PowerBox Systems cockpit User manual

Instruction Manual
PowErBox Cockpit
PowErBox CompEtition
PowErBox ProfEssionAl

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PowerBox-Systems − World Leaders in RC Power Supply Systems
Dear customer,
We are delighted that you have decided to purchase a power supply unit
from PowerBox-Systems.
We hope you have many hours of pleasure and great success with your new
PowerBox.
1. PRODUCT DESCRIPTION
The PowerBox Competition, Cockpit and Professional have undergone
constant development since their introduction in 2009. For example, the
menu system has been improved, and new functions such as telemetry and
the door sequencer assistant have been added.
These PowerBoxes are modern power supply systems which contain all
the electronic components required for modern receivers, servos and mo-
dels. All the essential components for a secure power supply voltage - ICs,
micro-controllers and electronic circuits - are duplicated.
The outstanding features of this High-End power supply unit are a raft of
the latest innovations such as an integral high-resolution graphic OLED
screen, door sequencer capable of multitasking with Setup Assistant, four
match-channels and the facility to bind to the downlink channels of various
RC system manufacturers.

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FEATURES:
Integral high-resolution graphic OLED screen with 128 x 64 pixels
Particularly user-friendly menu-based programming using the Sensor-
Switch
Door sequencer: six freely programmable outputs with set-up assistant
Channel lock when undercarriage is retracted
11 channels inclusive one channel for the doorsequencer in the Cockpit
Version
12 channels in the Competition version
8 channels in the Professional version
Signal amplification and interference suppression for all channels
Synchronised servo output for totally synchronous servo response
Variable frame rate, range 9 ms - 21 ms
16-bit processor for fast, high-resolution signal processing
Four match-channels, each for two servos. Accurate adjustment of all
eight servos
Double regulated output voltage for receivers and servos
Can be connected to Jeti, Futaba, Spektrum, HoTT and Multiplex down-
link channel bus systems
Direct transmission of battery voltages and capacities (not Professional)
to the transmitter
Separate voltage and capacity (not Professional) displays for each bat-
tery
Software-selectable servo voltage: 5.9 V or 7.4 V
Minimum value memory displays any voltage collapses
Large-area heat-sinks for high regulator power
Regulator monitor, regulator malfunction indicator
Support for three battery types: LiPo/LiIon, NiMH/NiCd, LiFePo
Suppresses any servo feedback currents which might develop
Can be updated using the PowerBox USB Interface or BlueCom adapter

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PowerBox-Systems − World Leaders in RC Power Supply Systems
2. CONNECTIONS, CONTROLS
The following illustrations show the essential sockets and controls:
Door sequencer
outputs
Servo sockets
OLED screen
Battery input,
Battery 1 and 2
Receiver inputs
Connector for Jeti, Futaba, Mul-
tiplex and HoTT Telemetrie
Left: socket for Spektrum telemetry
Right: SensorSwitch socket
LEDs for power
ON signal
SET-Button
Switch buttons for
Battery 1 and 2
LED for activation

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3. FIRST STEPS, THE UNIT IN USE:
In the following instructions we do not differentiate between the PowerBox
Cockpit, Competition and Professional, since the method of programming
the three units is absolutely identical. The only difference is that the Power-
Box Cockpit includes the door sequencer function.
3.1 CONNECTIONS
Plug the batteries into the MPX connectors on the backer with correct pola-
rity. We recommend PowerPak 2.5 X2 or 5.0 X2. If you prefer to use other
makes of battery, or packs you have assembled yourself, please take parti-
cular care over polarity - it is always better to check twice rather than make
a mistake. If you connect a battery to the backer incorrectly, this will immedi-
ately ruin the associated regulator. The unit does not feature reverse polarity
protection, as this minimises power losses between battery and backer. The
+markings are printed clearly on the case cover.
Connect the SensorSwitch to the appropriate red socket. Note that the
ribbon cable must run upwards. In models subject to powerful vibration we
recommend that you secure the ribbon cable at a minimum of one point in
order to prevent the connector working loose and falling out. Although this
would have no effect on the switched state of the backer, it would prevent
you switching it off.
3.2 THE PROCEDURE FOR SWITCHING ON AND OFF
The method of switching the unit on and off is very simple, and the process
effectively eliminates the possibility of changing the backer’s status acci-
dentally. This is the procedure
Locate the SET button on the SensorSwitch and hold it pressed in until the
central LED glows red. Now press buttons I and II in turn to switch the backer
on.
Repeat the procedure to switch off: hold the SET button pressed in, wait until
the central LED glows red, then confirm by pressing buttons I and II in turn.
Your PowerBox stores the last switched state (on or off). That means: if the
backer is switched off using the SensorSwitch, it stays switched off.

