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Powered-Lift RC Aircraft Operator`s Manual V1.5

1. 24 RC TRANSMITTER amp RECEIVER a 25 HITEC ECLIPSE 7 PQCM TRANSMITTER iiin eean 26 SPECTRA MODULE ENR TO TE E NAER E 27 RECEIVER ERN ANE N TER E T 28 BATTERY CHARGER oe R A n A ERER NE RR TEN N EEA 28 SECTION 4 VEHICLE OPERATION ccssssssssssssssssssssssssscsssescsscsssesesssssscssresesscssscsasssssassssesssecssneneses 30 MINIMUM EQUIPMENT E E E E E a 30 PREELIGH T e mer a A E EA O TN E N T E EN 30 FLIGHT OPERATIONS ce a E E EEN RE AE 33 POST FLIGHT SHUTDOWN i ER E RO 33 SAFETY EMERGENCIES AND HAZARDS EKE REE AE ENE EEE iek 34 STORAGE a a E OEE EE E A OE A E EE E E EAE EAA S 35 SECTION 5 ROUTINE SERVICING esesessesossesesesoeoesosseseseeoeeesoeseseseeoeeesosseseeesossesesesoreesossesesesoeeosoeseseeese 36 ROUTINE SERVICE SCHEDULE gevesteeuceseusdesscuttubesteueees 36 SERVICE TOOLKIT REQUIREMENT S AEREE EEE E 36 AIRFRAME SERVICING riren eE rE NEEE EEE EEN E I ENEE ESAE EA 41 COMPONENT REPLACEMENT SCHEDULE s esseseseeerseseresecsereseseseeeereneroesrseeereerereseseeereeseeserererreee 41 REPLACEMENTS PARTS O EEE 41 CONTACT US EE EEE EAE EE E ESES EEE AEA E 41 SECTION 6 MAI
2. 70 CONTROL SERVO REPLACEMENT Removing the Servo Make sure the machine is inactive Remove the batteries Disconnect the servo from the NAV This 15 a friction fitting and should pull apart easily Disconnect the control linkage from the duct using a 3 32 Allen wrench Hold the duct gently but firmly while loosening the screw holding the control linkage in place Note there is a brass spacer between the control linkage and the duct Disconnect the control linkage from the servo using a 3 32 Allen wrench Hold the servo gently but firmly while loosening the screw holding the control linkage to the servo Note there is a brass spacer between the control linkage and the servo The control servo is held in place with four screws and a threaded back plate Using a 5 64 Allen wrench remove the screws It may be easier to disconnect the wires leading from the motor controller to the motor The servo should be removed though the center of airframe Replacing the Servo Make sure the machine is inactive Remove the batteries Place the servo on its shelf inside the center of the airframe Place the back plate against the servo inside the center of airframe Hand thread the four screws through the airframe and servo into the back plate Tighten the screws with a 5 64 Allen wrench Connect the control linkage to the servo using a 3 32 A
3. 72 APPENDIX E COVERED CODE DISCLAIMER cccccssssssssssssssssesssssscssscsesscssecsaresssessssesesssessceeseess 73 DISCLAIMER OF WARRANTY 73 CONTACT US tute iat pots dua onic EE e 73 SECTION 1 INTRODUCTION INTRODUCTION Congratulations on your purchase of the first power lift dual ducted VTOL research vehicle on the market It is our goal to provide you with the best experience possible with respect to your purchase of this vehicle OVIWUN has been designed by our team of expert engineers over a period of nine years and built by skilled craftsmen We stand behind our design and will assist you in any reasonable way we can This vehicle has been tested before being delivered to you We strongly recommend that you attend one of our training classes before attempting to operate this vehicle We also recommend that you carefully read this Operator s Manual before attempting to operate this vehicle Your ultimate success with this vehicle is all up to you Understanding what you have purchased and how it operates are key to that success This one of a kind vehicle is easier to fly than some RC helicopters and more difficult to fly than most fixed wing airplanes You need to carefully read and fully understand the entire Operator s Manual before you begin to work on and to fly your OVIWUN vehicle WARNING This vehicle i
4. 24 Roll control is achieved by differentiating the RPM of the motors When the transmitter sends a roll control command the vehicle will differentiate the speed of the motors around the current position of the collective throttle position Pitch is a pure pitch maneuver This means that the ducts will pitch together at the same angle of attack when a pitch command is entered into the transmitter The Yaw maneuver differentiates the pitch on the ducts around the established pitch command The command will cause the ducts to differentiate equally The collective throttle is used for altitude and momentum This is achieved by increasing or decreasing the RPM of the motors The collective throttle does not provide for different speeds but increases or decreases the speed of the motors simultaneously The Gear switch on the transmitter is used to control one of the two modes of operation The normal operating mode is PD Meaning that the rates are taken proportionally and differentially There is also a PID mode meaning rates are taken proportionally integrally and differentially This mode is currently used for data collection and is primarily reserved for future enhancements The PID mode allows the vehicle to self trim There are many features of the Stargate and Nav system which are not currently being employed in the Beta version It is our goal to eventually integrate these features into the flight control system RC
5. Remove the Stargate or uNAV from the package The set offs should be on the same side of the Stargate as the PCIMA connection If not you need to move them there ESD WARNING The Stargate Processor Board Daughter Card and Nav are electronic devices and therefore can be damaged by Electrostatic Discharge ESD While handling these devices follow ESD prevention procedures and use an ESD wrist strap Hold the NAV by the edge closest to the 1 connector just above the Mote Connection and gently wiggle the two 51 pin connectors together Place the one of the spacers on the Stargate card Slide the washer on the screw and insert it into the hole Slide the nut on the end of the screw and loosely tighten Repeat with the second screw and nut Make sure the uNAV is seated before tightening down the screws holding the on the Stargate Connect the servo 1 to the NAV It is attached to the number 14 position The yellow wire is towards the inside of the Stargate uNA V Connect the motor controller 1 to the uNAV It is attached to the number 12 position The orange wire is towards the inside of the Stargate uNAV Connect the motor controller 2 to uNAV It is attached to the number 11 position The orange wire is towards the inside of the Stargate uNAV Connect the Servo 2 to the uNAV It is attached to the number 10 position The yellow wire is towards the inside of the Stargate uNAV Connect the RC Receiver to
6. Pull out the bus bar Disconnect both batteries Check the power state by looking at the LEDs on the uNav and Stargate They should be off Gently and slowly move the machine and determine that the ducts are not responding Now turn off the transmitter Remove the batteries from the lower bay and let them cool Examine the batteries for any damage before storage if damaged or in doubt dispose of them per the appropriate disposal procedures for Lithtum Polymer batteries CAUTION The batteries may be warm or hot to the touch Do a general visual check of your OVIWUN unit Look for any nicks scrapes gouges or other signs of wear and tear Inspect the ducts and fans with particular ardor These should be repaired before any flight If you are going to repack you machine in the case you need to remove the landing skids Before repacking make sure the batteries are cool You are ready to repack your machine in its case 33 SAFETY EMERGENCIES AND HAZARDS Remote operable vehicles such as OVIWUN can pose a hazard if not operated in a safe environment As with any vehicle your OVIWUN should be treated with the utmost respect and caution For most users this is just using common sense while operating your aircraft Keeping fingers and small objects away from the blades and knowing how to react if you inadvertently fly into a hazardous situation It is recommended that users wear eye and ear protection when flying t
7. 3 32 1 16 and 2 mm Open end wrench size 4 1 Philips Head screwdriver PRE FLIGHT WARNING You should always fly your vehicle in a safe environment You should select an area that is both large enough and clear of obstacles in which to operate your vehicle Have planned exits should the vehicle get out of control Remember the fans by their nature swirl the air and may cause any loose objects to be blown around Loose objects may also be ingested by the fans and thrown out of the fans with great velocity You should not operate the vehicle while wearing any loose clothing or jewelry When handling your vehicle you should remove any metal from your fingers rings and wrists watches Once you have chosen and prepared your flight area you are ready to begin 1 Remove the batteries from the case and make sure they are fully charged You should never begin a flight without making sure your batteries are fully charged See battery charging section of this manual and the manual for the battery charger for details Check the charge on the transmitter Charge the battery in the transmitter if necessary Remove the vehicle from the case and install the landing skids If you have not already done so see the assembly instructions above Do a general visual check of your OVIWUN unit Look for any nicks scrapes gouges or other signs of wear and tear Inspect the ducts and fans with particular ardor These should
