Titan ZG 45PCI-HV Instructions Manual

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Instructions

Toni Clark practical scale GmbH

TITAN ZG 45 PCI-HV

Instructions Titan ZG 45PCI-HV

5 years guarantee for TITAN model aircraft engines

More than 20 years experience with TITAN engines plus our quality control allows us to extend the period of guarantee from one to ve years. This guarantee covers the engine and the ignition only.

The following conditions must be met to obtain the guarantee:

Guarantee is for the rst owner only and is not transferable to any other person.

In the event of any claim, the engine must be returned to us with the original invoice. The serial number on the crankcase must be undamaged, and must not have been removed and reapplied. The serial number is registered by us with the buyers name and the date of purchase.

The only fuel to be used is the petrol oil mixture as specied in the instruction manual. Use of Methanol invalidates the guarantee.

The guarantee includes the Microprocessor Ignition unit, the maximum voltage of 9 volts must not be exceeded. Mechanical damage to the cables is not covered by guarantee.

The guarantee is that we replace any defective parts free of all labour and material costs and pay only the return postage and packing. This guarantee covers only the engine and can in no way be construed to cover anything else.

This guarantee does not cover crash and related damage in any form whatsoever.

Instructions Titan ZG 45PCI-HV

Congratulations on your purchase of a Titan ZG 45PCI-HV

About the biggest problem facing man is that he does not know what he does not know. To resolve this problem requires enormous eorts, however try to avoid so much as possible unnecessary mistakes and please read the following pages carefully. Do not take fright at the amount written here, it is really a list of mistakes many modellers have made and you should at all costs avoid. A reliable running engine stands or falls with the way you instal the engine in your model, and how you handle your engine. It is up to you, to read and carry out these instructions, to have success and be able to get real fun out of the hobby of ying model planes.

The Titan ZG 45PCI-HV, tted with the Microprocessor Ignition, will start just as easily as with the Easy Start System. Although the starting technique is totally dierent to the ZG 45SL with the standard magneto ignition and requires a fully new approach. In other words, please forget all you have learnt with starting the magneto ignition engine and follow the starting instructions for the Microprocessor Ignition, given towards the end of this manual!

The Titan ZG 45PCI-HV is not a complicated engine, it is a well proven industrial two stroke engine. To ensure your engine reaches you in perfect condition, we have specially trained people to completely strip each engine down and thoroughly check it. This stripping and reassembling takes between 25 and 30 minutes per engine and ensures that you receive an engine that is mechanically sound as can be.

The Titan ZG 45PCI-HV is a very powerful engine, the thrust from the propeller is such that you simply cannot aord to take any chances. You take a chance and you run the risk of not only endangering yourself, but other people as well. Take care before each start, double check to see the throttle is not on full power. If you do not have anyone to help, you must anchor your model securely or ick the propeller over from behind the engine, using the other hand to hold the model, this way you are in no danger from the prop. A screwdriver stuck in the ground in front of each wheel is not only useless, it is dangerous!

Do not taxi your model right back to the starting place on your ying eld, instead cut the engine and push the model back! Pushing your model back, you may think seems unprofessional. Forget such ideas! You never know, something might go wrong and your model suddenly has full throttle! Should the result be that you have reduced your club chairman’s model to its component parts, you can count yourself lucky if it’s not the chairman himself, or his dog.

Rigid mounting

The rigid mounting of your engine has the attraction that it is cheap and simple. A well constructed model can easily withstand the vibration. It is preferable to t the receiver in a Balsa box with plastic sponge material as opposed to tting the receiver to a rigid Balsa sheet with rubber bands or similar. It will certainly pay to buy more expensive servos with better motors and potentiometers as these will withstand the vibration without diculty. Whether the rigid mounting of the engine will cause more noise depends largely on the covering. A really tightly shrunk silk, nylon or plastic heat shrink material is to be avoided, for these coverings will act just like drum skin, amplifying the sound from the engine.

