 Champaign, IL 61822
Telephone: [phone], ext. 5 Fax: [phone]
E-mail: [email protected]
NOTE: Motor is only included in GPMG3911.
1. Ducted Fan Housing 6. Front Housing Flange
2. Stator Extension 7. 20mm Brushless Motor Adapter
3. Aft Cone 8. Mounting Screws and Washer
4. Rotor Cone 9. Fan Rotor Adapters
5. Fan Rotor 10. Motor
Replacement parts for the Great Planes HyperFlow EDF are
available using the order numbers in the Replacement Parts
List that follows. The fastest, most economical service can
be provided by your hobby dealer or mail-order company.
To locate a hobby dealer, visit the Great Planes web site at
www.greatplanes.com. Choose “Where to Buy” at the top of
the page on the right side. Follow the instructions provided on
the page to locate a U.S., Canadian or International dealer.
Parts may also be ordered directly from Hobby Services by
calling [phone], or via facsimile at [phone],
but full retail prices and shipping and handling charges will
apply. Illinois and Nevada residents will also be charged
sales tax. If ordering via fax, include a Visa®or MasterCard®
number and expiration date for payment.
Mail parts orders and payments by personal check to:
Hobby Services
3002 N Apollo Drive, Suite 1
Champaign IL 61822
Be certain to specify the order number exactly as listed in the
Replacement Parts List. Payment by credit card or personal
check only; no C.O.D.
If additional assistance is required for any reason contact
Product Support by telephone at [phone] or by
e-mail at [email protected]
Replacement Parts List
Order Number Description
GPMG3940.............Rotor Blade
GPMG3941.............Parts
GPMG3942.............Outer Duct
GPMG3943.............Rotor Adapter
ORDERING REPLACEMENT PARTS
1
23
4567
8
910
KIT INSPECTION
A0: Intake Area
3.5in2[22.6cm2] minimum
2.21in [56.3mm]
diameter circle
1.85in [47mm]
diameter circle
2.38in [60.5mm]
diameter circle
1.10in [28mm]
diameter circle
A0 A2 A3 A4
A0 A2 A3 A4
A4: Exhaust Area
2.7in2[17.4cm2]
A3: Fan Exit Area
2.71in2[17.5cm2]
A2: Fan Swept Area
2.71in2[17.5cm2]
Duct Cross-Section
s
TECHNICAL INFORMATION
3

At this point, based on the table above and the airplane you
will install the HyperFlow ducted fan into, you will need to
decide which motor, ESC, and batteries to use with the fan.
Remember that once a motor is chosen based on the power
output, a speed controller and battery must be used that are
capable of delivering the current drawn by the motor.Several
power systems are available from Great Planes. These are
the ONLY recommended power systems for this fan.
Brushed Power System:
Speed 370 BB Brushed Motor (GPMG0310)
ElectriFly C-25 ESC (GPMM2025)
ElectriFly 3-cell 910mAh LiPo (GPMP0605)
ElectriFly 3-cell 1250mAh LiPo (GPMP0609)
Brushless Power System:
ElectriFly Ammo 20-40-3500 Brushless Motor (GPMG5140)
ElectriFly Ammo 20-40-4040 Brushless Motor (GPMG5142)
ElectriFly Ammo 24-33-4875 Brushless Motor (GPMG5170)
ElectriFly Ammo 24-45-3790 Brushless Motor (GPMG5185)
ElectriFly SS 12A Brushless ESC (GPMM1810)
ElectriFly SS 25A Brushless ESC (GPMM1820)
ElectriFly SS 35A Brushless ESC (GPMM1830)
ElectriFly SS 45A Brushless ESC (GPMM1840)
ElectriFly 2-cell 910mAh LiPo (GPMP0604)
ElectriFly 3-cell 910mAh LiPo (GPMP0605)
ElectriFly 2-cell 1250mAh LiPo (GPMP0608)
ElectriFly 3-cell 1250mAh LiPo (GPMP0609)
ElectriFly 2-cell 1500mAh LiPo (GPMP0612)
ElectriFly 3-cell 1500mAh LiPo (GPMP0613)
ElectriFly 2-cell 2100mAh LiPo (GPMP0616)
ElectriFly 3-cell 2100mAh LiPo (GPMP0617)
ElectriFly 2-cell 3200mAh LiPo (GPMP0622)
ElectriFly 3-cell 3200mAh LiPo (GPMP0623)
❏Threadlocking compound (GPMR6060)
❏Phillips screwdriver (HCAR1024)
❏1.5mm hex wrench (GPMR8010)
❏Medium CA+ glue (GPMR6008)
The EP Ducted Fan Unit will work with 370 sized brushed
motors, 20mm brushless motors, and 24mm brushless motors.
All necessary parts are included for these motor installations.
Note: The aft cone might not be installed when using longer,
brushless motors.
If your motor does not already have leads attached, do so
prior to the motor installation into the ducted fan unit.
❏1. If installing a Great Planes T-370 brushed motor, slide
the motor into the ducted fan housing up to the mounting
plate. Align the slotted motor mounting holes in the housing
with the screw holes at the top of the motor.
❏2.Secure the motor to the fan housing using two 3 x 5mm
flat head screws with threadlocking compound.
Installing a Brushed Motor
ASSEMBLY
ADDITIONAL ITEMS REQUIRED
DECISIONSYOU MUST MAKE
4

