JetCat P80 User manual

Page 1/39
JetCAT P80
Instruction manual
Ing. Büro CAT
M.Zipperer GmbH
Etzenbach 16
79129 Staufen
Tel.: [phone]
Fax: [phone]
Internet: www.cat-ing.de

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Table of contents Page
Introduction............................................................................................................................................................3
Safety Precautions ................................................................................................................................................4
The Checklist.........................................................................................................................................................5
Before Running the Turbine .....................................................................................................................5
After Stopping the Turbine........................................................................................................................5
Electrical connection diagramm (1/2)....................................................................................................................6
Electrical connection diagramm (2/2)....................................................................................................................7
Power Supply............................................................................................................................................7
Charging the Battery.................................................................................................................................7
Glow Plug .................................................................................................................................................7
Fuel / Fuel Care.....................................................................................................................................................8
Fuel System..............................................................................................................................................8
Hopper Tank.............................................................................................................................................8
Fuel System Connection Diagram............................................................................................................9
Starting Gas Diagram.............................................................................................................................10
Filling the Starting Gas Tank:.................................................................................................................11
Mounting the Turbine...........................................................................................................................................12
Connections at the Turbine.................................................................................................................................13
The LED I/O Board..............................................................................................................................................14
Aligning the ECU to your R/C System.................................................................................................................15
Manual Mode.......................................................................................................................................................18
Turbine Starting / Running...................................................................................................................................19
Turbine Stopping / Cool Down.............................................................................................................................20
Manual Off..............................................................................................................................................20
Auto Off ..................................................................................................................................................20
Automatic Cooling Process ....................................................................................................................20
Battery / Fuel Warning Function..........................................................................................................................21
Turbine Running States.......................................................................................................................................21
Explanation of the Turbine States ..........................................................................................................21
Explanation for Turbine Shut Down........................................................................................................24
Ground Support Unit (GSU)................................................................................................................................25
GSU Control Panel Descriptions............................................................................................................25
GSU Switch Descriptions .......................................................................................................................26
GSU LED Descriptions...........................................................................................................................26
Menu Structure....................................................................................................................................................27
Menu Selections.....................................................................................................................................27
Selecting a Menu............................................................................................................................27
Change Values / Items ...................................................................................................................27
The RUN Menu.......................................................................................................................................28
The Min/Max Menu.................................................................................................................................28
The R/C Check Menu.............................................................................................................................28
The INFO Menu......................................................................................................................................29
The Statistic-Menu..................................................................................................................................30
The LIMITs Menu ...................................................................................................................................30
Troubleshooting...................................................................................................................................................31
Maintenance........................................................................................................................................................32
Parts List..............................................................................................................................................................33
Optional Accessories..............................................................................................................................33
Airspeed Sensor..................................................................................................................................................34

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Introduction
Welcome to the Jet Age of model aircraft! CAT is pleased to sell, support and service the
JetCAT P80 turbine engine and greatly appreciates your purchase. We hope the JetCAT P80
brings you many days of pleasurable flying.
Obviously, model turbine aviation - despite all the apparent fun involved - is serious business.
The JetCAT P80 has undergone extensive testing and redesign, in order to ensure it is a safe
and reliable model engine; however, it is not a recommended power source for the average
model builder. It requires a good background in model flying and a working understanding of
the principles of turbine engines, along with a disciplined commitment to correct and safe
operation, in accordance with these instructions.
To begin, read this manual thoroughly. Develop an overall impression of the engine and its
operating procedures, measuring equipment and accessories. Study the material step-by-step
and ascertain how to install, operate and maintain your turbine engine. If you are unsure about
anything, re-read it again.
DO NOT OPERATE THE JetCAT P80 BEFORE YOU HAVE READ THE MANUAL AND
FULLY UNDERSTAND EVERY PROCEDURAL DETAIL
Should you still have doubts or questions, do not hesitate to contact CAT for further assistance.
Once you are accustomed to handling the JetCAT P80, you will observe that it is a very reliable
engine. Some experienced operators have expressed their belief that it handles better than
many piston engines. However, always remember this is a REAL JET ENGINE, requiring
knowledge, discipline and maintenance.
In order to learn more about the development of the model turbine engine and understand its
function, we highly recommend reading Gas Turbine Engines for Model Aircraft by Kurt
Schreckling and Model Jet Engines by Thomas Kamps. These books are available through:
Traplet Publications
Traplet House
Severn Drive
Upton upon Severn, Worcestershire ISBN 0 9510589 1 6
United Kingdom WR8 0JL ISBN 0 9510589 9 1

