Pst jets J600, J600R User Manual

J600/R Instruction Manual

(Version 1.5.2/2004)

PST JETS

1063 Pattanakarn Road, Suanluang, Bangkok 10250, Thailand Tel : Intl + 66 2318-6918 Fax: Intl + 66 2318-6921

Website: http://www.pstjets.com : E-mail: [e-mail]

© Copyright 2004, PST Jets Co., Ltd. All Rights Reserved

J600 Instruction Manual

Welcome Notes

Dear PST J600/R owner,

Congratulations with your new PST J600/R miniature turbojet engine.

Let us greet you with our warm Thai tradition, “Sawasdee” which means welcome or greeting in Thai. We are committed in producing and delivering quality products to our customers.

The J600 is a result of R&D commitment and dedication since 1997 to turbojet design and manufacturing. In early 2003, we launched the J600R which is the derivative of the J600 incorporating modified diffuser, combustion chamber and tail cone resulting in higher thrust output. The engine controller unit, TEMS, is state-of-the-art device which is specifically manufactured/programmed for the J600/R. Your engine and the supporting system have been factory tested and passed our high quality control standard. The appearance of the bluish tinge on the exhaust cone is normal after factory starting and running of the engine prior to shipment. Factory test run also serves as “break-in” and seating of bearings and internal components.

Safety is our strict standard. Regardless of your turbine experience, it is necessary to carefully read this manual in its entirety before any attempt to operate the J600/R. This manual has important issues and notes that will ensure safe operation of the J600/R.

Please read it !

We are dedicated to customers’ satisfaction. Technical support is available thru email 7 days a week. Replacement parts are always in stock for prompt service ensuring quick turn-around time.

Thank you and enjoy.

PST Jets Co., Ltd.

1063 Pattanakarn Road

Suanluang, Bangkok 10250

Thailand

Web site: http://www.pstjets.com

Email: [e-mail]

Tel : Intl + 662 318-6918

Fax : Intl + 662 318-6921

Copyrights © PST Jets Co., Ltd.

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J600 Instruction Manual

Legal & Disclaimer

All contents copyright © PST JETS Co., Ltd., Bangkok, Thailand. All rights reserved.

No part of this manual may be reproduced, translated, transcribed or redistributed without written permission from PST JETS Co., Ltd. All product information and specifications are subject to change at any time without notice.

The “PST JETS” logo and “PST JETS with turbine wheel and passing jet” logo are trademarks of PST JETS Co., Ltd., Bangkok Thailand.

Disclaimer: Turbojet is a sophisticated piece of machinery. Experience and basic turbine knowledge is required. Always seek experts or experienced turbine operators before operating. If not operated properly, it is capable of causing property damage and/or bodily harm to both operator and spectators. PST Jets assumes no liability for damage that could occur from the use/misuse of this product. We recommend that you visit

GTBA and read about turbine safety and code of practice.

PST JETS assumes no responsibility for errors contained in this document and is not liable for any damages resulting from such errors. For most current updates, check our website www.pstjets.com or contact us at [e-mail]

Copyrights © PST Jets Co., Ltd.

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J600 Instruction Manual

Warranty

PST JETS Co., Ltd. is referred as “PST”. The warranty period for the PST J600 and

J600R is 1 year from original date of purchase or 150 run cycles, whichever reaches first. Warranty is valid for original owner only and non-transferable upon resale. The warranty includes parts and labor and is limited to manufacturing and material defects only. The limited warranty does not cover the electric starter motor, batteries, or glow plug. Upon replacement of components from a warranty failure, the replaced components will be

subject to the original warranty coverage period.

Shipping costs (including insurance and applicable duty taxes) to the local PST representative for any warranty claim are the sole responsibility of the customer. Return shipping is covered by PST in the same method of receiving the shipment from the customer. Should any part of the product need to be returned from the PST representative to PST headquarter (Bangkok, Thailand), this shipment cost is covered by PST. Any additional costs are the responsibility of the customer. PST assumes no liabilities for damage to products during shipping.

