JetCat EZ-Fuelstation User manual

04/2020, V12.01G Instruction Manual
EZ
-
Fuelstation
Item. No.: 61105-63

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Contents
SAFETY INSTRUCTIONS, MEANING OF THE SYMBOLS ..............................................................................................................3
EZ-FUELSTATION DESCRIPTION ...............................................................................................................................................4
MOUNTING THE FUEL STATION ON THE JERRY CAN ................................................................................................................6
CONNECTIONS.........................................................................................................................................................................7
CONNECTIONS ON THE FUEL STATION .................................................................................................................................................. 7
THE FUELDOCK CONNECTION ............................................................................................................................................................ 8
PRINCIPLE OF OPERATION .......................................................................................................................................................9
INTERNAL CONNECTION DIAGRAM ....................................................................................................................................................... 9
FUEL FEED: ..................................................................................................................................................................................... 9
FUEL RETURN/OVERFLOW: ................................................................................................................................................................ 9
"TANK FULL" DETECTION FUNCTIONALITY ........................................................................................................................................... 10
SAFETY FEATURES ................................................................................................................................................................. 11
OVERPRESSURE IN THE TANK ............................................................................................................................................................ 11
FILL-LINE DISCONNECTED ................................................................................................................................................................ 11
FUEL TANK EMPTY ......................................................................................................................................................................... 11
FUEL TANK OVERFLOW ................................................................................................................................................................... 11
CONNECTION DIAGRAM FOR MODEL TANK SYSTEMS ........................................................................................................... 12
A) REFUELING OF A "NORMAL" TANK SYSTEM WITH FLOWBACK LINE........................................................................................................ 12
A1) Connection diagram for refueling a "normal" tank system without EZ-Fueler filling valve .......................................... 13
A2) Connection diagram for refueling a "normal" tank system with the EZ-Fueler filling valve ......................................... 14
B) CONNECTION DIAGRAM, REFUELING WITH ONLY ONE FILLING LINE (WITHOUT FLOWBACK LINE) ................................................................. 17
B1) Connection diagram for single bag tanks ...................................................................................................................... 17
B2) Connection diagram for multiple bag tanks .................................................................................................................. 18
B3) Refueling of single normal tanks without flowback line................................................................................................ 19
CONTROL PANEL ................................................................................................................................................................... 20
OVERVIEW OF THE CONTROL KEYS ..................................................................................................................................................... 20
COMMISSIONING/SWITCHING ON ..................................................................................................................................................... 21
POWER SUPPLY ............................................................................................................................................................................. 21
SWITCHING ON/OFF ....................................................................................................................................................................... 21
OPERATING CONCEPT ..................................................................................................................................................................... 22
Menu structure .................................................................................................................................................................... 23
Run menu ............................................................................................................................................................................. 24
Select model/filling program .............................................................................................................................................................. 24
Explanation of the Run menu display ................................................................................................................................................. 26
Fill-Settings menu ................................................................................................................................................................ 27
System-Settings menu ......................................................................................................................................................... 30
Statistics menu .................................................................................................................................................................... 34
TABLES WITH KEY COMMANDS ......................................................................................................................................................... 34
Key commands, filling functions .......................................................................................................................................... 35
Key commands, special functions ........................................................................................................................................ 36
QUICK START GUIDE .............................................................................................................................................................. 37
1) SELECTING A NEW MODEL AND NAMING IT ..................................................................................................................................... 37
2) DEFINING REFUELING SETTINGS .................................................................................................................................................... 37

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3) SELECTING MODEL AND START FUELING PROCESS ............................................................................................................................. 37
RESETTING THE CONTAINER VOLUME ................................................................................................................................... 38
CHANGING THE MODEL NAME (FILL PROGRAM NAME) ........................................................................................................ 39
CHANGING THE CONTAINER NAME ....................................................................................................................................... 40
SERVICE FUNCTIONS ............................................................................................................................................................. 41
RESETTING THE VALUES OF THE STATISTICS MENU ................................................................................................................................ 41
RESETTING THE SYSTEM TO FACTORY SETTINGS .................................................................................................................................... 41
CALIBRATING THE FLOW METER ........................................................................................................................................................ 42
FIRMWARE UPDATE .............................................................................................................................................................. 49
ACCESSORIES ......................................................................................................................................................................... 50
Safety instructions, meaning of the symbols
Attention!
This symbol highlights the following instructions, which must be observed by the
user! Any disregard of the information given here may affect the safe functioning
of the device as well as the safety of the user.
Attention!
This symbol emphasizes prohibitions, which must be strictly observed by the
user! Any disregard of the prohibitions on the right can significantly impair the
functionality as well as the safety of the user.
This symbol highlights instructions that should be strictly observed by the user to
ensure safe operation of the device.
Attention!
Fire or explosion hazard!