For rigid mounting you have the choice between our three motor mounts #6590, #6561 and #6552. Alternatively you can cut a motor mount from a 5 mm thick aluminium sheet. The four screw holes in the rear crankcase half are M6 and are 38 mm equidistant. Secure the M6 mounting screws with either Loctite or spring washers. If you use a aluminium sheet mount, you must of coarse cut a hole in the rewall to take the rear crankshaft stub. No need to worry about oil getting into the fuselage, the seal is absolutely oil tight.

Instructions Titan ZG 45PCI-HV

Secure the motor mount in the well proven way with M5 socket screws, spring washers and crown nuts in a 9 mm thick birch plywood rewall. If the rewall is hardly bigger than the motor mount you can safely use 6 mm birch ply.

Hydro Mount System

When you wish to have a real quiet model and already have tried many would be solutions, you will nd our three HMS variations will bring astounding results. Our HMS uses two shock absorbers and four very soft rubber silent blocks, resulting in a very satisfactory decoupling of the engine from the airframe. The soft rubber silent blocks would not be possible without the shock absorbers. The swing amplitude of these rubber mounts with the engine throttled back would be 15 mm and with such a movement, a low speed tickover would be impossible, as the energy being absorbed by the rubber mounts would not leave enough over torque wise to bring the propeller over the next TDC. The use of harder rubber mounts to reduce the swing amplitude would only be partly eective at full throttle.

The purpose of the two shock-absorbers is to dampen the torsional oscillations. The shock-absorbers transmit some vibration from the engine into the airframe and this cannot be avoided. The advantage of these shock-absorbers is that they are purely dampening, without any form of springs, thereby it is impossible for them to come into resonance. The shock-absorbers can be regulated in their action from hard to soft by choice of oil viscosity. As opposed to various forms of xed rubber-covered stops or similar to limit movement, the shock-absorbers are much quieter. With the shock-absorbers you have the advantage of the airframe being eectively insulated from the engine at full throttle with most torsional oscillation being dampened out at the tickover.

Instructions Titan ZG 45PCI-HV

The shock-absorbers for our Hydro-Mount-System had to be specially designed and manufactured, using hydraulic rod seals, as none of the already available shock-absorbers could cope with the demands of being tted into our Hydro-Mount-System.

You will see that our shock-absorbers are nned to provide adequate cooling, (they transform movement energy into heat), and tted with a rubber grommet, which absorbs the very ne oscillatory movement at full throttle where the shock-absorber is getting stier.

The HMS is a complete system, with four special rubber silent blocks, two shock absorbers, mounting brackets and rubber grommets for the shock absorber, all screws nuts and washers and a ready formed spider leg engine mount are included.

The Hydro-Mount-System Piper is designed to t into our Piper PA-18. The cylinder is inverted and 7 degrees left from vertical. The stainless muer is placed right behind the crankcase and screwed to the aluminium spider leg mount. The Hydro-Mount-System Piper can be integrated in many other models, as long as the cowl is big enough to take the engine.

Cooling air opening

For cooling the Titan ZG 45PCI-HV it is not necessary to have a specially large opening in the cowl. But it is essential to ensure, that as much air as possible entering the cowl ows through the nning and around the carburettor, which also needs cold air. Air takes the path of least resistance and will not normally ow through the ns, unless you take positive steps to force it to do so by means of air-ducting. Balsa sheeting and blocks is the best material to use for this.

It is essential that the ducting almost makes contact with the engine, so balsa is better than aluminium, for should the latter make contact with the engine, this can easily cause severe radio interference due to metal to metal contact generated noise.

Instructions Titan ZG 45PCI-HV

Ignition installation in the model

The most important rule covering battery ignition systems rst:

Never ever switch the system on without the spark plug cap being on the spark plug!

Keep all parts of the battery ignition as far as possible from the receiver, minimum distance being 15 cm.

The microprocessor Ignition is protected with a tough metal case and the electronics inside are encapsulated to protect against vibration. In spite of this it is not a good idea to simply mount the ignition box onto the rewall with a couple of cable ties.