❏3. Press the 2mm fan rotor adapter onto the motor and
tighten the set screws against the shaft. Allow a small
amount of clearance (1/8" [3mm]) between the base of the
adapter and the motor to prevent binding. A 3/32" [2.4mm]
hole can be drilled into the side of the fan housing 9/16"
[14.3mm] from the front edge to insert an allen wrench for
the fan adapter set screws.
❏4. Fit the fan rotor over the brass fan adapter and thread
a 3 x 8mm phillips screw with a 3mm washer to hold it in
place.Be sure to use threadlocking compound on this screw.
❏5.Cut a portion of the aft cone away for motor cooling and
to allow the motor leads to pass through. For most motor
applications, the aft cone should be approximately 1-1/4"
[32mm] long after cutting it.
❏6.Attach the aft cone to the fan housing with a couple drops
of CA glue. Excess glue will make it difficult to remove the
motor from the housing should it be necessary in the future.
5

❏1. If installing a 20mm brushless motor, press the motor
adapter onto the rear of the motor can prior to sliding it into
the fan housing. The motor adapter is keyed to fit over the
three alignment guides inside the fan housing. Push the
motor up against the mounting plate, aligning the motor
mounting holes with the slots.Depending on the model motor
being used, you may need to cut away a part of the fan
housing in order for the motor to sit flush against the
mounting plate. Use the molded recess as a cutting guide.
IF INSTALLING 24mm MOTOR (ONLY)
If installing a 24mm brushless motor, the three alignment
guides inside the fan housing must be trimmed prior to
inserting the motor (a hobby knife works; however, a rotary
tool such as a Dremel makes the job much easier). Slide the
motor into the housing, positioning the screw holes in the
motor with the slots in the mounting plate.
❏2.Secure the motor to the fan housing using two 3 x 5mm
flat head screws with threadlocking compound.
❏3. There are brass fan rotor adapters provided for 2mm,
2.3mm, and 3mm motor shafts.Select the adapter that fits your
motor shaft and install the 3mm set screws with a 1.5mm
wrench into the hexagonal base.
Installing a Brushless Motor
6

❏4. Press the fan rotor adapter onto the motor and tighten
the set screws against the shaft. Allow a small amount of
clearance (1/8" [3mm]) between the base of the adapter and
the motor to prevent binding. A 3/32" [2.4mm] hole can be
drilled into the side of the fan housing 9/16" [14.3mm] from
the front edge to insert an allen wrench for the fan adapter
set screws.
❏5. Fit the fan rotor over the brass fan adapter and thread
a 3 x 8mm phillips screw with a 3mm washer to hold it in
place.Be sure to use threadlocking compound on this screw.
❏6. Slide the stator extension onto the back of the ducted
fan housing. There are small notches on the stator extension
that fit around the fan housing. Be sure that the extension
blades are aligned with the stator blades inside the motor
housing.Secure the extension with a couple drops of CA glue.
❏7.Cut a portion of the aft cone away for motor cooling and
to allow the motor leads to pass through. For most motor
applications, the aft cone should be approximately 1-1/4"
[32mm] long after cutting it. If using a long brushless motor,
the aft cone may not fit and can be omitted.
❏8.Attach the aft cone to the fan housing with a few drops
of CA glue. Excess glue will make it difficult to remove the
motor from the housing should it be necessary in the future.
7

