Emcotec PowerCube HBS Operating Manual
HBS Operating Instructions Version 1.0
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HBS Operating Instructions Version 1.0
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Contents
1. Preface .............................................................................................4
2. Safety Instructions..........................................................................5
3. What does HBS stand for?.............................................................6
4. HBS Connection Scheme...............................................................7
5. Characteristics ................................................................................8
5.1. Usage in an Electrical Motor Powered Model..........................8
5.2. Usage in a Combustion Engine Powered Model...................11
6. Recommended Accessories ........................................................ 15
7. Mounting........................................................................................ 16
8. Connecting the Supply Batteries.................................................16
9. Connecting the Receiver Battery.................................................17
10. External Status-LED.................................................................... 19
11. Mounting Examples ....................................................................19
11.1. Electrical Powered Model....................................................20
11.2. Electrical Powered Model with Dual Supply ........................20
11.3. Combustion Engine Powered Model ...................................21
11.4. Combustion Engine Powered Model with Dual Supply........22
12. Operating .....................................................................................23
13. Storage-Mode ..............................................................................25
14. Summarizing the HBS-Functions .............................................. 27
15. LED-Codes (Error- and Status Indications).............................. 28
15.1. Ext. LED at "Status Output".................................................29
15.2. Internal LED "Status"...........................................................30
15.3. Summary Table ...................................................................30
16. HBS Block Diagram .................................................................... 32
17. Technical Data of the HBS ......................................................... 33
18. Warranty.......................................................................................35
19. Declaration of Conformity..........................................................36
20. Disposal of Equipment ............................................................... 36
21. Legal Instructions .......................................................................36
HBS Operating Instructions Version 1.0
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1. Preface
With this PowerCube ® HBS (Hybrid Battery Supply) you purchased
a high grade, modern and secure power supply system. We appreciate
your trust and assure you that you made the right choice!
More than 25 years of experience in development and manufacturing
of electronically systems, knowledge of the world’s best model airplane
pilots as well as the experience in UAV's has influenced the
development of EMCOTEC products. All products are manufactured at
EMCOTEC GmbH in Germany on our own production line. Extensive
optically and electronically end tests for every system, which leaves
our house, assure that you, our customer acquire an absolute reliable
product, which considerably increases the reliability of your valuable
RC-Model.
Of course, the products not only have been tested extensively in the
laboratory, but also went through intensive flight-testing. Like done in
the automobile industry an FMEA (Failure Mode and Effect Analysis)
reduce the possibility of damage and malfunction on operating errors to
a minimum.
We kindly ask you to read these operating instructions carefully and to
observe the installation hints. Thus, errors can be avoided in advance.
We are all ears for your wishes and questions. Challenge us!
Wehringen, May 2013
The Staff of EMCOTEC GmbH
HBS Operating Instructions Version 1.0
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2. Safety Instructions
In general, all connecting lines should be run so that they do not
come into contact with moving or hot parts of the model (such as
servos, gears or mufflers).
The HBS (20V…75V) can be driven by high voltages but must be
according to IEC 60449 rules. This partial range of low voltage is
generally known as low tension current or light current. The limits
for direct current (DC) are ≤ 120 V. These values correspond to
continuously permissible effective touch voltages for adults and
are considered not life-threatening under normal circumstances.
For voltages greater than 60 volts DC all current leading cables
should be isolated and protected against touching.
The HBS must be protected from humidity and moisture.
The HBS must have sufficient distance to neighboring areas, in
order to allow for good heat dissipation.
Improper handling of the HBS can result in serious damage/injury
to property or persons!
Carry out a general inspection of all connections in your model
before each use! All plugs must be correctly polarized and have
clean contacts (i.e. fit tightly). Loose cables present a potential
hazard!
Under no circumstances may power sources be used that do not
meet the specified voltages.
The current-conducting contacts of the connector plugs may not
be short-circuited. If you fail to observe this warning, the shortcircuited cables may overheat and even melt.
The HBS may not be taken apart or technically altered under any
circumstances.
Never use the HBS for purposes other than for RC model making
as a hobby. Above all, their use in passenger-carrying equipment
is strictly prohibited.
Operate the HBS only with components provided for model
making (or UAS).
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Always ensure that you have fully charged batteries when
operating your model. Empty batteries inevitably lead to failure of
the RC components, which cause the model to crash.
Do not expose the HBS to any extremely hot or extremely cold
temperatures, moisture or humidity. This would lead to danger of
malfunction, damage or decreased efficiency.
Only use accessories approved by EMCOTEC with the HBS.
3. What does HBS stand for?
HBS stands for Hybrid Battery Supply. Hybrid means "bundled,
interbred or mixed". In this case, it relates to the voltage supply of the
receiver equipment or other components in a RC model or UAS
(Unmanned Aerial System).
The supply voltage of the HBS is generated by the flight battery of an
electrical powered model or another power source (e.g. generator). It is
actually a kind of BEC (Battery Elimination Circuit). Additionally, this
supply voltage is "interlaced" with a regular 2-cell Lithium-Polymer
battery. This additional battery serves as a buffer; it provides for high
current peaks and makes sure, that there is enough energy in case the
flight battery is empty or breaks.
Of course, the usage of the HBS is not limited to electrically powered
models. Stay tuned for more later on.
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4. HBS Connection Scheme
Rear:
Hint:
The HBS can get very hot depending on withdrawn power. Therefore, the total
aluminum housing is used as heat sink.
HBS Operating Instructions Version 1.0
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5. Characteristics
The HBS is available in two versions mend for different usages. Both
systems differ only in their input voltage range.
Version 1: HBS with 10V … 36V input voltag e
• Intelligent energy management system for combustion
powered models.
• Entire BEC substitute for electrical flight applications in
connection with a 2S LiPo buffer battery
Version 2: HBS with 20V … 75V input voltag e
• Entire BEC substitute for electrical flight applications in
connection with a 2S LiPo buffer battery
Hint:
The HBS is a totally new system and therefore remains under legal protection of
registered designs at the German patent office (Nr. 20 2013 000 114.2)
First, the function for electrical flight (BEC substitute) will be shown for
better appreciation as follows.
5.1. Usage in an Electrical Motor Powered Model
Charging of all batteries in an electrical powered model
Background of the development of the HBS is the necessity to
additionally charge the receiver battery in electrical powered models. In
huge models with redundant supply (battery switching operation) even
two receiver batteries must be charged in order to charge all batteries.
This causes a lot of work and thoughtfulness.
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Right here the HBS adds to it: It disburdens the pilot's everyday life
remarkably and makes sure there are less or even no errors during
charging of the batteries.
BEC was yesterday – HBS is today
The reason for the PowerCube ® HBS is to supply the receiver
equipment out of the flight battery similar to a BEC. Additionally, a
small receiver battery when mounted inside the model which actually
serves as buffer provides for high current peaks and serves for
reliability in case the flight battery is empty or malfunctions.
The receiver set is actually supplied by the HBS while the receiver
battery (2S Lithium-Polymer battery) serves for safety and is recharged
by the HBS at the same time. Manual charging of the receiver battery
is eliminated, as well as cell matching, which is done by the HBS, too.
The flight battery supplies the HBS. The DC/DC converter in the HBS
reduces the voltage of the flight battery to the charging voltage of the
2-cell LiPo battery which is directly connected to the balancing
connector of the HBS.
As soon as the flight battery is connected the HBS starts charging the
receiver battery – fully automatically. Charging current is 1.4 amps.
Simultaneously to charging, both cells of the receiver battery are
matched (equalizing function).
The receiver set gets its current via the receiver battery (when using a
battery switch via two receiver batteries with a HBS each) additionally
from the HBS (=> hybrid solution). Due to the HBS, the receiver
battery can be very small which practically leads to a weight neutral
solution. A 450mAh to 800mAh battery fully suffices – for huge models
2 batteries when using dual current supply operation.
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The HBS constantly recharges the receiver battery, thus, the receiver
battery is rarely discharged. Only when the flight battery fails, the
receiver set is supplied by the receiver battery only.
Hint:
As long as the average of the withdrawn current is lower than 1.4 amps (average
current consumption of the receiver set) the system acts as an "unlimited" big
receiver battery. The disadvantages of separate charging and balancing of the
(receiver) battery are eliminated.
The charging end voltage is 8.2 volts instead of normally 8.4 volts. This
reduces the usable capacity slightly but increases life expectancy
(charging cycles) significantly – similar to the batteries in a hybrid
vehicle. Here too, the bandwidth of the battery is not fully utilized in
order to increase life duration.
Extremely high Currents
The difference to a regular BEC without receiver battery is that, due to
the usage of a 2S Lipo battery, high current peaks are possible which a
BEC can not deliver. An 800mAh / 30C LiPo battery delivers 24 amps
continuous current. No BEC can do that! Additionally, the circuitries of
the flight battery and the receiver set are totally electrically separated
by the HBS. The advantages of motor controllers with optically isolated
couplers fully remain. The biggest advantage of the HBS compared to
a BEC is, that the receiver set works totally normal should the flight
battery fail because it is then supplied by the receiver battery.
The HBS is available in two versions which differ in their input voltage
range. Both versions apply to electrical flight; the version with the
smaller input voltage range applies for applications without electrical
drive as well.
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5.2. Usage in a Combustion Engine Powered Model
The HBS also works perfectly for motor models and jets – but is used
differently than in electrically powered models.
In a combustion engine powered model the HBS does not work as
hybrid supply but rather as a charger / equalizer which is constantly
mounted into the model. Charging of the receiver battery (or ignition /
turbine battery) is conducted by connecting an external voltage in the
range of 10 volts up to 36 volts (e.g. car battery, truck battery, solar
panel, 4S – 8S Li++ battery or any other voltage supply).
Integrated charging station in combustion engine powered model
Due to the circuitry design of the HBS a fully electrically isolation
(galvanic separation) of the input voltage (Input) and the output voltage
(Output) is accomplished.
Hint:
The output voltage (Output) of the HBS is galvanic separated from the input
voltage (Input) (electrically isolated).
Fully automatically charging several batteries with one single connector
In a model with e.g. three LiPo batteries (two for the receiver set and
one battery for ignition or turbine) three HBS are to be built in (one
HBS for each battery). All Inputs (Input) of the HBS' are connected
together and put onto one single charging connector (e.g. EMCOTEC
Part No. PC4205).
Now one single car battery suffices to be connected and all three
batteries are charged simultaneously and automatically!
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