This warranty is void if any one or more of the following conditions applies. If any one of the following statements is true, PST assumes no liability for personal damages, loss of models, or any other consequences arising from the J600/J600R operation.

a.The serial number or identification information is defaced, modified, or removed.

b.The product is used for purposes other than that of radio-controlled model airplanes without written authorization by PST.

c.The product has been damaged from a crash or otherwise accidental event, ingestion of foreign materials, improper installation / configuration, or weather / act(s) of god.

d.The product has been subject to any form of start-up or operation with any incorrect fuel, oil, or fuel/oil mixture ratio.

e.Dirty or contaminated fuel is used.

f.Unauthorized maintenance or modifications have been performed on any part(s) of the product.

g.The product has been abused, incorrectly maintained, or neglected.

h.The product has not followed the mandatory check-up procedure, whereby every PST J600 should be inspected by a certified PST service representative after 150 starts.

Yearly inspection is highly recommended but not mandatory. Components required in the inspection / warranty claim include the complete turbine as purchased, ECU, thermocouple, and fuel pump. Please contact your PST representative for further details.

All turbines will be partially disassembled, inspected, and shipped within 5 business days of receiving. Damaged components that are deemed to be warranty covered are replaced, tested, and returned at PST cost.

Copyrights © PST Jets Co., Ltd.

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Warranty (cont)

For crash damaged, depending on the extent of damage, the turbine may required more than 5 days downtime, at which time the customer will be immediately contacted for a consultation. Please verify all service details with PST representative before shipping. Shipping cost and insurance is the sole responsibility of the customer in addition to the repair/service costs.

When upgrade option becomes available and the original owner wishes to have the engine upgraded, the newly installed components shall be given a 1-year warranty

(valid from the return shipment date). Other original parts/components remain under the original warranty. Shipping cost and insurance is again the sole responsibility of the customer and is not covered under the modification costs.

Copyrights © PST Jets Co., Ltd.

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PST Dealers/Representatives

USA/Canada

Dean Wichmann, HeliJet R/C International; [e-mail]; www.helijet.ca Kelly Williams, HeliJet R/C International; [e-mail]; www.helijet.ca

Australia/New Zealand

Kevin Dodd (TMAC), Brisbane, QLD - very experienced flight instructor and certified turbine inspector. Tel: [phone] ; Mobile: [phone] ; E-mail: [e-mail] ;

Website: www.qarm.com.au/ezy/

Phillip Collings, Brisbane - Australia Service / Repair Center; E-mail: [e-mail] Rick Butnaro, Sydney, NSW - Tel: [phone]; E-mail: [e-mail]

Trim Aircraft, Melbourne, Victoria – Website: www.trimair.com.au

Rene Redmond, New Zealand - Galtech Models Ltd.; Tel: [phone]; Fax: [phone]; E-mail: [e-mail]; Website: www.galtechmodels.com

Japan

Masashi Tahara, Osaka, JetSet; Email: [e-mail] ; [e-mail] ; www.jetsetj.com

Singapore

G. Kalidas, - Hobby Shack Singapore, Fughai Building; Email: [e-mail]

South Africa

Bruce Rattray, GB Hobby Electronics

Website: http://www.gbhobby.com; Email: [e-mail]

South Korea

Jai Young Shim, Seoul - Turbine pioneer/builder; Email: [e-mail] Byung Jun Park, Seoul - BJ Hobbycraft, Korea's Top F3A Pattern flyer/builder

Taiwan

Anton Lin, RC ARF.com; Email: [e-mail]

United Kingdom/Europe

Rob Rowbottam, England - Tel: [phone]; E-mail: [e-mail]

Iain Nicol, Scotland - I.A.D. Model Designs, Tel [phone]; Home of "Serpent" Email: [e-mail] : Website: www.iadmodeldesigns.co.uk/home.htm Martin Forrest, England – Email: [e-mail] ; [e-mail]

U.A.E

Kajoor Power Models, Dubai – Website: www.kajoorpower.com

For more updated information, please visit our website at www.pstjets.com

Copyrights © PST Jets Co., Ltd.