This completes the basic ducted fan assembly. If the ducted
fan application requires the fan housing to be installed into
an existing duct tube that provides properly distributed
airflow into the fan rotor, then the ducted fan unit is ready for
use. If the ducted fan is to be installed in a nacelle or into a
duct tube that does not properly direct airflow into the fan
rotor, follow the additional instructions below.
❏1.Attach the rotor cone to the fan rotor with a couple drops
of CA glue. Excess glue will make it difficult to remove the
motor from the housing should it be necessary in the future.
❏2.For a nacelle installation, secure the front housing flange
to the fan housing using a couple drops of thin CA. The front
housing flange is not used on most internal fan installations.
Before you run the fan make sure that:
•The motor selected is one of the recommended motors.
•An appropriate ESC is being used.
•An appropriate LiPo battery is being used.
•All the screws and set screws are secured with
threadlocking compound.
•All the fan parts are properly attached to the fan and to
the airframe.
•If any part of this fan should become damaged, replace all
parts. Never attempt to repair damaged parts.
•Keep the fan away from objects as it will try to suck them
in, which can cause damage to the fan and/or bodily injury.
•Always use eye protection when operating the fan unit.
• NEVER look into the fan as it is running.
•Ensure all persons in the immediate area are using eye
protection while the fan is in operation.
• NEVER point the fan in the direction of anyone.
•Make sure you inspect the fan and all its parts before
each run.
•Never use motors larger than those recommended.
•Never run a fan that is damaged in any way.
•Never run the fan while holding it in your hands.
• NEVER run the fan above 50,000 rpm!
•Never run the fan rotor on any motor outside of the housing.
This is a device that runs at very high rpm and as such it
needs to be handled carefully. There is a very short “break-
in” period that needs to be followed to ensure that all parts
fit well, everything is tight, and that no excessive vibration is
present when running the fan. Also, if the power system
chosen has a large power output, the fan blades will expand
as rpm are increased to the point of possibly touching the
housing. This is expected and it is within the “break-in”
procedures. The blades will get shortened slightly to fit the
fan housing as they wear on the sides.
The procedure below must be followed carefully:
1. If the fan is properly installed on an airframe and everything
is ready to be tested, arm the speed controller and advance the
throttle slowly to approximately 1/4 power for three minutes.
Check for vibration and/or unusual noises.If there is vibration or
unusual noise present during the test, do not proceed to step 2
until the problem is resolved. Inspect all moving parts, being
sure that motor screws and the rotor adapter screws are tight.
Confirm that the fan blades rotate smoothly within the housing
and the rotor is not rubbing on the mounting plate (Be sure to
unplug the battery from the ESC before handling the fan!).
2. If the fan operates smoothly, move the stick to 1/2 throttle
and repeat the test as described in step 1.
3. Slowly advance the throttle to 3/4 power. When using high-
power systems, the fan blades may rub a bit on the fan housing.
You can see this by powering down the system and checking
for marks or grooves in the housing. If this is the case, return to
1/2 throttle and cycle between 1/2 throttle and 3/4 throttle for
three to four minutes. Doing so will adjust the length of the fan
blades as they slowly wear on the fan housing.
4. Repeat the procedure described in step 3 between 3/4
throttle and full throttle.
5. Unplug the battery from the ESC and check the fan for
rubbing, cracks, or missing parts.
If your fan appears damaged, vibrates excessively, or
makes unexpected noises, please return it to Hobby
Services for inspection.
Happy flying!
PREPARE TO RUN THE FAN
Installing the Rotor Cone