Please t the cables very carefully into your model, especially the high tension cable, as this will not contain the 21,000 volts if it is damaged due to scung against the cowl inner surface. If the screening ex is damaged due to scung when threaded through a GRP cowl opening, it will not be long before the inner insulation is damaged also. Then the HT will short out to the screening ex and this may cause massive radio interference and will of course lead to an ignition cutout.

Switch

Mechanical damage caused to the HT cable is not covered by the guarantee!

Use only knife edge contact switches such as our switch order no. #2024 or the Graupner receiver cable with charger socket order no. 3046. Toggle switches with roller contacts are not suitable as these are intended for 240 V. Used on low voltage, oxidation can occur, this increases the contact resistance and will lead to ignition failure.

Take care with plugging together the JR-plugs and sockets by noting that the colours should line up on opposite sides. It is possible with a little extra eort to push these together with reverse polarity. No damage will be done but the ignition will of course be dead. I tape these plugs and sockets with insulation tape for additional safety.

We recommend to secure the connection additionally witch tape!

Pickup installation

Instructions Titan ZG 45PCI-HV

Fit the pickup head with the power coil screws as shown.

The ignition timing is automatically correct and cannot (and need not) be adjusted.

The gap between the pickup and magnet is not critical, it can be anything from 0,2 to 2 mm.

Looked at from the side, the pickup position is even less critical, you see here the middle position. Although 2 mm forwards or backwards will work perfectly well. The pickup is a tight t in the pickup mount and secured with cyano. If the pickup is sitting outside the tolerance, washers can be used for packing between the pickup head and the crankcase.

Ground connection of the ignition with rubber spark plug cap

Please attach the ground strap on the ignition coil bracket on the crankcase. Because of the insulator, the carburattor screws are not suitable.

If a intake bend is used the one of the intake bend screws can be used to attach the ground strap.

Please make a range test prior the rst ight.

Without a good ground connection severe interferings will occur!

Battery

Instructions Titan ZG 45PCI-HV

With the new PCI-HV ignition we have set the greatest value on a really strong spark. Of course, high- energy sparks are not possible without higher input power from the battery, but we believe this is a fair price to pay. With modern battery technology, the battery weight no longer matters, so why not go for the best possible starting, reliability and performance?

The PCI-HV ignition contains a very ecient voltage converter, which is capable of using the higher voltage instead of converting it to heat, as in the case of the common linear voltage regulators. With the PCI-HV ignition the rule is: the higher the voltage, the lower the current. Therefor it is best to use a 2s LiPo directly, without an external regulator, the ying time will be the longest.

Beside the 2s LiPo battery, there are quite a few other options. This can be a two cell A123 or LiFePO4 battery.

Also a 5 or 6 cell Sanyo Enerloop 2000 NiMh can be used.

Be warned, that if you go for a 4 cell NiCd or NiMH type, this has to be one with a low internal resistance. When the voltage drops below 4.8 V, the engine will start to misre. A 2s LiPo is rst choice for best capacity to weight ratio.

Current mA

Voltage V

Current consumption single cylinder-ignition PCI v1.HV

2000 1/min 6000 1/min 8000 1/min 5,0 V 300 mA 800 mA 1090 mA 5,5 V 270 mA 700 mA 920 mA 5,9 V 250 mA 660 mA 810 mA 6,6 V 220 mA 550 mA 750 mA 7,4 V 190 mA 490 mA 630 mA 8,4 V 170 mA 420 mA 550 mA

RPM

Current

RPM

consumption in relation of batteryvoltage and engine speed

Under normal conditions, you will not y at full throttle and certainly not at 8000 RPM all the time, therefor a 1000 mAh 2s LiPo battery is enough for two hours ying with safety. The idle current with engine stopped is approximately 30 mA. The PCI ignition does no longer automatically shut down when one minute has elapsed without the propeller being turned. This safety switching in the past has caused more frustration than doing any good.

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Titan ZG 45PCI-HV Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual