UAV Factory GPU User manual

UAV Factory USA LLC.
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UAV Factory LTD. EUROPE
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LV1005, Latvia
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1
USER MANUAL 1.5
100 W GENERATOR POWER UNIT

UAV Factory USA LLC.
50 South Buckhout Street,
Irvington, NY 10533 USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
UAV Factory LTD. EUROPE
24A-52 Ganibu Dambis,
LV1005, Latvia
Phone: [phone]
Fax: [phone]
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1. Description
100 W Generator Power Unit (GPU) is designed to provide onboard dual voltage regulated power supply for the
unmanned aircraft vehicles.
Despite small size, power unit offers outstanding efficiency as well as unique features such as the ability to monitor load,
battery current, engine rpm, generator and battery voltage through TTL serial communication. All power distribution
parameters can be transmitted to the ground station and monitored during the flight.
Generator power unit can be used with brushless or brushed generators that have a voltage output within 10-35 Volts
and 13-50 Volts respectively. Integrated Lithium Polymer charger is used for the backup battery, which is switched on
during the pre-flight checks, power peaks, or in the event of the engine failure.
Power unit is packed in a sealed aluminum enclosure and fitted with the high-end industrial push-pull connectors. Fan
assisted cooling option is available.
Please contact for customized solutions.
2. Key Features
Light weight, small and efficient
13 V to 50 V input range
100 W continuous load
Compatible with brushed or brushless
generators
6 V and 12 V output
Load current up to 10 A
Short circuit protection
Battery backup connection
3 cell Li-Poly integrated charger
External power connection
Integrated current sensors
TTL connection
IP 64 housing, IP 68 on request

UAV Factory USA LLC.
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Irvington, NY 10533 USA
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UAV Factory LTD. EUROPE
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LV1005, Latvia
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1Enclosure temperature must not exceed 70 °C, additional cooling may be required
2The tachometer range is valid for serial number starting from GPU0042
Electrical Specifications
Brushed generator voltage range
Brushless generator voltage range
13 –50 V
10 –35 V
External power supply voltage range
13 –50 V
Battery Type
3 cells, Lithium Polymer
Battery Voltage
12.6 V
Maximum battery charging current
2 A
Maximum continuous generator input current
8 A
Maximum continuous battery input current
8 A
Maximum continuous external power current
8 A
Output voltage
6 V and 12 V
Maximum output voltage ripple
200 mV@6V 400mV@12V
Continuous load current, 6 Volt output1
5A
Continuous load current, 12 Volt output1
5A
Maximum peak load current
10 A for 10 seconds
Efficiency of 6 Volt output
85% typical
Efficiency of 12 Volt output
90% typical
No load GPU current
110 mA
Tachometer range2
1000-90000 rpm
Tachometer accuracy
200 rpm
Current sensor range
0 to 10 A
Current sensor accuracy
0.2 A
Voltage sensor accuracy
0.1 V
Serial Communication
5V TTL
Mechanical Specifications
Dimensions
59.4 x 115.8 x 32.4 mm
Weight ( with conductive enclosure)
190 grams
Cooling method
Conductive or fan-assisted
Maximum enclosure temperature
70°C
Environmental protection
IP 64 standard, IP 68 on request
Operating temperature
- 40°C to +50°C 1
Electrical connectors
Fischer 104 Series push-pull connector

UAV Factory USA LLC.
50 South Buckhout Street,
Irvington, NY 10533 USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
UAV Factory LTD. EUROPE
24A-52 Ganibu Dambis,
LV1005, Latvia
Phone: [phone]
Fax: [phone]
Email: [email protected]
4

UAV Factory USA LLC.
50 South Buckhout Street,
Irvington, NY 10533 USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
UAV Factory LTD. EUROPE
24A-52 Ganibu Dambis,
LV1005, Latvia
Phone: [phone]
Fax: [phone]
Email: [email protected]
5
3. Performance
The GPU performance graphs are presented below. Efficiency for the 6 V output against the input voltage is shown in
Figure 1, efficiency for 12 V output is shown in Figure 2.
The maximum continuous power of the GPU is dependent on the ambient temperature and the ability to dissipate heat
generated by the GPU. The maximum continuous power to ambient temperature relation is shown in Figure 3. At no
circumstances operating GPU enclosure temperature should reach 70°C.
Figure 1 Efficiency at 6 Volt output vs input voltage
Load current 5 A

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Figure 2 Efficiency at 12 Volt output vs input voltage
Figure 3 Allowable continuous power depending on ambient temperature
Load current 5 A

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4. Generator
GPU is available in brushed or brushless versions. In the brushed GPU version, the brushed generator’s voltage output
must be within 13-50 V range. If the voltage out is below 13 V, GPU will automatically switch to battery source.
In the brushless GPU version, the 3-phase rectifier is used between the generator and the internal DC-DC converter of
the GPU (refer to Figure 5). Therefore DC voltage at the DC-DC converter is equal to rectified value of generator’s AC
voltage. In this case generator’s line voltage RMS value must be within 10 - 35V range. Line voltage RMS value can be
measured between any two leads of the generator. If the voltage out is below 10 V, GPU will automatically switch to
battery source
G
GPU
Brushed
generator
DC-DC
converter
J2
connector
Figure 4 Brushed generator and GPU internal connection
G
GPU
Brushless
generator
DC-DC
converter
J2
connector
a
b
c
Figure 5 Brushless generator and GPU internal connection