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	J600 Instruction Manual
	Table of Contents
Welcome Notes		i
Legal & Disclaimer		ii
Warranty		iii
PST Dealers/Representatives		v
Table of Contents		vi
Introduction to turbine		1
Packing Lists		3
Safety Tips and Notes		4
Fuel System
A. Fuel Tanks		6
B. Fuel Pump		7
C. Fuel & Oil		7
Gas System
A. Internal Gas Canister		8
B. External Gas Tank		9
C. One-way Valve		9
D. Quick Disconnect Valve		9
Accessories
A. Battery		10
B. Fuel & Gas Filters		10
C. Glow Plug		10
D. Chargers		11
E. Battery Checker		11
PST TEMS -Turbine Engine Management System
A. System Components		12
B. Features of TEMS		13
C. Software Version		13
D. Installation of TEMS		13
E. GDT (Ground Display Terminal)		15
F. Programming Features		16
G. GDT Diagnostics Display Interpretation		18
H. TEMS Trouble Shooting		19
I. Auto Start Sequences		20
J. Calibrating MIN and MAX rpm		21
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J600 Instruction Manual
Table of Contents (cont)
Mounting & Installation	22
Before Start	23
Starting	24
Maintenance	25
J600/R Trouble Shooting	26
J600/R Specifications	28
Diagrams
A. Fuel & Propane	29
B. Internal Propane Tank	30
C. Main & Header Tanks	31
D. J600/R Sectional View & Parts list	32
FAQ	33
J600/R Log Sheet	34

Copyrights © PST Jets Co., Ltd.

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J600 Instruction Manual

Introduction to turbine

First phase of turbine operation is intake and compression. In large-scale jet engines, the compression phase may involve several stages of axial and radial compression. For simplicity only a single centrifugal (radial) stage will be discussed in this manual. Axial compression is rarely seen in model turbines and is more reliant on having a clean air intake, similar to a ducted fan configuration. Centrifugal compressors are far less reliant on ram air effects, clean intakes, and Reynolds number effects, making them much more predictable at speed and much more suitable for use in model jets. After the air leaves the radial compressor, it flows outward through a set of primary and secondary diffuser vanes which harness the high velocity radial flow and transform it to high pressure axial flow into the pressure chamber. Diffuser design is critical due to the amount of losses induced in the transformation; the less energy lost in the compression process, the less energy is needed to drive the compressor for the same overall mass flow and thrust output. Poorly designed diffusers can be susceptible to elevated temperature at the engine’s front end and compressor surge / stall at different atmospheric situations. The turbine outer diameter of this size is also a contributing factor to the efficiency of the diffuser design. As the outside diameter increases, the airflow though the diffuser is smoother and has lower velocity gradients. PST J600/R is an excellent example of a balancing act between performance vs. size and design complexity.

Next is the combustion phase. The combustion chamber is basically just a container that houses a continuous and very intense explosion. High temperature materials such as stainless steel Inconel and titanium are commonly used in large-scale turbines, but thin stainless steel / Inconel sheet is usually the more cost effective material of choice for models. The annular style chambers used in models have holes strategically located in the inner and outer walls for feeding the combustion flame and for cooling the exhaust gasses as they exit. Some holes are dimpled inward to produce higher velocity mixing jets. Fuel is added from the rear end of the chamber, sprayed forward through a number of vaporizer tubes that heat the fluid to produce a combustion ready air-fuel mixture. Combustion occurs in the front section of the chamber and only persists for a short distance rearward. After combustion, the optimized holes mix cool air (relatively cool…+100°C approx.) with the exhaust gasses to bring them down to a more suitable level in the exhaust turbine. (Absolute design maximum: 800° C in this case)

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Introduction to turbine (cont)

The turbine stage can also be radial or axial and involve multiple stages. For simplicity, a single stage is discussed here. As the exhaust exits the combustion chamber, it enters the nozzle guide vanes (NGV) which convert axial velocity to axial flow with a large radial component. The swirl induced in the NGV is optimized for interaction with the blade profile on the turbine wheel. The turbine wheel then harnesses a great deal of energy from the exhaust gas flow’s radial component, leaving axial flow behind. The harnessed energy is transferred through the shaft and used to drive the compressor while the energy remaining in the exhaust flow after the turbine stage is converted directly into thrust. Miniature turbines today are equipped with modern technology’s ceramic bearing to support the shaft with the rotor assembly turning at more than 160,000 rpm. The J600/R uses two GRW angular contact, cageless ceramic bearings with rating up to 220,000 rpm.

That’s enough for introduction and theory on turbine. Let’s begin the exploration of the miniature turbine world and see what we have in stored for you.

Copyrights © PST Jets Co., Ltd.