8. and Nav are secure Place the batteries in the airframe The battery placement can affect the center of gravity of the vehicle They should be centered left to right side to side and front to back in the lower bay WARNING Do not plug the batteries in Yet Turn on the transmitter Set the controls on the transmitter a The collective throttle stick should be down toward the bottom the transmitter and locked into this position b The collective throttle trim control should be set at 50 Center zero out the other three trim controls Roll trim control MUST BE ZEROED out before the vehicle is booted up before EVERY flight VR 1 amp 2 should be set to zero centered Flight Mode switch should be centered Rudder D R and Elevator D R switches should be in the down position Channel 7 and Aileron D R switches should be in the down position Flight Condition Switch should be forward towards the front of the transmitter Gear Switch should be in the forward position towards the front of the transmitter With the Gear Switch in the forward position the vehicle operates in the PD mode the back position the vehicle operates in the PID mode Extend the transmitter antenna Check Radio Antenna Lead the receiver antenna out of the body of the vehicle and attach it with tape to one of the landing rails leaving the full length of the antenna hanging free It is very important that the antenna should be hanging free to help preven
9. back through the vane until they are free of the vane Using a 2 mm Allen wrench remove the four screws holding the motor to the motor mount Note There are four washers on each screw one under the screw head and three between the motor and motor mount plate The motor should fall free There is no need to remove the two bearings on the support arm The replacement duct will come with the bearings installed The full duct assembly and its components has now been removed REASSEMBLING THE DUCT Make sure the machine is inactive If they have not been removed remove the batteries Mount the motor first You will need the 2 mm Allen wrench There are four screws holding the motor to the motor mount Note There are four washers on each screw three between the motor and motor mount and one under the head of the screw Get all four screws started and then tighten in rotation Carefully feed the wires from the motor back through the vane Leave a small amount of slack do not pull the wires tight Place the collet shaft over the motor shaft Place the collet pressure fitting on the collet shaft large end down Place the spinner back plate on the collet shaft flange side down Place the prop on the collet shaft Screw the top of the prop collet on the collet shaft Tighten using a 3 32 Allen wrench as a lever Hold the prop in place and get a good tight fit Note that the screw holes in the sp
10. battery without turning the charger off first Always follow the manufacturer s recommendations when charging your batteries During the first few seconds of charging the display will show the charging mode and the number of cells that the microprocessor thinks are in the battery pack The display should be 4C1 for the batteries packaged with your unit WARNING If the display reads more cells than your battery contains STOP AT ONCE Something is wrong Your battery could have a damaged or high resistance cell it could already be fully charged or you could be trying to charge too fast Turn the current back to zero and try to determine what is causing the problem During Mode 1 the charger will continue charging your battery for three minutes regardless of the battery voltage It acts like a dumb charger during this first phase This is necessary in order to be able to charge packs that have been discharged to a very low voltage WARNING If your battery is already charged do not try over charge it A fully charged 4 cell pack will have a voltage of 16 60 to 16 80 volts After three minutes the charger automatically switches from Mode 1 to Mode 2 The display changes to indicate Mode 2 and will now read 4C2 Mode 2 will last about 45 minutes At the end of Mode 2 the battery charger automatically switches to Mode 3 In Mode 3 the charging current is turned on and off periodic
11. be returned to the factory for reprogramming o CAUTION Have someone restrain the vehicle while you complete the next four steps They should do so by holding the machine firmly on the ground by placing a hand on the machine between the ducts and pressing down WARNING The vehicle will be active with the next step Have the vehicle in a clear and open space If the switches are improperly set and procedures not followed the fans may start without any warning 16 Double check the polarity of the batteries the first battery should be connected to the bus bar in one smooth and definite operation Avoid multiple touches of the connectors Immediately the motor controllers uNav and Stargate will go through the boot procedure The ducts will move and you will hear a series of 13 single beeps from the motor controllers RF interference may cause one or both of the fans to spin briefly 17 You should see the red LED on the uNav and red yellow and green LEDs on the Stargate come on The LEDs on the Stargate will flash on and off 18 Double check the polarity of the batteries in one smooth and definite operation plug the second battery into the bus bar 19 Carefully tuck the bus bar into the lower bay and replace the back cover 20 You can now check the controls a Lift the machine GENTLY SLOWLY and SLIGHTLY pitch the machine forward and backwards The ducts should move in response to your pitch mo
12. is involved in a crash dropped or exposed to excessive heat a Remove the Lithium Polymer Battery pack from the vehicle b Carefully inspect the pack for shorts in the wiring or connections If in doubt replace the battery pack with a new one Inspect cells for punctures dents cracks tears and splits d Examine cells for leakage or an electrolyte smell 42 2 Dispose of cells packs as follows a Discharge with the pack in a safe area use your battery charger to discharge the pack to the recommended cut off voltage Usually 3 0 volts per cell CAUTION pack may get hot b Allow to cool and then puncture each cell in the battery pack and immerse in salt water for several hours c Apply electricians tape over the terminals and place in a sealed bag d They are then safe to dispose of in your regular trash 3 Handle all cells packs with care as they can deliver high currents if shorted Shorting by a ring for example can result in the loss of your finger 4 Always store cells packs in a secure location where they cannot be shorted dropped overheated to 140 F 60 C or handled by children 5 Follow the manufacturer s recommendations for proper long term battery storage AIRFRAME MAINTENANCE Minor airframe repairs can be accomplished with fiberglass and epoxy For more extensive damage it is suggested that individual airframe components i e Upper Body Cargo Pod Duct Assembly be replaced BLADE REPL
13. overheated to 140 F 60 C or handled by children Follow the manufacturer s recommendations for proper long term battery storage 2 CHARGING YOUR BATTERY Connect the power supply to an appropriate outlet Connect the alligator cords to the power supply Wait a few seconds the digital display should first announce AstroFlight Lithium and then waiting for battery Double check the correct polarity when connecting cell packs to the charger Connect the short output cord to the Lithtum Polymer battery you wish to charge The charging sequence will automatically begin If your battery is properly connected the display will begin indicating the charge current the battery voltage the duration of the charge and the milliamp hours delivered to the battery Z CAUTION Always start charging with the current adjust at zero amps slowly increasing the charging rate until the rate equals the capacity of the battery pack We recommend charging Lithium Polymer batteries at a 1C rate a rate equal to the mahr rating of the cells 63 If your battery is not connected has a loose connection is connected backwards or is drained to less than 3 volts the microprocessor will not detect the battery and waiting for battery will still be displayed Check your battery and the connections attempt to charge again NOTE Some manufacturers recommend NEVER disconnecting your
14. pack has a normal capacity of 4 amp hours 4000 mAH A fully charged 4 cell pack will have a voltage of 16 60 to 16 80 volts NAVIGATION amp GUIDANCE CROSSBOW S The uNAV100CA is a calibrated digital sensor and servo control system designed for use in Radio Control R C vehicles The onboard sensor package includes accelerometers angular rate sensors and magnetometers for use in inner loop control applications as well as static pressure altitude and dynamic pressure airspeed sensors for use in airborne robotics A GPS sensor is included for both path planning and navigation The MNAV100CA s comprehensive onboard servo control solution includes both R C servo control hardware and an R C receiver Pulse Position Modulation PPM interface R C servo hardware provides users with software based control of up to nine separate servos while the PPM interface enables software interpretation of R C receiver commands thereby offering users both automated software control as well as manual takeover capability 23 Output data is provided in a digital RS 232 format Each uNAV100CA system comes with a GPS antenna interface cables and User s Manual Crossbow s MICRO VIEW software is included to assist users with sensor calibration servo control data collection and overall system development When connected to Crossbow s Stargate Processor Board SPB400 via the standard 51 pin connector the UNAVIO0CA combines w