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GPU can be used for both - brushed and brushless generators. Please state the required generator type in your order.
The typical connection diagram for the brushless and brushed generator systems is shown in Figure 7 and Figure 8
respectively.
GPU can be used both with inline generators and geared generators. An example of a belt-driven generator is shown in
Figure 6. The ratio between the pulleys is chosen to keep the GPU input voltage under the 50 V limit
Figure 6 Belt-driven onboard generator example
In many cases, at low engine rpm, the voltage generated is less than 13 V, which means that the onboard battery will be
used for powering the unmanned aircraft systems. This is not an issue, since aircraft do not generally fly at low idle
settings for extended periods of time and the power requirements can be met by the onboard battery. The onboard
battery capacity needs to be calculated depending on actual mission profile of the UAV, taking into account possible
aircraft descend time as well as desired pre-flight operation time- please see section 10 for more details and battery
capacity estimation formula. Please use adequate safety factor for your battery capacity estimation results.

UAV Factory USA LLC.
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Irvington, NY 10533 USA
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UAV Factory LTD. EUROPE
24A-52 Ganibu Dambis,
LV1005, Latvia
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Figure 7 Typical connection diagram for brushless generator
Figure 8 Typical connection diagram for brushed generator
GPU
Generator
Battery
6 V load
12 V load
Transmitter
Battery +
GND
Brushed gen +
Ext. power +
GND
+
-
GND
+ 6 V out
+ 12 V out
GND
Serial GND
Serial Tx
RPM sensor
RPM sensor
GND
External power
connector
Generator GND
+
-
GPU
Generator
Battery
6 V load
12 V load
Transmitter
Battery +
GND
Brushless
generator
Ext. power +
GND
+
-
GND
+ 6 V out
+ 12 V out
GND
Serial GND
Serial Tx
RPM sensor
RPM sensor
GND
External power
connector

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UAV Factory LTD. EUROPE
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LV1005, Latvia
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5. Short circuit protection
The GPU has integrated short circuit protection for avoiding the regulator damage in case of a short circuit.
In case multiple loads are used on the same voltage line it is highly recommended to use fuses- this will allow the GPU to
operate in the event of load short circuit. Please see Figure 9 for a diagram of fuse installation.
As an example, fuses can be installed before the payload, rf-transmitters as well as before the individual servos. If, for
instance, there is a short-circuit in the payload - unmanned aircraft can still perform a safe landing.
6. Battery backup
External battery provides power supply to the system in case the input voltage drops below the battery voltage. This
may occur because of several reasons:
a) During engine idle, when generator provides insufficient voltage at the given load
b) During pre-flight preparation when the engine is not operating and the external power supply is not
connected
c) During mechanical generator failure
d) During engine failure
The following formula should be used to calculate approximate battery capacity for a particular UAV configuration:
Battery capacity (Ah) = operation time (h) average load power (W) / battery voltage (V) / 0.8
Where operation time is desired operation time, battery voltage is 11.1 V and 0.8 is regulator typical efficiency.
Load 1
Load 2
Load 3
Fuse
Fuse
Fuse
Figure 9 Installation of the fuse before each load will allow the GPU to supply power in case of the load short-circuit

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Do not use other type of battery except Lithium Polymer 3 cell battery. Maximum battery current should not exceed 8
A. When battery voltage is less than 12.6 V the charger charges the battery with current of <2 A. It is recommended to
connect battery to the system through the switch with current rating not less than 10 A.
When the battery source is used, GPU is not producing exactly 12 volt power output, please see Figure 10 for details.
The battery voltage and output voltage difference is approximately 0.4V and GPU cannot provide 12 V voltage if battery
voltage is less than 12.4 V and starts to operate with 100 % duty cycle.
Figure 10 Output voltage in battery source mode
7. External Power Supply
External power supply can be used as a power source when the engine is no operating. This is especially useful for
laboratory environment testing, during set-ups, during pre-flight checks on field as well as for charging the onboard
battery. The input voltage range should be in range of 13-50 Volts.
8. Connector Description
GPU enclosure has two electrical connectors - J1 and J2, as seen on Figure 11. Pinout of J1 connector is shown in Figure
12 and is the same for both, brushed and brushless GPU configurations.
Please note, pinout of J2 connector is different for brushless and brushed GPU configurations. Figure 13 shows pinout
configuration for brushless GPU option and Figure 14 shows pinout configuration for brushed GPU option.
6 Volt output
12 Volt output

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Figure 11 Input, Output connectors and status LEDs
Figure 12 Connector J1 description
Red mark
RPM sensor
Battery +
GND
GND
External power +
Brushless generator
Red mark
+ 12 V out
+ 6 V out
GND
Serial Tx
Serial GND
Figure 13 Connector J2 description (for brushless generator)