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Safety Precautions
If other persons or animals are present while operating the JetCAT P80, ALWAYS ENFORCE
THE PROPER MINIMUM SAFE DISTANCES FROM THE TURBINE!
The recommended minimum safe distances are:
In front of the turbine = 15 feet
On the side of the turbine = 25 feet
Behind the turbine =15 feet
In case of a mishap, fire extinguishers should be on hand at all times. CAT recommends the
CO/2 variety. Powdered extinguishers will contaminate the precision components, upsetting the
integrity of the turbine.
To the avoid hearing damage, always use hearing protection when you are near a running
turbine engine!
When the turbine is running, never place your hands closer than six inches into the area of the
intake. An extreme suction - which can grasp a hand, fingers or other objects in a flash -
prevails in this area. Be aware of this source of danger, always!
Prevent foreign materials from entering the intake or exhaust when working with the turbine.
Before operation, make sure there are no lose parts or debris near the turbine. Objects being
sucked in can cause severe damage.
Always exercise caution around the hot parts of the turbine, to avoid burns. The outer case at
the turbine stage and nozzle reaches 450-500°(Celsius), while the exhaust gas may exceed
720 °C.
Assure that the fuel is mixed with approximately 5% synthetic oil. Use only synthetic turbine oils
available at local airport fuel suppliers or from CAT.
Never run the turbine in a closed room, or an area near any kind of flammable matter. Do not
fly turbine-powered aircraft near flammable materials, nor in forested tracts or areas
experiencing drought or dryness. Obey all forest fire regulations and warnings by refraining
from operating the JetCAT P80 in restricted fire zones. Never operate model turbine jet aircraft
in or around residential or heavily populated areas.
After running the turbine, briefly point the nose upward to assure that there is no fuel left in the
engine.
Installation of unauthorized parts from another manufacturing source may also result in engine
failure. Do not introduce engine or electronic components other than those delivered by CAT,
unless you are willing to risk destroying your turbine! CAT‘ parts are designed and engineered
specifically for the JetCAT P80. Accept no substitutes, unless you are prepared to sacrifice
your aircraft.

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Warning:
A flying model with a turbine can reach higher flight speeds than ducted fan-powered models,
because the turbine’s thrust degrades less with higher flight speeds. With attainable flight
speeds of over 250 MPH, you can quickly run out if flying room. There is also a danger of
developing control surface flutter or mechanical overload, causing the model to fail in flight.
When piloting a turbine powered aircraft, one must properly control the throttle. Full power
should be used for takeoff or vertical maneuvers and a reduced setting for level or descending
flight. To restrict the maximum flight speed, an optional airspeed sensor is available.
The Checklist
Before Running the Turbine
•Charge ECU Battery
•Prepare fire extinguisher
•Check fuel lines and filter. Make sure they are clean with no restrictions
•Check that the fuel tank vent is unobstructed
•Mix 5 % oil in fuel (i.e.: 1 quart per 5 gallons of kerosene)
•Fill fuel tank(s). Make sure the main and header tanks are full
•Be certain the starting gas release valve is closed, before filling the starting gas tank
•Turn on receiver switch
•Place the model with nose into the wind
•Activate brakes and start turbine
After Stopping the Turbine
•Turn model into the wind. Activate brakes and stop turbine
•After the cooling process (approximately two minutes), turn off receiver switch
•After each flying session, open starting gas release valve, to empty the tank, before storing
the model. This should be executed in a safe area

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Electrical connection diagramm (1/2)
AUXTHR
RC
receiver
(Empfänger)
"phone"- cable
("Telefonkabel")
The sequence of these connections can be changed as required (parallel bus system)
(Die Reihenfolge der Verbindungen spielt keine Rolle --> paralleles Bussystem)
Connection - diagramm
(Verbindungsschema)
ECU top-view
(von oben)
NiCad
battery (6 or 7cells)
(optional)
linked to a 3 position switch
on the RC-transmitter
(3-Stufenschalter)
Throttle stick
(Gaskanal)
Receiver-
battery
(Empfänger akku)
Receiver-
ON/OFF switch
(Empfängerschalter)
The ECU is automatically
powered up whenever the
receiver is switched on
(Die Elektronik schaltet sich automatisch EIN
sobald der Empfänger eingeschaltet wird)
Jet-tronic
Info Min/Max
Change
Value
Item
Select
Menu
Run Limits
++ -
Manual
Standby / Man.
Ignition
Ignition on
Pump running
OK / Reset...
Remote - GSU
Oilpump :max. 0.6A
FuzzylogicFuzzylogic
Microcomputer-
Control
Ba
tte
ry
:
7,2
-12
V
-
+
6-
10
Ce
lls
Te
mp
.&
Rp
m
Se
ns
or
Oil
pu
mp
Ai
rs
pe
ed
Jet-tronic -
II- P80
Pr
op
an
e
Sh
ut-
Off
val
ves
Da
ta-
BU
S
V2.0
Fu
el
-
+
-
+
"phone"- cable
("Telefonkabel")
LED I/O-
board
RS232
Adapter
PC
GSU =ground support unit
(Programmier- und Anzeigegerät)
Airspeed
Sensor air pressure
(Staudruck)
static pressure
(statischer Druck)
(optional)
Shut-off
valve
fuel
Shut-off
valve
propane
pitot-tube
(Staurohr)
6-wire phone cable to turbine
6-adriges Telefonkabel, zur Turbine
6-wire phone cable
6-adriges Telefonkabel

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Electrical connection diagramm (2/2)
Power Supply
Power for all electrical components of the turbine (starter / glow plug / ECU / fuel pump /
fuel and gas valves) are supplied by the six-cell, 1250 mah ECU battery. The amount
of battery capacity used per flight is approximately 300-400 mah. This includes starting
and cool down. The ECU NiCad battery must be recharged after three (3) flights! CAT
recommends recharging after every flight, making it a routine that is not overlooked.
The battery should be cycled periodically, to prevent NiCad memory problems that
lower the battery’s capacity.
Charging the Battery
Do not charge the battery, with a quick charger using negative discharge pulses, when
connected to the ECU. This will destroy the electronics of the ECU. The only
recommended method is to disconnect the battery from the ECU and charge it directly.
If you are absolutely sure that this is not the case with your charger, the battery can be
charged using an Y cable.
Glow Plug
A modified, conventional (hot range, non-idle bar) glow plug (Rossi #3) is appropriate.
The glow plug is installed on the turbine without a washer. Do not over-tighten or you
may damage the threaded bushing. Light torque is fine; there is no vibration to loosen
it. The glow plug is modified, so that two turns of the element extend beyond the bottom
of the plug. With a pin, pull out two turns of the element. Make sure the plug glows
brightly red. The limits menu features an adjustment for glow plug voltage, if needed.
This adjustment is described later.
Connection - diagramm (2/2)
(Verbindungsschema)
ECU bottom-view
(von unten)
Glow-plug
Starter device
Fuel-pump
Outputs are unfused !
max. 12A
Fuzzylogic
Microcomputer-Control
Jet-tronic -II- P80
-
To turbine (3 wire cable)
(Zur Turbine 3-adriges Kabel)
Fuelpump
(Kraftstoffpumpe)

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Fuel / Fuel Care
The JetCAT P80 can use Jet-A1, 1-K kerosene or deodorized kerosene for fuel. Fuel
must be mixed with 5% synthetic turbine oil.
Example formula: 1 quart of oil in 5 gallons of fuel.
Oil brands like Aeroshell 500 or Exxon 2380 are suitable.
Fuel System
If a header tank is used, the clunk is placed in the main tank. Otherwise, place the
clunk in the last tank before the fuel valve. Do not use a felt clunk. The supplied
clunk is designed to reduce the amount of bubbles in the fuel line.
When installing the fuel lines on components with nipples, slightly heat the tubing
before connecting. This will soften the tube, making it easier to install. When installing
tubing on a metal tube, secure the tubing by placing a tie-wrap around the connection.
To remove tubing from nipples, you must cut the tubing off. Be careful not to damage
the nipple when cutting off tubing. To insert tubing into Festo quick release fittings, use
firm pressure until you feel the tube snap in. To release, press in on the front ring, while
pulling the tubing out.
ALWAYS use a gasoline-compatible stopper. Silicon stoppers swell and leak.
Check your fuel filters every ten (10) flights. You may be surprised how rapidly they can
clog up! The filter is installed with the O-ring located toward the fuel shut-off valve.
When running the engine at full power, check the fuel line from the pump to the engine.
If there is a large quantity of air bubbles flowing with the fuel, there is probably a
restriction in the fuel system or an air leak in a fitting.
Hopper Tank
A hopper tank is strongly recommended, between the main fuel tank and the engine.
Using a hopper tank greatly lessens the possibility of air bubbles in the fuel system,
thus reducing the risk of a flameout. The hopper tank should accommodate
approximately two to four (2 to 4) ounces and the fuel pickup should be a brass tube,
positioned in the center of the tank. Do not use a clunk.

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Fuel System Connection Diagram
Hoppertank
main tank ( Haupttank)
Sinterpendel
Entlüftung
Filter
to turbine (zur Turbine)
in
out
Shut-off
valve
( Ventil )
Fuelpump
(Pumpe)
tank fill connector
(Befüllungsanschluß)
hopper-tank

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Starting Gas Diagram
Version 1
Version 2
gastank fill connector
(Befüllungsanschluß
selbstabsperrend,
Kupplungsdose)
do not remove stopper !
(Blindstopfen nicht entfernen !)
gastank fill connector
male
(Kupplungsstecker)
4 -> 3mm tubing adaptor
4 -> 3mm Schlauchadapter
3mm tubing to turbine
3mm Schlauch zur Turbine
(Hilfsgas) Turbine
4mm tubing
4mm Schlauch 3mm tubing 3mm Schlauch 4mm tubing
4mm Schlauch
gastank
shut-off valve propane
Gasventil
connector allways up !
Anschluß immer nach oben !
gastank fill connector
(Befüllungsanschluß
selbstabsperrend,
Kupplungsdose)
gastank fill connector
male
(Kupplungsstecker)
4 -> 3mm tubing adaptor
4 -> 3mm Schlauchadapter
3mm tubing to turbine
3mm Schlauch zur Turbine
(Hilfsgas)
Turbine
4mm tubing
4mm Schlauch
4mm tubing
4mm Schlauch
gastank
connector allways up !
Anschluß immer nach oben !
Shut-off
valve
( Ventil )
Filter