15. rpm and are capable of injuring someone We recommend learning to fly in an area that affords as much room as possible Starting your flight training indoors allows you learn to operate the vehicle without natural disturbances You must take care when you are flying indoors to make sure there are no children or animals in the room In addition make sure the room is large enough with no obstacles such as furniture that could be hit while you are learning how to operate OVIWUN Suitable indoor flying spaces should be large enough to allow free movement of the vehicle The room should be free of obstacles You should have all doors closed as any wind can affect your control of the vehicle If there is air conditioning or heating in the room this should be turned off until you get used to the characteristics and feel of operating OVIWUN The floor should be a smooth surface Be prepared until the flight rpm has been reached that OVIWUN may slide around on the floor We suggest that you avoid using carpet for your first flights as the skids can catch on the carpeting and cause the vehicle to flip over Step 1 Preflight the vehicle as you normally would Place OVIWUN in the middle of the room If everything checks out in the preflight position yourself at least six feet 1 8 meters behind the vehicle and slightly off to one side Please be sure that you are able to clearly see the vehicle Please note when flying that you always watc
16. slowly move the machine and determine that the ducts are not responding Now turn off the transmitter Remove the batteries from the lower bay and let them cool CAUTION The batteries may be warm or hot to the touch Do a general visual check of your OVIWUN unit Look for any nicks scrapes gouges or other signs of wear and tear Inspect the ducts and fans with particular ardor These should be repaired before any flight If you are going to repack you machine in the case you need to remove the landing skids Before repacking make sure the batteries are cool You are ready to repack your machine in its case STORAGE The case in which your OVIWUN was delivered has been designed for storage transportation and shipping Before storing your OVIWUN unit you must remove the batteries from the vehicle Be sure to inspect the batteries for damage tears rips dents signs of leakage or if you smell electrolyte the battery is no longer operable NOTE Immediately dispose of any damaged battery safely by following the Lithium Polymer battery disposal instructions CAUTION Never store the vehicle with the batteries in place Have the batteries cooled down They should be cool to the touch before storage 60 Z CAUTION Never attempt to store your batteries in the case in they are hot Wait until the batteries
17. the Stargate and uNav On the 2 side is a 6V BEC that supplies power to the servos and receiver There are leads running from the uNav units to the servos on the ducts There is also a lead running from the Nav to the GPS antenna This arrangement depicted in the Battery section below BATTERY Your OVIWUN comes with two Lithium Polymer rechargeable battery packs Lithium Polymer rechargeable batteries utilize the latest technology to become available for consumer use Lithium Polymer batteries have high voltage per cell 3 7 volts avg and excellent energy on both a weight and volume basis providing more energy per gram and resulting in more watt hours Kg than their counterparts such as NiCd NiMH These Li Poly batteries are specifically designed to be as thin as possible with large footprint configurations There are several different types of polymer technologies and chemistries Some require high temperatures to operate effectively while others work efficiently over a broad temperature range The Lithtum Polymer rechargeable batteries which came with your OVIWUN work over a board range of temperatures but they can adversely be affected and their performance reduced if they overheat are allowed to get too cold or are improperly discharged It is crucial that you familiarize yourself with the proper handling and storage of these types of batteries Each battery pack provided with your OVIWUN contains four 4 cells Each battery
18. the entire system before and after each flight for possible damage from the heat of the batteries Wires can become overheated or stressed from the heat causing the vehicle to malfunction which in turn may cause harm to those operating or near the vehicle The batteries also pose a hazard when being charged Again the batteries heat up during the charging process and can cause fire or burns Carefully and completely follow the instructions provided on charging your batteries Although we have tried to inculde as much information as possible about the safe handling of the vehicle it s batteries and the hazards that may exist we have undoubtedly missed some combination of events which can lead to someone or something getting hurt You must use all care in operating the vehicle SOFTWARE SET UP All the software necessary to operate OVIWUN comes preloaded into the vehicle There are two parts of the software 1 open source code software for Stargate and Nav 2 Trek s Flight Control Code that has already been compiled and loaded on the Nav INITIAL TRAINING RECOMMENDATIONS OVIWUN is easy to operate but you should make yourself familiar with the machine before attempting to operate it You should begin by first reading this entire operating manual to become familiar with the vehicle The information in Appendix B will also give you some guidance on your initial operation of the vehicle We suggest you have an experienced OVIWUN ope
19. to allow cooling of the armature and magnets Avoid running your motor under dusty or wet conditions Avoid foreign matter getting into the cooling holes of your motor Beware of small bolts screws and other small items that can be attracted to the magnets of your motor Do not disassemble motor The bearings of this motor are greased with special high quality grease that will last through 20 the expected life of the motor Do not use any organic solvents cleaners or detergents to clean your motor these agents may wash out the grease and substantially decrease the lifetime of your motor If there is some dirt in your motor after an accident do not try to rotate the shaft First carefully remove the dirt with compressed air In the case of serious damage the motor should be returned for service Never try to straighten a bent shaft If the large diameter hardened steel shaft becomes bent there will be more serious damage inside the motor If you are in doubt replace your motor Avoid unnecessary dismantling of your motor AK1 2820 amp 2625 870 RMP Volt 83 Maximum Efficiency Max Efficiency Current 15 25 275 Current Capacity 42 A 60 s Dimensions 35 x 54 mm Shaft Diameter 5mm Weight with cables 181 g 01201 RE 71018 SPEED CONTROLLERS OVIWUN comes equipped with two speed controllers We have chosen the Jeti Model Advance 40 Opto Plus speed controller This is a new type of sensor less speed controller especi
20. 5 mph Cruise Speed 50 kph 31 mph Hover Ceiling 6140 m 20150 ft Endurance 20 minutes Rate of Climb 695 m min 2280 fpm 15 OVIWUN Flight Envelope with 500g payload 30000 25000 20000 15000 4 10000 5000 0 0 10 20 30 40 50 Airspeed mph VEHICLE LIMITATIONS The Beta version of OVIWUN has only been tested to an airspeed of 7 mph and a density altitude of 2500 feet in calm conditions This is the guaranteed performance envelope until further software refinements and testing have been performed As software upgrades become available they will be provided free of charge to purchasers of Beta versions of OVIWUN 16 AIRFRAME OVIWUN s airframe is comprised of three major components a Upper Body The upper body has compartments that house batteries and flight systems These compartments are accessible through the rear of the airframe The removable access cover attaches to the upper body with Velcro b Cargo Pod The cargo pod provides storage space for payloads and is easily removed by loosening four thumbscrews c Landing Skids The landing skid struts are pre assembled attached to the upper body The skids are removable for storage by loosening four thumbscrews 17 DUCTS The ducts easily detach from OVIWUN s airframe by loosening two thumbscrews per duct and disconnecting the motor wires Each duct unit is comprised of 1 Duct Assembly The duct assembly includes the duct
21. ACEMENT If a fan becomes chipped or cracked you will need to replace it This is done by 1 2 3 59 11 12 Using the supplied Torx wrench remove the three screws holding the spinner in place Remove the spinner If damaged replace otherwise set aside Using the supplied Torx wrench remove the three screws holding the center body in place Remove the center body If damaged replace otherwise set aside Insert the long arm of the Torx wrench or any Allen wrench through the hole in the nosepiece of the prop adapter Holding the motor casing loosen the prop adapter Once the prop adapter is loose slide the prop off the motor shaft Remove the prop adapter from the damaged prop and discard the damaged prop Make sure that you are replacing the prop with a prop of the same type 1 left or right handed Loosely install the prop adapter to the replacement prop and slide it all the way on to the motor shaft Holding the motor casing tighten the prop adapter Gently pull on the prop to make sure a secure installation has been achieved 13 Reinstall the center body and spinner 43 DUCT MAINTENANCE Minor duct repairs can be accomplished with fiberglass and epoxy For more extensive damage it is suggested that the duct assembly be replaced To replace a duct assembly 1 Remove the thumbscrew securing the control linkage to the duct 2 Disconnect the electrical connectio