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PowerBox-Systems − World Leaders in RC Power Supply Systems
Once switched on, the backer can only be turned off again using the switch
unit. Intermittent contacts or interruptions in the power supply cannot cause
the backer to be switched off.
3.3 MAIN SCREEN DISPLAY
When switched on, the unit’s integral screen shows this display:
Key to the individual display points:
- Digital voltage display:
This extremely accurate display allows you to read off the voltage of the bat-
tery directly, i.e. the voltage which is present at the input of the PowerBox.
- Graphic voltage display:
A brief glance into the model provides you with information about the bat-
teries’ state of charge. This display is always correct for the type of battery
you have selected. This means that the bar will extend right to the top of the
box if the connected battery is fully charged - assuming that you have set
the correct battery type. If the bar only fills the bottom third of the box, then
the corresponding battery is almost flat. This indicator is supplemented by
the residual capacity display.
- Residual battery capacity (Cockpit/Competition only):
This display shows the momentary capacity value of the battery - again, as-
suming that you have previously set the battery type correctly. This display
is capable of providing very accurate information about the remaining bat-
tery capacity, although ageing effects or defective batteries may falsify the
value. In practice this means that you should always take both values into
account: if the remaining capacity appears to be high, but the voltage has
already fallen to a low level, you should consider it an urgent necessity to
check the battery more closely.

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- Graphic indicator of battery charge state:
This display is set to match the capacity you previously entered for the bat-
teries connected to the backer. Assuming that the battery is of good quality,
this means: if the bar only reaches the half-way point, then the battery is
still half-full.
- Operating time:
This figure shows the elapsed time since the last RESET. It is important al-
ways to carry out a RESET after each battery charge process.
- Output voltage:
This value displays the backer’s exact output voltage. The voltage fed to the
servos and receiver is the exact value displayed here.
Note: The residual capacity of the two batteries as displayed on the
screen is likely to drift apart as the packs are discharged; this is due to
minor differences in the rate of discharge of the batteries through the
PowerBox. This by no means indicates a fault in the PowerBox; in fact it
proves that the system features genuine redundancy. Here at PowerBox
Systems we take great trouble to compensate for manufacturing tole-
rances between the two regulators, but it is never possible to produce
a system which is completely devoid of tolerances. The only method of
discharging two batteries at 100% identical rates is to use a system fit-
ted with only one regulator. However, such systems cannot be claimed to
offer redundancy!
3.4 AFTER THE CHARGE PROCESS
The PowerBox must be reset after each charge process, otherwise it is im-
possible for the unit to display reliable values for energy consumption and
operating times. The latest software release detects a charging process and
resets the capacity counters automatically.
The capacity counters can be reset ma-
nually: With the system switched on, lo-
cate both buttons I and II on the Sensor-
Switch and press them simultaneously;
hold them pressed in until the following
screen display appears:

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PowerBox-Systems − World Leaders in RC Power Supply Systems
3.5 BASIC SETTINGS
The PowerBox Cockpit, Competition and Professional feature a new kind
of graphic OLED screen, intended to do away with old-fashioned program-
ming methods based on flashing LED codes, morse code beeps or mecha-
nical jumpers. The screen provides the basis for an extremely user-friendly
control system, and eliminates the need for a supplementary setup unit or
programming device. The SensorSwitch is employed as a convenient me-
ans of entering settings within the menu system, and since the Sensor-
Switch is always used as the main ON / OFF switch, it is always installed in
the model, so you cannot forget it. Wherever possible the screen provides
full information in English; few abbreviations are used. The overall result is
an intuitive method of programming which is a great advantage at the flying
field, as you will rarely need to consult the operating instructions.
This is the basic rule in programming: buttons I and II are used to move the
cursor or change values, while the SET button is used to select or confirm
your inputs.
The breadth of functions offered by the PowerBox Cockpit, Competition
and Professional is enormous, but the unit is by no means difficult to ope-
rate. To provide a clear idea of the sequence required in order to use the
backer, we have drawn up a brief list of operations
1. Battery setting Point 3.6
2. Servo matching and door sequencer Points 4 and 5
3. Telemetry settings Point 8
3.6 BATTERY SETTINGS
These settings should always be entered first, so that you have an accura-
te view of the state of the battery while you carry out further adjustments.
In the screenshot below you will see the default settings of the PowerBox
Cockpit, Competition and Professional. If you wish to change them, this is
the procedure:

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- Switch both batteries on.
- Press the SET button and hold it pressed in until the following display ap-
pears:
- Press button II until the cursor (hollow circular ring) lines up with Power
Manager, then press the SET button. The following display now appears:
If you wish to change one of the settings, use buttons Iand II to move the
cursor to the appropriate menu point, then press the SET button to select it
(cursor changes to a solid disc). You can now alter the value using buttons
Iand II. Once you have selected the desired value, press the SET button to
confirm it; this saves (stores) the new value. Select the menu point OK to
return to the main menu.
Note: the presence of a solid disc (instead of a ring) indicates that you
are in a menu point.
It is possible to alter a value more quickly by holding one of the two buttons I
or II pressed in; the value then starts to change slowly in the corresponding
direction, and the rate of change accelerates with time.

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PowerBox-Systems − World Leaders in RC Power Supply Systems
Key to the individual menu points:
- Chemistry: this is where you set the battery type. Three different types of
battery are available:
• Two-cell LiPo
• Two-cell LiIon
• Five-cell NiMH
• Two-cell LiFe
- Capacity: you can enter the nominal capacity of your batteries at this point.
- Output voltage: you can select the output voltage to 7.4V or 5.9V
CAUTION: if you intend to select the 7.4V output voltage, please ensure
before you make the change that all the consumer units connected to
the unit, i.e. all servos, receivers and gyros, are compatible with a 7.4V
supply. Information on this subject can be found in the instructions for
these components supplied by the manufacturers.
Compared with a direct, unregulated voltage of 8.4V, the advantage of a sta-
bilised 7.4V supply is that the voltage is always constant. This means that
the servos in your model always run at the same speed and with the same
torque, regardless of the manoeuvres you fly. For example, if you were to
operate the servos on the unregulated voltage of LiPo batteries, their run-
ning characteristics would alter as the freshly charged batteries steadily
discharged during the flight. Another major advantage of a regulated 7.4V
voltage is that it completely eliminates damaging voltage peaks (spikes);
this extends the useful life of the servos substantially.

