JetCat EZ-Fuelstation User manual

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

2/ 53
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

3/ 53
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!

4/ 53
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

5/ 53
 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.

6/ 53
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.

7/ 53
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)

8/ 53
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

9/ 53
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.

10/ 53
"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").

11/ 53
Safety features
The fuel station has various safety features that try to intercept typical operating errors. In practice, the
possible errors that occur are:
Overpressure in the tank
Forgetting at the beginning of refueling to remove the plug from the tank overflow.
Incorrectly refueling a model with bag tank with a program that has set the flowback line as a "tank full"
signal.
In these cases, the flow during refueling will drop unusually quickly. This circumstance is evaluated by
the system and can be used for shutdown. The sensitivity of this monitoring function is set via the Burst
Protection parameter in System-Settings.
If this monitoring function is triggered, the following is displayed in the upper line:
Fill-line disconnected
A refueling process is under way and the refueling hose unintentionally separates from the refueling
connection or a tank bursts. These circumstances lead to a sudden, unusual increase in the flow, which
can be utilized to end the refueling process. In this case, the pump stops and the display shows:
This monitoring function can be switched on/off via the Burst Protection parameter in System-Settings.
Fuel tank empty
If, during refueling, air is permanently detected in the refueling hose and no flow can be detected, the
system terminates the refueling process with the message:
Fuel tank overflow
If fuel is detected on the return flow sensor for at least a certain amount of time during defueling, this
normally means that the jerry can is completely full and that, instead of air, fuel is leaving the overflow.
In this case, the system ends the defueling process with the message:

12/ 53
Connection diagram for model tank systems
A) Refueling of a "normal" tank system with flowback line
Flow
Sensor Pump
Fuel detector
Fuel detector
Fuelstation
Fuel container
/Kraftstoffreservoir
Flowback line / Rücklauf
Fuel supply line
Kraftstoffversorgung
Fueltank(s)
Header tank
to engine
/zur Turbine
Model
Fuel overflow
/Kraftstoff-Überlauf
Fueling
connector
/Kraftstoff-
befüllanschluß
Fill-line
/Befüll-Leitung
Flowback-line
/Rücklauf-Leitung
This is the ideal variant for normal or even complex tank systems, consisting of one or more "normal"
fuel tanks connected in series (not for bag tanks!).
"Tank full" detection occurs with fuel flowback on the overflow pipe:
The tank overflow line, which is normally led out of the bottom of the model, must be connected to the
flowback line of the fuel station!
Once all the fuel tanks have been filled, fuel flows back to the fuel station via the flowback line at the
end of refueling. Typically, first, a mixture of fuel and air bubbles will flow back/escape from the tank
overflow (Tanks are almost, but not quite full).
At that moment, the system is already reducing pump performance to counteract the excessive pressure
rise in the model fuel system.
When the tanks are finally full, bubble-free fuel will eventually flow back to the fuel station. This
circumstance is recognized by the system and evaluated as a "tank full" signal.
Now, the fuel pump is automatically reversed, and fuel is reverse pumped from the model tank until
"air" is detected again on the flowback line instead of "fuel".
This causes overpressure possibly built-up during the refueling in the model tanks to be reduced. This
pressure reduction is terminated precisely when no more fuel leaks out via the flowback line and instead
air is sucked back from the fuel container into the flowback line. The refueling process is basically
complete. In addition, an optional programmable volume (Drawback Volume parameter p.27) can be
reverse pumped to possibly further drain the return hose or additionally decompress the system.

13/ 53
A1) Connection diagram for refueling a "normal" tank system without EZ-Fueler filling valve
This results in the following filling cycle:
Fuel is first filled into the hopper tank from the blue filling hose.
If this is full, the fuel flows into the subsequent tanks until they are also full.
At this moment, the fuel then flows into the fuel overflow (or the tank vent hose). The fuel flows back
into the filling station and from there into the fuel container via the flowback line, which is additionally
connected to the model fuel overflow  a closed circuit.
The fuel flowing back via the overflow line is recognized by the detector in the fuel station and used to
terminate the refueling process as soon as "bubble-free" fuel is detected in the flowback line.

14/ 53
A2) Connection diagram for refueling a "normal" tank system with the EZ-Fueler filling valve
Refueling position:
The figure above shows the valve position and the resulting connections when the "EZ-Fueler" filling
connector is inserted (=filling position).
 The filling line of the fuel station is connected to the tank filling line.
 The tank overflow is connected to the return hose to the fuel station.

15/ 53
Flight position:
The figure above shows the valve position and the resulting connections with a disconnected "EZ-Fueler"
filling connector (=flight position).
 Refueling connection actively closed
 Tank overflow connected to model overflow

16/ 53
EZ-Fueler features, summary

17/ 53
B) Connection diagram, refueling with only one filling line (without flowback line)
B1) Connection diagram for single bag tanks
This variant is used for bag tanks. As soon as the tank is full, the pressure in the tank will rise and fuel
flow will drop slightly.
This circumstance is recognized by the system and evaluated as a "tank full" signal.
In this configuration, the flowback line is not used/analyzed!
Flow
Sensor Pump
Fuel detector
Fuel detector
Fuelstation
to engine
/zur Turbine
Model
Bladder-tank
/Beuteltank
Flowback line / Rücklauf
Fuel supply line
Kraftstoffversorgung
Fill-line
/Befüll-Leitung
Fuel container
/Kraftstoffreservoir
This results in the following filling cycle:
Fuel is first filled into the bag tank from the blue filling hose. If the bag is full, the pressure in the bag will
increase and at the same time the fuel flow will drop slightly. This circumstance is recognized by the
control of the fuel station and evaluated as a "tank full" signal. There is now an automatic drawback of
fuel and/or air bubbles into the fuel station/fuel container. Should the situation arise, aspirated air
bubbles are detected by the detector in the fuel station. Only when "bubble-free" fuel is sucked in (and
detected), is it ensured that all air has been removed from the bag tank. If necessary, the system
performs a second fill/drawback cycle to remove all air bubbles from the bag tank.
Once the air bubbles have been removed, the tank is completely refilled and then emptied by a defined
volume (decompression).
You then have a full bag tank without overpressure.

18/ 53
B2) Connection diagram for multiple bag tanks
Flow
Sensor PumpFuel detector
Fuel detector
Fuelstation
Fuel container
Flowback line
Fuel supply line
to engine
Model
Fill-line
Bladder-tank(s)
Bladder-tank(s)
Fueling
connector
/Kraftstoff-
befüllanschluß
This results in the following filling cycle:
Fuel is first filled into the bag tank from the blue filling hose. If both bags are full, the pressure in the
bags will increase and at the same time the fuel flow will drop slightly. This circumstance is recognized by
the control of the fuel station and evaluated as a "tank full" signal. There is now an automatic drawback
of fuel and/or air bubbles into the fuel station. Should the situation arise, aspirated air bubbles are
detected by the detector in the fuel station. Only when "bubble-free" fuel is sucked in (and detected), is
it ensured that all air has been removed from the bag tank. If necessary, the system performs a second
fill/drawback cycle to remove all air bubbles from the bag tanks.
Once the air bubbles have been removed, the tanks are completely refilled and then emptied by a
defined volume (decompression).
You then have a full bag tanks without overpressure.

19/ 53
B3) Refueling of single normal tanks without flowback line
This option is suitable for filling single "normal" tanks.
Tanks of the same size connected in parallel can also be conditionally filled (if they fill up quickly).
Flow
Sensor Pump
Fuel detector
Fuel detector
Fuelstation
to engine
/zur Turbine
Model
normal-tank
Flowback line / Rücklauf
Fuel supply line
Kraftstoffversorgung
Fill-line
/Befüll-Leitung
Fuel container
/Kraftstoffreservoir
tiny-overflow catch tank
Kleiner Überlauftank
ca. 30-70ml
tank overflow
Tankentlüftung/Überlauf
Optional
In normal tanks (not bag tanks) the fuel flow will also drop slightly as fuel flows into the tank overflow.
However, if several such tanks are connected in series, this circumstance may occur several times until
all individual tanks are full. Certain "tank full" detection is not guaranteed in these cases on the flow
signal alone and the flowback line should be used! See option A).
However, the flow rate decrease can be used as a "tank full" signal for a tank system consisting of only a
single "normal" tank. In this case, you can dispense with the connection of the flowback line. At the end
of refueling, a small volume of fuel will escape from the overflow of the main tank (about 30ml). This
overflow of fuel into the environment can be prevented by optionally interposing a small overflow tank
before the actual overflow. This "mini-tank" then collects small amounts of fuel that could otherwise
flow into the environment until the over-pressure trip triggers.
Advantage: A single refueling line is enough, and no fuel gets into the environment.
Disadvantage: Not suitable for series connection of several tanks.

20/ 53
Control panel
Overview of the control keys
I
Stop
Fill
Empty
Fu e l- Sta tio n
On/Off key as
well as Stop key
Starts the filling
process or
pumping
forwards
Starts the
emptying
process or
pumping
backwards
Change key.
To change values/settings,
keep this key pressed.
Then change the value with
the +/- keys
Menu selection key
While holding down the key,
use the +/- keys to select the
desired setting menu, then
release the key to jump to
the selected menu.
+ key
Scroll forward or
increase a value
- key
Scroll backward
or decrease a
value