22. E COVERED CODE DISCLAIMER DISCLAIMER OF WARRANTY Covered code is provided under this license on an as is basis without warranty of any kind either expressed or implied including without limitation warranties that the covered code is free of defects merchantable fit for a particular purpose or non infringing The entire risk as to the quality and performance of the covered code is with you Should any covered code prove defective in any respect you not the initial developer or any other contributor assume the cost of any necessary servicing repair or correction This disclaimer of warranty constitutes an essential part of this license No use of any covered code is authorized hereunder except under this disclaimer CONTACT US You can contact us by phone web email writing us or visiting us Our phone number is 209 368 5800 our webpage is at www trekaero com You can email us at info trekaero com the general questions or comments parts trekaero com for parts questions or orders service trekaero com for service questions sales trekaero com for sales and ordering You can write us at You can visit us at Trek Aerospace Inc Trek Aerospace Inc PO Box 748 23987 N Hwy 99 Hanger 21 Acampo CA 95220 0748 Acampo CA 95220 USA USA 73
23. Lithium Polymer cells can ignite because of unmatched cell capacity or voltage cell damage charger failure incorrect charger settings and other factors Never combine different sized packs capacities or cells together in series or parallel WARNING IN CASE OF A FIRE NEVER EXTINGUISH WITH WATER ALWAYS USE SAND OR A DRY FIRE EXTINGUISHER It is extremely important to double check the correct polarity when connecting cell packs to the charger or to your vehicle Always check your batteries for damage before and after each charging sequence Always use the correct charging voltage The Lithium Polymer Battery pack may ignite if connected to a charger supplying more than 6 volts per cell Check your charger to assure it is working properly Charge your batteries in a safe area where no harm can result Never attempt to charge your batteries while they are in the OVIWUN vehicle This may cause damage to your vehicle or its components Do not charge your batteries inside a motor vehicle or in a vehicle s engine compartment Additionally do not store or leave your batteries in a vehicle where they can overheat Do not charge your batteries on a wooden workbench or on or near any flammable material Wood plastic foam etc The seal of Lithium Polymer cells can degrade at excessive temperatures and cause electrolyte leakage Especially when left in the trunk of a car or on the dash If you come in contac
24. NTENANCE ccssssssssssssssssscsesssssssscsssecssessssssenesensesscssecsssssssscsssssscsssnssonsesnsessessessoees 42 MAINTENANCE TOOLKIT REQUIREMENTS eeaeee ieaie Es 42 TROUBLESHOOTING 42 42 AIRFRAME MAINTENANCE 43 BEADE REPLACEMENSD tonsbsce sede sdantueedbesueetes iednedbsensedtobagintets oteqaneniganeavontentesdidiees 43 DUCT MAINTENANCE a ra aa sesh snbstosepceseceuag sgdneUbnensedhbbigintotsctequadiogsseepontestestigines 44 PAR TS ORDERINGsieosi2s i 44 CONTACT PHONE NUMBER onise meninin eae a eA 44 SECTION 7 ADVANCED FLIGHT CONTROL MODIFICATIONS scscsssssssssssssseseresssecssreseseres 45 SETTING THE DEFAULT GAINS a a e a E e a ieena ina an een 45 MODIFYING THE GAINS 45 OPEN SOURCE CODE a aa e aa a ra aaa EE eaa A aiii 45 SECTION 8 PAYLOAD ADDITIONS AND MODIFICATIONS cssssssssssesssssssscsssssssecssresessesseseees 46 PAYLOAD VOLUME pirin Ene n T T EE AN EE T TAN ER 46 WEIGHT POTENTIAL ena cre reek RRE ETA TLSE NEEE T 46 RADIO FREQUENCY INTERFERENCE CONSIDERATIONS sssssesssssseiesssssssiseerssesisesressssssererereeses 48 APDDINGRADIOLINK E EE E N ERTES 48 APPENDIX A DETAILED PARTS LIST cccssssssssssrcssss
25. OVIWUN Powered Lift RC Aircraft Operator s Manual V1 5 Beta Version April 2006 EK Aerospace Trek Aerospace Inc PO Box 748 Acampo CA 95220 209 368 5800 All rights reserved Reproduction by any means electronic or mechanical including photocopying recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Trek Aerospace Inc Copyright 2006 Trek Aerospace Inc TABLE OF CONTENTS SECTION 1 INTRODUCTION cccssssssssssssscsscsscsssssssenssssecssrescsscesccsessesessssenesssesccscsssesasesssecssnesesesees 4 INTRODUCTION icc sacs Ee ae 4 VEHICLE OVERVIEW thease saci 4 OPERATING OVERVIEW 6 SER VICING O VER VIEW a R a E 6 MODIFICATION POTENTIAL A 6 p E 6 WARRANTY ons E A A dotnet E R 7 SECTION 2 ASSEMBLY AND INITIAL SET 0 8 UNPACKING EE E 8 ASSEMBLY REQUIREMENT AND TOOLKIT i ia 9 ASSEMBLE Y ty 10 SABE AND HAZARDS stu a
26. TRANSMITTER amp RECEIVER OVIWUN comes complete with a transmitter and receiver We have chosen the HiTec Eclipse 7 This radio features 7 channels with model memory and specific programming for different vehicles It has most of the commonly needed features as well as added extras like shift changeability and an optional 50 channel PLL module which is included in your kit You should refer to the HiTec manual included in your materials for specifics on the operation of this transmitter 25 HITEC ECLIPSE 7 PQCM TRANSMITTER The controls on your radio have been programmed to do specific things for your OVIWUN aircraft The Eclipse 7 should be in Mode 2 when operating OVIWUN Each control has the following operation Left top of Receiver Trainer toggle switch This switch is used by the trainer when operating the transmitter in conjunction with a student Flight mode toggle switch Not Currently Used see transmitter manual for description VR 1 Not Currently Used see transmitter manual for description Rudder D R Not Currently Used see transmitter manual for description Elevator D R Not Currently Used see transmitter manual for description Right top of receiver Flt Control Not Currently Used see transmitter manual for description Gear Forward is PD control and Backward is PID Control VR 2 Not Currently Used see transmitter manual for description Ch 7 Not Curr
27. ally After charging is complete the digital display will indicate that the battery charging is complete The display will show the highest resting voltage reached and the number of milliamp hours of charge put into the battery 64 DUCT REPLACEMENT There are two methods of replacing the duct The first and by far the easiest is to purchase an entire duct assembly A duct assembly comes already assembled with the motor spinner and center body It is as simple as removing the duct and plugging the new one it This is the preferred method as it insures that the support arm bearings and other components which may also be damaged are replaced at the same time However you can also replace just the duct You should completely remove and disassemble the duct assembly You should carefully inspect all the various components to determine if they are damaged as well If you determine that the various components are in acceptable condition proceed with a partial replacement of the duct assembly REMOVING THE DUCT Make sure the machine is inactive Remove the batteries Disconnect the control linkage from the duct using a 3 32 Allen wrench Hold the duct gently but firmly while loosening the bolt holding the control linkage in place Note There is a brass spacer on the screw between the control linkage and the duct Disconnect the motor controller from the motor Three wires are connected by press fittin
28. ally designed for your AXI 2826 10 brushless motor Temperature overload protection is built into the speed controller which turns off the motor when the temperature reaches 110 centigrade These speed controllers are equipped with protection functions that take care of the correct start and operation of the motor across the whole range of revolutions and current Do not connect the speed controller to just any kind of power source Take care to ensure the correct polarity of the supplied batteries 21 ELECTRICAL SYSTEM Trek Aerospace OAY 1 fee gt 1 Tim Page 1 of 1 The electrical system on OVIWUN is relatively simple There two brushless electrical motors mounted in the duct housing Each of these is connected to a sensor less speed controller by three wires On the 1 side of OVIWUN the black and white wires are reversed so that the motor operates in the opposite direction The motor controllers are then connected to the battery buss bar The battery bus bar has two or more 14 8 v 4 cell Li Poly batteries connected to it using Deans Connectors The battery bus bar also has leads running to two battery elimination circuits BEC On the 1 side is 5V BEC that supplies power to