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4. SERVO MATCH FUNCTION
The Servo-Match function provides the facility for adjusting the centre po-
sition and end-points of the servos connected to the backer. If you have a
model aircraft with more than one servo per control surface, this makes it
possible to set up multiple servos to move to identical positions at identical
times. Since this ensures that the servos do not work against each other,
their effective life is increased, and more power is available to move the con-
trol surfaces; matched servos also draw lower current.
It is also possible to reverse the direction of rotation of individual servos.
This function is useful if you wish to employ fewer channels at the trans-
mitter. For example, the right and left elevators, or the right and left landing
flaps, can be controlled using only one radio channel. In models such as jets
and warbirds, which by their nature have a large number of working sys-
tems, this feature can be very important, but it can also make transmitter
programming much easier with other types of model.
Select SERVO-MATCHING in the Main menu, and the following screen dis-
play appears:
To ensure accurate servo matching, the output to be adjusted must first be
initialised. Leave the associated transmitter stick at centre. Move the cursor
to INIT OUTPUT and press the SET button. Now move the transmitter stick
to both end-points.
The graphic display shows the movement of the upper arrow, which indi-
cates the input signal. The bar inside the box shows the movement of the
output. The three lower arrows indicate the centre and end-point positions
which are ‘learned’ in this process.
Note: if the channel has not yet been initialised, it is not possible to select
the START SERVOMATCHING and REVERSE SERVO points.

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PowerBox-Systems − World Leaders in RC Power Supply Systems
The following examples illustrate the correct procedure for the Servo-Match
function:
a) Fine-tuning multiple servos to operate on a single control surface; in
this case the aileron of the right-hand wing.
- Disconnect the linkages to the - as yet unmatched - servos, to avoid them
being subjected to severe forces during the adjustment procedure.
- Set up one servo (generally the inboard one – Servo 1) in mechanical terms,
using the transmitter if necessary; continue adjusting until the centre point
and the maximum end-points are exactly as required.
- Now access the Servo-Matching menu and select the servo to be matched.
In our example this would be Output B and Servo 2.
- Initialise Output B as described above.
- Move the cursor to START SERVOMATCHING » but do not press the SET
button at this stage!
- At the transmitter, move the aileron stick to the position to be adjusted,
then press the SET button.
- You can now release the aileron stick: the PowerBox maintains this positi-
on. You now have both hands free, and can adjust the position accurately
with one hand, using buttons I and II, whilst checking the length (matching)
of the disconnected ball-link at the horn with the other hand.
- Press the SET button again to conclude this adjustment.
- Complete the set-up procedure for the centre position and both end-points
before re-connecting the servo linkage.
- If you need to carry out further adjustments to another end-point or centre
position, move the aileron stick in the desired direction again, and press
the SET button again to start the procedure.
- Repeat the procedure with all the servos connected to the same control
surface.
Note: if your model is fitted with very large ailerons, it can be advan-
tageous not to match the servos with 100% accuracy. If the servos are
precisely matched, gearbox play may allow aileron flutter to develop. You
can eliminate this risk as follows: first match the servos exactly to each
other, and then press buttons I or II two or three times to reduce the ef-
fect of lost motion in the servo gears to a controlled extent.

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b) Reversing an output when servos are installed in a “mirror-image” ar-
rangement: in this case left and right landing flaps.
- Disconnect the linkage to the left-hand landing flap, to avoid the servo
being subjected to severe forces during the adjustment procedure.
- Connect right landing flap to Output D, Servo 1
- First set up the right-hand landing flap servo in mechanical terms, using
the transmitter; continue adjusting until the centre point and the maximum
end-points are exactly as required.
- Now access the Servo-Matching menu and select the servo to be matched
(left landing flap Output D, Servo 2).
- Move the landing flap switch to the centre position – not one end-point!
- Now select: INIT OUTPUT
- The output is initialised by moving the switch on your transmitter to both
end-points. If you have set up a delay at the transmitter, wait until the end-
point has been reached.
- Use the SET button to select REVERSE SERVO. A tick appears after the
function, and the left-hand landing flap servo now operates in the correct
direction.
- Move the cursor to START SERVOMATCHING and press the SET button.
- Use button I or II to adjust the centre position of the left-hand landing flap
to the exact position required, then press the SET button.
- Move the transmitter switch to the “flaps extended” position, then press
the SET button again.
- Now set the appropriate end-point using button I or II before concluding
the procedure with the SET button.
- Move the transmitter switch to the “retracted” position, then press the SET
button again.
- Now set the corresponding end-point with button I or II, and conclude the
procedure by pressing the SET button.
- Both landing flaps will now move synchronously.

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PowerBox-Systems − World Leaders in RC Power Supply Systems
5. SETTING UP THE DOOR SEQUENCER
Select the SEQUENCER point at the main menu; this takes you to the follo-
wing screen display:
The SETUP ASSISTANT is a function in the Cockpit which has been included
since software version V15; it makes the task of programming the actual
door sequencer function considerably easier.
The EXPERT MENU provides a very powerful programming interface, with
which you can program highly individual sequences, or alternatively expand
the settings previously entered using the SETUP ASSISTANT.
The SETUP ASSISTANT describes the TASKs in the actual door sequencer
in accordance with the data you enter. The Assistant guides you through
the settings: everything you need to do is described on the screen. These
printed instructions simply provide additional information which cannot be
displayed on the PowerBox screen due to size limitations.
The recommended programming procedure is as follows: first enter the ba-
sic settings using the SETUP ASSISTANT. At this point the system setup will
be complete for 95% of all models. If you wish to add more wheel doors or
adjust the sequence to cater for other details, this can be carried out in the
EXPERT MENUE.
Select the SETUP ASSISTANT in the menu; this takes you to the following
screen display:
Operate the appropriate transmitter switch, and the PowerBox automati-
cally detects it as the switch which you have assigned to the retract system.

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The on-screen arrows should now be located in front of UP/DOWN. If you
find that your retract switch works in the wrong “sense” (direction), correct it
by reversing that output at the transmitter.
Press the SET button again to leave this function, and move the cursor to OK.
The door sequencer’s method of working is determined in the following
menu:
The following sequences are available:
Mode 1:
Extend undercarriage:
Open wheel doors extend undercarriage
Retract undercarriage:
Retract undercarriage close wheel doors
Mode 2:
Extend undercarriage:
Open nosewheel doors extend nosewheel
Open main wheel doors extend main undercarriage close main wheel
doors
Retract undercarriage:
Retract nosewheel Close nosewheel doors
Open main wheel doors retract main undercarriage close main wheel
doors

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PowerBox-Systems − World Leaders in RC Power Supply Systems
Mode 3:
Extend undercarriage:
Open nosewheel doors extend nosewheel close nosewheel doors
Open main wheel doors extend main undercarriage close main wheel
doors
Retract undercarriage:
Open nosewheel doors retract nosewheel close nosewheel doors
Open main wheel doors retract main undercarriage close main wheel
doors
Move the cursor to the appropriate mode, and press the SET button to con-
firm your choice. Select OK to move on to the next screen display:
Connect your retract system valve to output 4. One of the following will now
occur, depending on the way your valve is programmed:
Valve is triggered, and the undercarriage retracts. Press button II on your
SensorSwitch, and hold it pressed in until the undercarriage extends again.
Valve is not triggered, and the undercarriage remains in the extended state.
Press the SET button twice to move to the next screen display:

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The undercarriage should now retract. If not, hold button I pressed in until
the valve is triggered, and the undercarriage retracts. Press the SET button
to move on to the next stage of the procedure.
Connect the nosewheel door servo to output 1. Press the SET button to clo-
se the nosewheel door; repeat the procedure in the next set-up screen to
open the door.
The succeeding steps are used to set up the second front wheel door and
the rear wheel doors; the procedure is identical to that described for the
nosewheel door. The servo for the right-hand wheel door is connected to
output 2, that for the left-hand wheel door to output 3.