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J600 Instruction Manual

Packing List

Please check that all components listed below are shipped with the J600/R turbine. Contact us if any items below are missing or damaged during shipment. E-mail: [e-mail]

SN600AC or SN600RAC – Auto start complete package:

1 PST J600/R Turbojet Engine with electric starter

1 PST TEMS

1 GDT (Ground Display Terminal)

1 Fuel Pump

1 Gas solenoid valve

1 Festo ball valve (Fuel Shutoff valve)

1 EGT probe

1 Glow plug (mounted on engine)

1 ECU switch with protective 15A Slow-Blow fuse 1 Battery pack (Ni-Cad 7.2V 1800mAh)

1 set of engine mounting brackets

1 set of quick disconnect fitting

1 set of 4mm gas/fuel tubing (tubing for fuel tanks installation not included) 1 Gas Canister with 3-way connector and 1-way valve

1 PST J600/R Instruction Manual

1 set of promotion batch and stickers (while supply last)

Copyrights © PST Jets Co., Ltd.

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J600 Instruction Manual

Safety & Notes

I M P O R T A N T !!!

Safety: Model turbine engine is highly sophisticated and should be treated with high level of safety standard. The following safety guidelines must be adhered to for successful and continual enjoyment of model aviation.

	Fire Extinguishers		Eyes & Ears Protection

a.Always have good fire extinguisher ready when starting turbine engines (Halon 1211 or BF2000 type recommended). Chemical fire extinguisher can be used but the engine must be returned to PST Jets for cleaning and inspection.

b.Always protect your eyes and ears during start or in close vicinity of starting turbine.

c.Always start the turbine outdoors with good ventilation.

d.Always handle Jet A1, Kerosene, and propane/butane gas in well-ventilated area away from any open flame or heat sources. These substances are highly flammable.

e.Do not stay in the high-risk perimeters of the turbine: on the side and in the area of hot air behind it; and immediate area in front of the compressor wheel.

f.Do not touch the engine while it is running. Turbine rotates at very high rpm and the engine casing can reach very high temperature. Severe burns or body injuries can occur if come into contact with the casing and/or exhaust nozzle.

g.Do seek expert advice for installing the turbine and support system to the airframe.

h.Abort start or any flight attempts if excessive vibration or abnormal noise is evident.

i.Keep unauthorized persons, especially children, away from starting area.

Recommended at least 25 feet away.

Notes:

a.The recommended and default settings programmed into the ECU should not be altered unless absolutely necessary. The engine is tested and operated to the designed performance and specification under these parameters. We cannot guarantee proper operation of the J600 if the parameters are altered or different fuel pump and accessories are used. E-mail us for technical helps if uncertain.

b.Use good chargers to charge both ECU and Rx batteries. Limit the ECU battery

(7.2V Nickel Cadmium with at least 1700mAh capacity) to two flights for one full charge. The fuel pump drains lots of amps at high rpm and the flight should not be made without recharging the ECU battery after approximately 25 minutes run time.

c.Make certain that all wiring and plumbing are correct.

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J600 Instruction Manual

Safety & Notes (cont)

d.Use filtered and moisture free Jet A1, Jet A, or kerosene fuel only.

e.Use turbojet oil, we recommend Exxon 2380, Aero Shell 500, or Mobil Jet Oil II). 2- stroke oil is not allowed and will cause damage to the engine thus voiding the warranty.

f.Fuel/Oil mixture of 5% should be used (See Fuel section for more details).

g.Extra fuel and gas filters are highly recommended to avoid clogging up of the “last chance filters” located inside the front cover. Kavan filter as shown in this manual is suitable. Avoid cheap motorcycle or automobile plastic filters, they may be used in the refueling system but not in the main system.

h.Bubble-elimination devices should be used in or as the header tanks for bubble-free fuel. Seek expert advice if you are not experienced.

i.For manual or emergency shutdown, fuel shut-off valve (Festo Ball Valve) is included and should be installed between header tank and turbine fuel inlet.

j.LPG or camping gas with maximum 70/30 Propane/Butane mix can be used. Use one-way valve for filling the gas canister. High pressure propane can freeze up the solenoid valve thus locking the valve in the close position.

k.Fitting valves and connectors supplied are of high quality and other similar products may be used.

l.When new devices or accessories are adopted, it is wise to test them on the bench prior to installation into airframe.

Copyrights © PST Jets Co., Ltd.

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