29. and epoxy COMPONENT REPLACEMENT SCHEDULE There is no component replacement schedule The parts used should last the lifetime of the vehicle Periodic inspection of the servos may show wear in the gear train If that occurs the servos can be replaced REPLACEMENTS PARTS ORDERING If it is time to replace one or more parts on the vehicle you can order replacements parts directly from us You will find a list of parts in Appendix A You can also call us at the number below or email us at parts trekaero com CONTACT US You can contact us by phone web email writing us or visiting us Our phone number is 209 368 5800 our webpage is at www trekaero com You can email us at info trekaero com the general questions or comments parts trekaero com for parts questions or orders service trekaero com for service questions sales trekaero com for sales and ordering You can write us at You can visit us at Trek Aerospace Inc Trek Aerospace Inc PO Box 748 23987 N Hwy 99 Hanger 21 Acampo CA 95220 0748 Acampo CA 95220 USA USA 41 SECTION 6 MAINTENANCE MAINTENANCE TOOLKIT REQUIREMENTS T7 Torx wrench Allen wrenches sizes 7 64 3 32 1 16 and 2 mm Open end wrench size 1 4 1 Philips Head screwdriver Soft cloth for cleaning and drying the airframe TROUBLESHOOTING We are still developing this section of the manual While we have nearly 100 hours of flight on OVIWUN we have n
30. ansmitters supplied are common frequencies used by most radio controlled aircraft hobbyists When flying at an RC airfield or with a group of RC aircrafts the best RFI prevention is to create a pilot s box approximately 15 to 20 feet apart for each flyer and never walk too close to another flyer if your antennas are up Keep in mind other devices or flyers may be transmitting signals on these same frequencies and it is important that when flying in a group to display your transmitter channel number on your antenna when flying Always check the area you are operating in to be sure that no one else is operating on the same frequency never try to fly more than one vehicle on the same channel If you change the equipment on your OVIWUN such as replacing the motor controllers motors batteries or other electrical devices which have not been tested for RFI conditions you should be prepared for possible spurious false commands One of these may be the unintentional start up of the fans This can be very dangerous Of course this can also happen if any unwanted signal is received once the vehicle is active Always use proper care when you make your vehicle systems active For additional information on setting up your radio and ways to avoid RFI problems please refer to your HiTec Eclipse 7 Manual ADDING RADIO LINKS You may be interested in adding a range of extra radio links for gathering additional data When doing so you should alway
31. as a wall tree or bush Do not try to catch the machine by the ducts or fly towards someone hoping they will catch the machine Otherwise simply wait out the batteries 34 This is an electrical vehicle and as such electrical shock is possible Flying in the rain snow or wet conditions is not recommended As with any other electrical device use caution not to touch power leads NEVER expose the batteries to water With the exception of salt water which is only used on Lithium Polymer batteries during the battery disposal process WARNING Always unplug the batteries before attempting any repair or carrying the vehicle Static electricity can damage your Stargate and uNav units Make sure you only touch these components after you have discharged any static electricity that may be built up on either you or the machine STORAGE The case in which your OVIWUN was delivered has been designed for storage transportation and shipping Before storing your OVIWUN unit you must remove the batteries from the vehicle CAUTION Never store the vehicle with the batteries in place You should inspect and clean your vehicle before storing it Flying in the rain snow or wet conditions is not recommended If a vehicle becomes wet it should be dried before storage If the inside of the case becomes damp be sure to let it air dry thoroughly before storing your vehicle If you are going to store your vehicle for an extended p
32. attery you wish to charge The charging sequence will automatically begin If your battery is not connected has a loose connection is connected backwards or is drained to less than 3 volts the microprocessor will not detect the battery and waiting for battery will still be displayed If your battery is properly connected the display will begin indicating the charge current the battery voltage the duration of the charge and the milliamp hours delivered to the battery CAUTION Always start charging with the current adjust at zero amps slowly increasing the charging rate until the rate equals the capacity of the battery pack We recommend charging Lithium Polymer batteries at a 1C rate a rate equal to the mahr rating of the cells After a few minutes the charging current may decrease slightly as the battery voltage rises so you may want to re adjust the rate During the first few seconds of charging the display will show the charging mode and the number of cells that the microprocessor thinks are in the battery pack The display will read 1 1 ona single cell 2C1 on two cells and 3C1 on three cells etc Discharging your Lithium Polymer Battery You can use the discharge function to measure the capacity of your battery First fully charge the battery then after it is fully charged disconnect the alligator clips to the power source and reconnect the alligator clips to the Astro Model 120 power supply Discharging will automa
33. be repaired before any flight Remove the back cover from the vehicle Match the frequency of the receiver with that of the transmitter Check with other people operating any RC controlled vehicle in the vicinity to ensure that you will not be operating on the same frequency Check the fans The fans should be secure and rotate freely within the ducts Examine the control linkages They should be straight and be connected The screws holding the linkage should be tight 30 10 11 12 13 14 15 16 Verify that the wires from the motor controllers to the motors are tightly connected The black and white wires on the 1 side of the vehicle are reversed on purpose The fans are counter rotating and this configuration allows this Remove the cargo bay and check the weights in the cargo bay They should be positioned and attached by the Velcro The position of the weights can affect the weight and balance of the vehicle This may throw the center of gravity off Reinstall the cargo bay make sure the receiver antenna and other wires are free and not pinched when reinstalling Looking inside the vehicle starting at the top a Check the duct retaining thumbscrews They should be tight b The RC receiver should be securely fastened by Velcro c There are two battery elimination circuits in the next bay They should be securely fastened to the sides of the airframe with Velcro d Check to see that the Stargate
34. below The weight of the extra batteries however does reduce the maximum payload capability These charts are based on Li Poly batteries OVIWUN Flight Time with 1 Ib Payload 60 50 E 40 g 30 5 20 2 10 0 0 1 2 3 4 5 6 7 8 9 Number of Battery Packs Mission profile is 90 loiter and 10 hover at sea level 46 Mission Endurance min OVIWUN Fight Time with Various Payload Weights 0 5 Ib 1 0 Ib 1 5 Ib 2 0 Ib 2 5 Ib 3 0 Ib 3 5 Ib 4 0 lb 2 4 6 8 10 Number of Battery Packs Mission profile is 90 loiter and 10 hover at sea level 47 RADIO FREQUENCY INTERFERENCE CONSIDERATIONS Radio Frequency Interference RFI is also known as Electromagnetic Interference EMI and can affect anything that receives transmissions including radios televisions phones wireless computers and remote operable vehicles such as OVIWUN Radio Frequency Interference results when unwanted signals are received by the device and prevent the desired signal from getting through As a radio controlled vehicle OVIWUN is susceptible to a number of RFI issues Keeping your antenna free from electromagnetic interference avoids one of the most common Make sure it is hanging freely not touching any of the electric or electromechanical parts of the vehicle The radio frequencies used in the tr
35. duct support vanes motor mount lollipop arm with fairing and two bearings 2 Fan Assembly The fan assembly includes the fan either right or left and the prop collet adapter 3 Spinner Assembly The spinner assembly includes the spinner spinner base plate and attaching screws 4 Center body Assembly The center body assembly covers the motor and includes the center body and its attaching screws AERODYNAMICS OVIWUN is unlike any aircraft you have ever flown before Unlike fixed wing aircraft no takeoff or landing rolls are required there are no separate propulsion units and lifting surfaces Unlike rotary wing aircraft there are no cyclic and collective controls OVIWUN is a powered lift vehicle In hover the fans provide the majority of the lift in forward flight the ducts provide the majority of the lift The core of OVIWUN is its dual duct system The fans rotate in opposite directions negating torque effects Advanced CFD analysis has been used to match the geometries of the fan and the duct Working together they exhibit sensational lift to power ratios 18 All control of OVIWUN is generated through two methods duct tilt and fan speed modulation The ducts tilt individually on a common lateral axis By tilting the ducts in unison in the fore and aft direction forward and rearward motion of the machine is generated By tilting the ducts in opposite directions a yawing motion is created By altering fan speed in uni
36. ear a series of single beeps from the motor controllers RF interference may cause one or both of the fans to spin 20 You should see the red LED on the uNav and red yellow and green LEDs the Stargate come on The LEDs on the Stargate will flash on and off 21 Double check the polarity of the second battery and in one smooth and definite operation plug the second battery into the bus bar 22 Carefully tuck the bus bar into the lower bay and replace the back cover 23 You can now check the controls a Lift the machine GENTLY SLOWLY and SLIGHTLY pitch the machine forward and backwards The ducts should move in response to your pitch movement They will be attempting to keep the machine level b Repeat the motion in yaw turning the vehicle GENTLY SLOWLY and SLIGHTLY to the right and left If the machine does not respond follow the SHUTDOWN PROCEDURE on page 15 and start over 24 Your OVIWUN is now ready to fly 32 FLIGHT OPERATIONS WARNING Having a safe environment in which to operate you OVIWUN vehicle is extremely important The area you chose should be clear and free of any loose debris You should have adequate room to maneuver the vehicle and get away from your vehicle should it become uncontrollable POST FLIGHT SHUTDOWN DO NOT TURN OFF THE TRANSMITTER UNTIL TOLD TO DO SO ie 10 11 12 Lock the collective throttle in the down position Remove the rear cover
37. ec Warranty Card Astro Flight Warranty Cards BON OR PRE ASSEMBLY REQUIREMENT AND TOOLKIT OVIWUN arrives nearly preassembled in the shipping and storage case Your first task upon receipt is to make sure all of the parts listed as being in the box are indeed in the box The following list will serve as a guideline Airframe Batteries Shipped and stored separately for safety Transmitter Battery Charger Power Supply Landing Skids 7T Torx Allen Wrench SD AE You should need no additional tools when assembling or servicing OVIWUN ASSEMBLY OVIWUN has already been assembled and tested at the factory It has been slightly disassembled for packing and shipping Before operating you will need to install the landing skids and batteries 1 Installing the Landing Skids a Remove the aircraft and the skids from the transport container b While holding the aircraft by the landing strut slide each landing skid into the landing strut pushing the skid in from the front of the vehicle A slight rotating motion may help Continue to push the skid through both struts until the skid protrudes 3 4 8 cm from the rear strut d Tighten the thumbscrews attached to the strut to secure the skid SAFETY AND HAZARDS One of OVIWUN s greatest advantages is its ducted fan propulsion system The ducted fan offers greater safety than the exposed rotors of a helicopter or the propeller on a fixed wing plane How
38. ently Used see transmitter manual for description Aileron D R Not Currently Used see transmitter manual for description Center body of receiver Left joy stick Up Down is the collective throttle Right Left is Yaw Control 26 Left trim switch just below left joy stick Yaw Trim On Off Turns receiver on and off Left center trim switch Collective Throttle Trim Right center trim switch Pitch Trim Right joy stick Up Down is Pitch Control Right Left is Roll Control Right trim switch just below right joy stick Roll Trim Lower body of receiver Edit display up Used in programming see transmitter manual Edit display down Used in programming see transmitter manual Cursor left Used in programming see transmitter manual Cursor right Used in programming see transmitter manual Timer off Used in programming see transmitter manual Timer start stop Used in programming see transmitter manual Data increase Used in programming see transmitter manual Data decrease Used in programming see transmitter manual Save left Used in programming see transmitter manual Save right Used in programming see transmitter manual Clear active inhibit Used in programming see transmitter manual Engine lock Used to lock the Collective Throttle Position Engine cut Not Currently Used see transmitter manual for description SPECTRA MODULE Spectra 72MHz fre
39. ently until they pop The fitting itself should not show just the covering Remember the black and white wires on the 1 side of the vehicle are intentionally reversed Test the duct to see if the movement is easy Connect the control linkage to the duct using a 3 32 Allen wrench Place the screw into the control linkage Place the brass spacer between the control linkage and the duct with the flat side of the spacer against the duct All the components are now in place You have a complete Duct Assembly MOTOR REPLACEMENT REMOVING THE MOTOR Make sure the machine is inactive Remove the batteries Disconnect the motor controller from the motor Three wires are connected by press fittings They should pull apart easily Hold the wire on either side of the press fitting and pull gently until they separate Remove the spinner and center body Three screws hold each piece Use the T7 Torx wrench Once the screws have been removed each piece should pull away easily Using a 3 32 Allen wrench as a lever unscrew the top of the prop collet Put the Allen wrench through the hole in the top of the collet hold the prop at the same time and turn the collet counter clockwise Remove the prop subassembly by pulling the prop gently straight up off the motor shaft There are four parts here prop spinner back plate and the bottom two parts of the collet Carefully feed the wires from the mot
40. er Li Poly rechargeable battery packs Lithium Polymer rechargeable batteries utilize the latest technology available for consumer use Since the electrolyte is a solid polymer not liquid these polymer battery cells are designed to be safer than most batteries on the market However we recommend familiarizing yourself with this new technology to ensure the batteries are used properly as they dangerous if not used per the manufacturer s specifications The Lithium Polymer batteries included with your OVIWUN have high voltage per cell 3 7 volts average and excellent energy on weight and volume basis providing more energy per gram and resulting in more watt hours Kg than their counterparts such as NiCd NiMH These Li Poly batteries are specifically designed to be as thin as possible with large footprint configurations The Lithium Polymer rechargeable batteries which came with your OVIWUN work over a board range of temperatures Each battery pack contains four 4 cells A fully charged 4 cell pack will have a voltage of 16 60 to 16 80 volts These packs have a normal capacity of 4 amp hours 4000 mAH Li Poly Batteries can adversely be affected and their performance reduced if they overheat are allowed to get too cold or are improperly discharged To avoid cell damage from over discharge it is important to land when you hear a drop in speed or performance of your OVIWUN 36 It is crucial that the batteries are charged on a unit
41. eriod you should remove the battery from the transmitter and follow the manufacturer s recommendations for proper battery storage As a precaution all batteries should be stored in a separate location if they will not be used for extended periods CAUTION Never attempt to store your batteries in the case if they are hot Wait until the batteries have cooled before placing in the storage container The case and vehicle should be stored in cool dry location Excessive heat and moisture can cause damage to the components 35 SECTION 5 ROUTINE SERVICING ROUTINE SERVICE SCHEDULE The only routine service on the vehicle is keeping it clean dry and dust free There are no serviceable parts on the vehicle The bearings are sealed The control linkages should last for thousands of hours The motors require no lubrication The transmitter power supply and battery charger should also be kept clean dry and dust free These are not customer serviceable parts If your unit becomes damaged or stops working you should replace it or return it for service SERVICE TOOLKIT REQUIREMENTS T7 Torx wrench Allen wrenches sizes 7 64 3 32 1 16 and 2 mm Open end wrench size 4 1 Philips Head screwdriver BATTERY CHARGING When OVIWUN sounds as if it is slowing down begins to descend by itself or is not able to take off you most likely need to recharge the battery pack Your OVIWUN vehicle comes with two Lithium Polym
42. ever this does not mean that we have eliminated all the safety concerns Although the blades are shielded within the duct they are still operating at a high RPM have relatively sharp edges and can cause serious damage WARNING Never wear any loose clothing while operating the vehicle Ties cords from sweatshirts loose T shirts and many other things can be indigested into the duct and wrapped around the blade When operating the vehicle be on the look out for loose and particularly lightweight objects which may be ingested into the duct or fan WARNING Ingested materials may cause the vehicle to travel in an undesired direction In doing so it may inadvertently hit something or someone causing harm Ingested material which passes through the ducted fan could come out the other side and eject towards someone or something causing severe damage Everyone near the vehicle when it is operating should be wearing protective eyewear and hearing protection OVIWUN uses several Lithium Polymer batteries All batteries get hot during use especially so during longer flights Heat can cause damage to the vehicle s operating systems and subsystems They can also get hot enough to burn you if you touch them After operating the vehicle use extreme caution when handling the batteries 10 The heat from the batteries may also cause damage to objects on which they reside or are in close proximity to You must carefully and completely check