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EZ-Fuelstation description
 Fully automatic filling or emptying of the model fuel tanks.
For this purpose, only a single key is required, the entire refueling/emptying process is then fully
automatic! At the end of the refueling process, the pump always switches off automatically.
 Integrated flow meter for precise measurement/indication of filled or emptied volume.
At the end of the refueling/emptying process, the refueled or defueled volume in ml, as well as
the refueling time are always displayed. If the fuel station has switched itself off after refueling
(after an adjustable inactivity time), the last refueled quantity/action will be displayed at the next
switch on!
 Optical flow rate detectors for the detection off fuel flow/presence on refueling and fuel
return/overflow!
 Intelligent "tank full" detection via the optical detectors on the fuel flowback line and/or the
integrated flow meter if only a single refueling hose without flowback line is used (change of
volume flow).
 Provides a hermetically sealed, fully automatic refueling process that eliminates the possibility of
fuel from the model entering the soil/environment, as the fuel overflow can be returned to the
fuel station. Ideally in conjunction with the "EZ-Fueler" tank filling valve. Otherwise, the return
hose can also be connected to the tank overflow.
 Automatic switch off when fuel containers are empty or when the fuel container overflows (e.g.
when defueling large quantities into an almost full jerry can)
 Automatic shut-off when the refueling hose unintentionally "falls off"/disconnects during filling.
 Protective system to prevent fuel tank bursting if the tank overflow/vent has unintentionally not
been opened.
 Display of the residual fuel volume in the fuel container
 Suitable for all conceivable model tank systems, in particular also for bag tanks with automatic
venting of the bag tank, as well as automatic or adjustable decompression of the tank system at
the end of the refueling process.
 Automatic shutdown when the system has not been used for a programmable time (auto power
down, time adjustable).
 Automatic power-off when the battery is empty (battery protection function).
 Statistics menu for displaying: number of refueling operations, total volume conveyed, etc.
 Calibration option of the internal flow meter by the user.
 2-line backlit LCD screen, membrane keypad with 7 keys.
 MPX input for 8-18V battery (recommended: 3S LiPo); battery is attached under the fuel station
with Velcro®. Battery type adjustable.
 Data connector for free firmware updates via the Internet

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 Freely programmable system, with 20 model memories (=filling programs). For each memory, the
tank system can be individually programmed/preset e.g.:
Model name (plain text)
-Type of fuel tank ("normal" tank or bag tank)
-Refueling speed (pump capacity)
-Drawback volume at the end of the refueling process
-Optional "defueling volume" (to remove/lighten by a defined volume after the tank has been
completely filled)
-Decompression factor in bag tanks (defines how "plump" the bag tank should be filled)
-Maximum or dosing volume (safety shutdown)
-Use of fuel flowback line on/off (1 or 2-hose mode)
 Different filling methods/algorithms selectable:
 "Normal tank" (automatic filling program)
Optimized filling algorithm for any combination of several series-connected "normal" tanks.
Filling is ideally carried out with a filling line and a flowback line to the fuel container. The
flowback line guarantees certain "tank full" detection every time.
However, it is also possible to fill with only one line without a flowback line. In this case, "tank
full" detection occurs as soon as fuel flows into the overflow (Detection of the flow loss in
the tank system)!
 "Bladder tank" (automatic filling program)
Special filling algorithm for bag tanks which are refueled with only one filling line. Intelligent
"tank full" detection and automatic decompression of the bag tank. Air bubbles are
automatically detected and removed if necessary by repeated drawback.
 "Dosing mode" for defined filling or emptying of an adjustable quantity.
This mode can also be used, for example, for the targeted dosing/filling of programmable
quantities.
 "Manual mode with auto-stop", the pump starts directly in forward or reverse. If a "tank full"
signal is detected by the integrated sensors, the pump stops automatically. Likewise, the
pump automatically stops when the tank is empty ( no more fuel flow)
 "Manual mode without auto-stop"
Pump runs forwards or backwards in continuous operation until the stop key is pressed.
 For all automatic filling programs, a programmable quantity (ml) can optionally be taken from
the tank at the end of the refueling process. For example, to reduce/adjust the total weight of
the model.
 Two rotatable Festo L quick connectors for fuel inlet/venting as well as refueling outlet and
return flow.
 Suitable for all common fuels/smoke oil.
 Replaceable adapters for various fuel tanks.