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9. LED Indication
Four indication LEDs are located on the front side of the GPU, see Figure 11 for reference. The main purpose of LEDs is to
facilitate set-up procedure, simplify pre-flight checks as well as to provide clear identification of the battery status
before the flight. The following LED operation is implemented in the GPU:
6 V –green LED indicates 6 V voltage presence.
12 V –green LED indicates 12 V voltage presence.
BAT –green LED indicates that battery is supplying the system. When LED is off the generator or external power is
supplying the system.
CHRG –red LED indicates battery charging. When LED is flashing the battery voltage is low and the generator provides
not enough power.
10. Tachometer
Tachometer input allows to monitor engine or generator rotation speed using engine ignition system hall sensor. This
reading can be sent through TTL port to autopilot and transmitted to the UAV ground station via the rf-link.
Connect signal output to RPM sensor input and ground pin to common ground of the power unit - see Figure 13 and
Figure 14 for details.
Red mark
RPM sensor
Battery +
GND
Generator
GND
External power +
Brushed generator +
Figure 14 Connector J2 description (for brushed generator)

UAV Factory USA LLC.
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Irvington, NY 10533 USA
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LV1005, Latvia
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11. Serial communication
Serial communication allows to monitor system variables such as: generator and battery voltage, battery and load
currents, total system power and RPM value.
Serial protocol uses 83 bytes packet and send it one per second, Figure 15 shows the output string format. This protocol
is valid for GPU serial number starting from GPU0042. For older serial number, refer to the user manual version 1.4.
Variables are separated with 3 spaces. The output string example is:
Rpm=3400 Vgen=27.3 Vbatt=11.82 Ibatt=-1.3 I6v=1.2 I12v=0.8 Pout=16
Rpm –rpm value
Vlin –internal line voltage
Vbatt –battery voltage
Ibatt –battery current (negative value for charging)
I6v –load current at 6 V line
I12v –load current at 12 V line
Pout –total output power
Serial communication settings:
Baud rate 9600
Bits 8
No parity

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B00
B01
B02
B03
B04
B05
B06
B07
B08
B09
B10
B11
B12
B13
B14
B15
B16
B17
R
p
m
=
space
space
space
V
g
e
n
=
B18
B19
B20
B21
B22
B23
B24
B25
B26
B27
B28
B29
B30
B31
B32
B33
B34
space
space
space
V
b
a
t
t
=
B35
B36
B37
B38
B39
B40
B41
B42
B43
B44
B45
B46
B47
B48
B49
B50
B51
space
space
space
I
b
a
t
t
=
space
space
space
B52
B53
B54
B55
B56
B57
B58
B59
B60
B61
B62
B63
B64
B65
B66
B67
B68
I
6
v
=
space
space
space
I
1
2
v
=
B69
B70
B71
B72
B73
B74
B75
B76
B77
B78
B79
B80
B81
B82
space
space
space
P
o
u
t
=
/r
/n
Figure 15 Output string format

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12. Cable set with plug for J1 and J2 wiring
Cable set with plug for J1 and J2 can be optionally ordered from UAV Factory. Figure 16 shows cable set schematic
diagram for J1 and J2. Cable set is labeled to specify connection of each wire. For description of connections please refer
to Table 1.
J2
J1
Ignition
Serial
12Vout
6Vout
GEN
RPM Input
EXT
BATT
Figure 16 Cable set wiring schematic diagram
Table 1 Cable set description of connections
Label
Wire color
Connection description
GEN
red
Brushless generator phase A
red
Brushless generator phase B
red
Brushless generator phase C
GEN
red
Brushed generator “+” lead
black
Brushed generator “–” lead
Ignition
red
Power output for ignition module (6V)
black
Power ground for ignition module (GND)
RPM input
orange
RPM sensor input (Signal)
black
RPM sensor ground (GND )
Serial
green
Serial interface output (Tx)
black
Serial interface ground (GND)
BATT
red
Battery power input (3 Cell LiPo)
black
Battery power ground (GND)
EXT
red
External power supply input (13-50V)
black
External power ground GND)
6Vout
red
6V power output (6.0V)
black
6V power ground (GND)
12Vout
red
12V power output (12.0V)
black
12V power ground (GND)

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13. Order Information
Brushed version GPU100
Brushless version GPU100B
GPU Accessories
Item
Order code
Qty
FISCHER cable plug for J1
S104A056
1
FISCHER cable plug for J2
S104Z056
1
Cable set with plug for J1, 50 cm
SJ105
1
Cable set with plug for J2, 50 cm
SJ205
1
Cable set with plug for J1, 100 cm
SJ110
1
Cable set with plug for J2, 100 cm
SJ210
1
14. User manual version history
Version
Comments, Updates
Date
Author
1.4
Voltage range is added for BLDC generator
in electrical specification
5/15/2012
AG
1.5
Tachometer range is extended to 90000
rpm
2/11/2013
AG