43. g Life Potentiometer tC 30Metal Gears amp 1 Resin Metal Gear Dual Ball Bearing Waterproof amp Dustproof Indirect Drive Potentiometer Gold Plated Contacts MOS FET Motor Drivers _ 1 D Ls ST e MOTORS OVIWUN comes with two Model Motors Ltd s AXI2826 10 brushless electric motors These brushless motors with neodymium magnets in a rotating case are manufactured using advanced technology from the highest quality materials A hardened steel driveshaft mounted in two ball bearings and overall robust but lightweight construction ensure long motor life The motors come installed in the vehicle When connecting the motors to the motor controller you must be careful to install the wires correctly Connecting the wires incorrectly may cause the motors to operate in the same direction or in the wrong direction Please consult the installation section for further details Please note that your AXI is a high performance electric motor working under high current loading which produces some heat Proper cooling is essential in just that same way as it is with an internal combustion engine Overheating of your motor causes increased wear in the bearings and partial demagnetization which decreases performance of the motor As with all types of magnetic material complete demagnetization of the neodymium magnets can occur at over 130 C Please make sure that cooling air can flow through the holes in the front plate
44. go outside to achieve some forward flying circuits If you do fly outside please remember any wind will affect the performance of the vehicle Keep this in mind and do not get surprised if it suddenly climbs or drops without you making any input A slight breeze or even a thermal wind coming through can cause this Remember practice makes perfect We suggest practicing on a computer flight simulator to enhance and speed up the learning process In addition a simulator allows you to expand your abilities without damaging the vehicle or property If you notice that the performance of the vehicle is dropping this is a sign that the battery pack is going flat We suggest that you immediately land and recharge your battery Remember the proper environment of no wind and a large space without obstacles is the key to learning Step 4 You are now ready to go outside We suggest that you begin on days when the winds are dead clam Begin again with expanding your ability by yawing the vehicle slightly to the left or right Once you feel you are able to fully control the vehicle pick a large area with unobstructed views and transition the vehicle to forward flight You should begin by combining bunny hops with forward movement Slowly expanding the distance you travel forward Follow your vehicle from a safe distance about six feet 1 8 meters Once you have successfully mastered this operation pick a simple pattern such as a square and w
45. gs They should pull apart easily Hold the wire on either side of the press fitting and pull gently until they separate Remove the duct retaining thumbscrew This screw is in the uppermost bay of the airframe This may require the 3 32 Allen wrench to loosen There are TWO small aluminum washers to watch out for Gently and yet firmly hold the machine by the center top of the airframe and pull the duct assembly gently from the support tube Note Pull straight from the support tube be careful not to pull at an angle as it may damage the support tube The full duct assembly has now been removed If you are replacing the entire assembly you are done otherwise proceed to the next page To remove the components begin by removing the spinner and center body There are three screws holding each piece Use the T7 Torx wrench to remove the screws Once the screws have been removed each piece should pull away easily Using a 3 32 Allen wrench as a lever unscrew the top of the prop collet Put the Allen wrench through the hole in the top of the collet hold the prop at the same time and turn the collet counter clockwise 65 Remove the prop subassembly by pulling the prop gently straight up off the motor shaft There are four parts here prop spinner back plate and the bottom two parts of the collet Carefully feed the wires from the motor
46. h the nose of the vehicle Watch the nose and slightly apply enough throttle until the vehicle becomes light on its skids Always when applying the throttle please apply it softly Too much throttle will make the vehicle climb too quickly and you may have difficulties in correcting it quickly enough 54 Step 2 First flights should be what are called bunny hops This is initially applying a slight amount of power to get the vehicle light on its skids Once this has happened apply more power to lift the vehicle so it is approximately two feet 60 centimeters off the ground Watch for any change of direction of the vehicle If you cannot correct it immediately decrease the throttle and land This is the initial step in learning to operate the vehicle You should do this until you believe you are controlling the vehicle and understand the commands necessary to operate the vehicle How many times and how many batteries you will need to achieve this level of understanding it will depend on your ability to become familiar with the feeling and feedback from the vehicle We find two feet 60 centimeters is best for flight training Always make sure you watch the nose of your vehicle Keep practicing and you will find that your flights will become more under control and longer Also please note that depending on the size of your room the air created by the vehicle can circulate around the room within a few seconds and cause turbulence If yo
47. have cooled before placing them in the storage container Inspect clean and dry your vehicle before storing it Is the inside of the case wet Let it air dry thoroughly before attempting to store your vehicle Are you going to store your vehicle for an extended period If so you should remove the battery from the transmitter It is better to store the batteries in a separate location for extended periods o Remember to keep your batteries in a place away from excessive heat or flammable materials o Werecommend using extra precautions when handling Lithium Polymer batteries and storing them in a fireproof container The case and vehicle should be stored in a cool dry location Excessive heat and moisture may cause damage to the components 61 APPENDIX D SERVICE AND MAINTENANCE CHECKLISTS BATTERY CHARGING Your OVIWUN vehicle comes with two Lithium Polymer rechargeable battery packs Your transmitter also comes with a battery and has a built in charger NOTE The following Safety Tips are guidelines for the safely using Lithium Polymer batteries it is important for you to familiarize yourself with and follow the manufacturer s requirements regarding the safe handling charging and discharging of Lithium Polymer batteries SAFETY TIPS FOR HANDLING BATTERIES Never charge any battery type unattended Only charge a battery with a charger designed specifically for that type of battery
48. he machine As an added precaution a first aid kit should be kept on hand in case of minor emergencies Sand or a dry fire extinguisher should be kept at hand in case of a battery fire In extreme cases you should establish the location of and quickest method of transport to the nearest emergency medical treatment facility Z WARNING Do not place anything in the ducts while the vehicle is operating When flying your OVIWUN always should ensure that people and animals are safely out of range While bumping up against the duct will not cause damage loose clothing or appendages can be sucked into the ducts if they get too close and may cause major damage Likewise if loose items are drawn into the ducts they are liable to be ejected at great speeds WARNING Always wear eye protection during the operation of your vehicle OVIWUN is not very loud especially at distances However within a hundred or so feet it is loud enough to cause ear damage with prolonged exposure WARNING Always wear hearing protection during the operation of your vehicle Should OVIWUN become unstable during flight and you are unable to recover control you should first put your collective throttle stick to zero OVIWUN should respond by losing power and falling Be careful where it is going to fall and chose a place where damage will be nonexistent or at least minimal Should this fail turn off the transmitter or try flying into a stationary object such
49. he receiver with that of the transmitter Again they have been set at the factory but should be rechecked See the transmitter instructions Check the charge on the transmitter Charge the battery in the transmitter if necessary Check the fans The fans should be secure and rotate freely within the ducts Examine the control linkages They should be straight and be connected The screws holding the linkage should be tight Verify that the wires from the motor controllers to the motors are tightly connected The black and white wires on the 1 side of the vehicle are reversed on purpose The fans are counter rotating and this configuration allows this Remove the cargo bay and check the weights in the cargo bay They should be positioned and attached by the Velcro The position of the weights can affect the weight and balance of the vehicle This may throw the center of gravity off Reinstall the cargo bay make sure the receiver antenna and other wires are free and not pinched when reinstalling Looking inside the vehicle starting at the top a Check the duct retaining thumbscrews They should be tight b The RC receiver should be securely fastened by Velcro c There are two battery elimination circuits in the next bay They should be securely fastened to the sides of the airframe with Velcro d Check to see that the Stargate and Nav are secure Place the batteries in the airframe However do NOT connect them The batte