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Mounting the fuel station on the jerry can
Depending on the fuel container used, different jerry can mounting brackets can be attached to the fuel
station.
The scope of delivery includes interchangeable adapters for fuel jerry cans with nominal diameters of 61
and 71mm.
The 71mm adapter is suitable for "short" fuel containers.
The 61mm adapter for the "tall" 20L fuel containers.

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Connections
Connections on the fuel station
Fuel inlet
6mm hose
Fuel return
4mm hose
Battery input socket,
+ terminal is on top!
Fuel return (B), above,
black hose
(for 6mm hose)
Fuel outlet (A), below, blue
hose
(for 6mm hose)
Expansion socket
(e.g. for updates)
FuelDock
(see the next page)

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The FuelDock connection
The optional FuelDock connection, which can be mounted on the right side of the fuel station, has
several functions:
It serves as a "park" and storage position for the "EZ-Fueler" filling connector. With the "EZ-Fueler" plug-
in connector plugged in, the fuel fill hose is connected to outlet A, the fuel flowback line is connected to
inlet B.
This allows several configurations/functions:
1) If no second/alternative fuel filling hose is to be used, then the two Festo connections A & B are
simply "shorted" with a short length of hose. This has the consequence that the system is
hermetically sealed as soon as the EZ-Fueler filling connector is hooked into the FuelDock (e.g. for
transport).
2) Alternatively, another/alternative filling hose can be connected to outlet A (e.g. with a
different/conventional hose coupling). Inlet B can then optionally be connected to the model's
fuel overflow with another hose. For transport, the filling hose is then connected to the return
hose, so that the system is again hermetically sealed! If refueling with the EZ-Fueler system,
simply remove the EZ-Fueler fueling connector from the FuelDock for refueling. An additional fuel
hose connected to the expansion port remains unaffected.
Inlet B fuel return
Outlet A
fuel outlet
(Filling line)
Expansion port

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Principle of operation
Internal connection diagram
Flow
Sensor Pump
Fuel detector
Fuel detector
Fuelstation Flowback line
Rücklauf zum Kraftstoffcontainer
Fuel supply line
Kraftstoffversorgungsleitung
(Eingang) vom Kraftstoffcontainer
Overflow line from model (input)
Überlaufleitung, an den Kraftstoffüberlauf
des Modells anschließen.
Fueling line to model (outut)
Kraftstoffbefüllleitung (Ausgang) zum
Betankungsanschluß am Modell.
Fuel feed:
The fuel coming from the fuel container is first conducted to the pump inlet.
From the pump outlet, it then goes to the integrated flow meter for balancing the volume delivered, as
well as for calculating the flow rate.
There is a detector immediately before the fuel outlet (connection point of the external refueling hose)
which can detect the presence of fuel in the supply hose. The detector can distinguish whether there is
bubble-free fuel, a fuel/air mixture or only air or is being conveyed in the hose.
Fuel return/overflow:
The fuel overflow coming from the model is connected to the return inlet of the fuel station. In the fuel
station, this hose then also passes through a detector for detecting fuel or air bubbles in the return hose.
Subsequently, this line is then connected to the vent of the actual fuel container.

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"Tank full" detection functionality
"Tank full" detection takes place via two different operating principles:
A) Fuel returns in the overflow pipe, through the fuel station and then back into the fuel container.
As soon as the detector detects fuel in the flowback line, this is a sign that the tank is full.
This setting applies when the Stop-Signal parameter is set to 2-line flowback.
This option is not available for bag tanks as they do not use flowback lines.
B) The second detection principle for "tank full" does not use the signal on the fuel flowback line,
but only the fuel flow rate is evaluated.
With bag tanks, as soon as the tank becomes full, the pressure rises slightly. This has the
consequence that the fuel flow drops slightly.
In a normal tank, the same happens as soon as fuel flows into the tank overflow line. Here, too,
the pressure in the tank rises slightly, causing the fuel flow to drop slightly.
The fuel station software evaluates the fuel flow with appropriate algorithms and can derive the
"tank full" signal from it.
The evaluation is not based on the absolute flow, but on its relative change.
This setting applies when the Stop-Signal parameter is set to "Flow/Pressure".
This option is automatically enabled for bag tanks.
The type of "tank full" detection assigned to the model memory can be set in the Fill-Settings menu
(Page: 27 Parameter: "Stop-Signal").