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PowerBox-Systems − World Leaders in RC Power Supply Systems
Note: if you are only using one valve for all the wheel doors, you can by-
pass the last five points by selecting OK.
All the settings are now complete, and you will see one final safety query:
Move your transmitter switch to the “gear down” position. It will now take a
few moments for the Assistant to create the necessary tasks, and move the
doors to the correct position without any fouling or jamming.
If the timing (pauses, opening times and closing times) is not exactly as you
wish, you can change the settings manually at any time.
Select the EXPERT MENUE point in the DOORSEQUENCER menu and you will
see this screen display:
In the Expert Menue, the sequencer does not constrain you to use pre-set
modes, forcing you to adopt fixed, pre-determined vectors for retracting and
extending the undercarriage.
The PowerBox door sequencer offers innumerable options, because the
modeller has the freedom to define each step in terms of travel, sequence
and timing. For example, all the wheel doors can be set to open or close at
entirely different speeds. It is also possible to set up multiple forward-and-
back sequences. If the full-size aircraft features a “jerk” when the legs lock,
that can also be simulated. The opening and closing processes can be set
up entirely individually and independently of one another.

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In spite of the vast scope of these facilities, the sequencer is simple and
user-friendly to set up, as the screen and menu system guide you through
the procedure. The sequencer software also features supplementary pro-
gramming aids. Once you understand the principle, the system can easily be
programmed without recourse to the manual.
We always recommend that you start the set-up procedure using the SET-
UP ASSISTANT. This incremental set-up aid creates the tasks required, au-
tomatically detects the retract switch channel, and assigns the transmitter
channel for the gear switch. If you use the Assistant, but find it necessary
or desirable to alter the settings subsequently - perhaps to fine-tune the
timing - then this can be carried out using the menu points outlined below.
To help you arrive quickly at a satisfactory result, the following section lists
the door sequencer functions in detail:
The primary component of the procedure is the TASK, which is self-expla-
natory: a task refers to the movement of a servo from its starting point to its
stop point with a defined start and stop time. Twelve tasks are available for
the retraction process, and a further twelve for extension. In total 24 diffe-
rent movement sequences can be programmed.
A TASK contains the following information:
Value Range
Task number 1 - 12
Extend or retract undercarriage UP » DOWN / DOWN » UP
Servo number 1 – 6
Servo START position 700µs – 2300µs
Servo STOP position 700µs – 2300µs
Start time 0 – 25.0s
Stop time 0 – 25.0s

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PowerBox-Systems − World Leaders in RC Power Supply Systems
Intelligent programming aid:
If you wish to set up multiple tasks in order to move the wheel doors to
several positions, it should be obvious that the new task’s initial positional
value and start time are determined by the previous position and time for
the servo concerned. This is carried out automatically, helping to speed up
the programming procedure, and eliminates the need for you to note down
the servo’s previous position and stop time.
A similar situation applies when you set the retract process DOWN » UP.
When you set up the extend process UP » DOWN, the positional values for
Start and Stop for that servo are already entered as Stop and Start.
The following example demonstrates how one wheel door opens half-way
when the transmitter switch is operated, pauses for a while, then runs to
its end-point. When the switch is reversed, the door returns to its original
position in a single movement lasting three seconds.
UP » DOWN means undercarriage exten-
sion. Output 3 of the door sequencer has
been selected. The servo runs from its
initial value of 1100 µs (right servo end-
point) to the stop value of 1500 µs (servo
centre).
The servo only starts moving 1.0 seconds
after the switch is operated, and the period is 3.0 seconds (4.0 s – 1.0 s).
Task 1 has now completed its course.
After a pause lasting 2.0 seconds at servo
centre, the servo starts moving in the di-
rection of 1800 µs (left servo end-point).
The movement period is 2.0 seconds (8.0
s – 6.0 s).
Task 2 has completed its course.
DOWN » UP means undercarriage retrac-
tion. In this example, when the switch is
operated, the servo immediately starts
running slowly from the left to the right
servo end-point (Start time 0.0 s).