50. inner back plate must be positioned to mate with the spinner Attach the center body Place the center body over the motor and line up the screw holes with the motor mount Be sure to align the cutout for the motor wires Three screws hold the center body it in place Use the T7 Torx wrench to tighten the screws Attach the spinner Place the spinner over the prop and line up the screws Three screws hold it in place Use the T7 Torx wrench to tighten the screws All the components are now in place You have a complete Duct Assembly If you purchased a full duct assembly begin here Gently yet firmly hold the machine by the center top of the airframe and insert the duct assembly carefully into the support tube Note Stay level and even with the support tube being careful not to force the Duct Assembly in at an angle as it may damage the support tube 66 Replace the duct retaining thumbscrew This screw is in the uppermost bay of the airframe This may require the 3 32 Allen wrench Remember there are TWO small aluminum washers on this screw If they are not there you may damage the support arm and or restrict the operation of the duct Connect the motor controller to the motor There are three wires that are connected by press fittings They should slide together easily Hold the wire on either side of the press fitting and slide g
51. is electronically limited to 1 25 amps Six messages are displayed during a normal charging sequence The amount of charging current flowing into the Lithtum Polymer battery pack The number of cells the charger thinks the battery contains The charging mode The voltage of the battery being charged The duration of charge in hours minutes and seconds The number of milliamp hours of charge put into the battery pack ON eS When the Lithium charger software detects the fully charged condition charging will automatically stop The digital display will indicate the maximum battery voltage reached the duration of the charge and the total milliamp hours of charge delivered to the battery The buzzer will then beep three times Three messages will be displayed during the discharging sequence 1 The voltage of the battery packs being discharged 2 The duration of the discharge in hours minutes and seconds 3 The total number of milliamp hours delivered to the load When the Lithium Polymer battery has been discharged to a voltage of approximately 3 volts per cell the discharging will automatically stop 38 Charging your Lithium Polymer Battery Connect the alligator cords to the Astro Model 120 After a few seconds the digital display should first announce AstroFlight Lithium and then waiting for battery Wait for the display to say waiting for battery then connect the short output cord to the Lithtum Polymer b
52. ith the SPB400 to form a sophisticated open source robotics platform This comprehensive robotics solution offers users a flexible development platform for state estimation WiFi telemetry command uplink downlink and closed loop navigation and control Payload sensors e g USB image sensor can be connected and processed by the Stargate to support intelligent robotics applications The Crossbow manuals and data sheets enclosed with the kit have additional information on uNav CROSSBOW S STARGATE The Stargate is a powerful single board computer with enhanced communications and sensor signal processing capabilities The Stargate uses Intel s latest generation 400MHz X Scale processor PXA255 This product was designed within Intel s Ubiquitous Computing Research Program and licensed to Crossbow for production In addition to traditional single board computer applications the Stargate directly supports applications designed around Intel s Open Source Robotics initiative as well as Tiny OS based Wireless Sensor Networks Crossbow s manuals and data sheets enclosed with the kit have additional information on the Stargate FLIGHT CONTROL SYSTEM As of the writing of this manual the flight control system on OVIWUN is a work in progress The flight control software is located within the uNav The system is rate based only as it is only using the rate sensors on the uNav to assist in flight It is rated based in all three axes
53. ium battery If you have modified your charger to a different connector please check to make sure that the polarity of your connector is correct and that you have done a good solder job Wiggle all connections just to be sure Shorted Output The Shorted Output message will occur if the lithium battery voltage drops below 3 volts while charging This should never happen on a good lithium battery You have either a bad connection or a bad battery Another possibility is that you have long wires between the charger and the battery These wires should be no longer than foot Find out what is wrong before proceeding The Shorted Output message will also occur in Mode 2 and Mode 3 if the resting battery voltage drops below 3 volts per cell based on the cell count detected during Mode 1 Again you have a bad connection a bad battery or long wires To continue first remove the lithium battery pack then disconnect from the 12 volt source and re connect the 12 volt source to reset the microprocessor in the charger Then reconnect the battery to continue charging Timed Out The Timed Out message will be displayed if the charger has not reached Mode 3 within one hour Remove the lithium battery then reconnect to continue charging On future charges you may want to increase the charge rate a bit 40 AIRFRAME SERVICING The airframe requires no scheduled servicing Repair work can be accomplished with fiberglass
54. llen wrench Hold the servo gently but firmly while tightening the screw that holds the control linkage to the servo Note There is a brass spacer between the control linkage and the servo The flat side of the brass spacer goes against the servo Connect the control linkage to the duct using a 3 32 Allen wrench Hold the duct gently but firmly while tightening the screw holding the control linkage in place Note There is a brass spacer between the control linkage and the bolt The flat side of the brass spacer goes against the duct Connect the servo to the uNAV This is a friction fitting and they should easily slip together 71 LANDING SKID amp STRUT REPLACEMENT If a landing skid becomes broken or bent you can replace the skid by loosening the two retaining thumbscrews and sliding the skid out of the struts Inspect the struts for damage before placing a new skid in the strut Should a strut become damaged it can also be replaced Remove the cargo bay and loosen the two nuts holding the strut in place The batteries will have to be removed from the vehicle to do this Put a new strut in its place and tighten the nuts back into place AIRFRAME REPLACEMENT If you feel for some reason that the entire airframe needs to be replaced It is recommended that you return your vehicle and all of its components to Trek Aerospace for inspection and replacement 72 APPENDIX
55. ly charged batteries are used when flying and landing when you hear a drop in speed or performance of your OVIWUN 9 The Lithium Polymer Battery pack may ignite if connected to a charger supplying more than 6 volts per cell 10 Always assure the AstroFlight 109 charger is working properly 11 Always charge your Lithium Polymer Battery pack in a safe environment away from flammable or combustible materials and where no harm can result 12 Never charge your Lithium Polymer Battery pack in the OVIWUN vehicle A hot pack may cause damage to your vehicle or components 13 Never charge your Lithium Polymer Battery pack inside a motor vehicle or in a vehicle s engine compartment 14 Never charge your Lithium Polymer Battery pack on a wooden workbench or on any flammable material 15 The seal of Polymer cells can degrade at excessive temperatures and cause electrolyte leakage Especially when left in the trunk of a car or on the dash If you come in contact with this electrolyte scrub the area with soap and water If the electrolyte splashes into your eyes flush with water and seek immediate medical attention 16 If your Lithium Polymer Battery pack is involved in a crash a Remove the Lithium Polymer Battery pack from the vehicle b Carefully inspect the pack for shorts in the wiring or connections If in doubt replace the battery pack with a new one 37 c Inspect cells for dents crack splits warping or leaking Dispose of
56. mental aircraft which has undergone only limited testing and development Many of you will want to modify the vehicle in one way or another While we encourage you and challenge you to improve on our design we have to state that modification of additions to or subtractions from the equipment provided may cause the vehicle to not operate to operate in an unsafe manner or to operate other than intended Trek Aerospace is not responsible for the operation of the vehicle or the modifications you may have made PERFORMANCE SPECIFICATIONS This vehicle has been designed and tested to operate with the equipment provided The Beta version of OVIWUN has only been tested to an airspeed of 7 mph and a density altitude of 2500 feet in calm conditions as of October 2005 This is the guaranteed performance envelope until further software refinements and testing have been performed As software upgrades become available they will be provided free of charge to purchasers of Beta versions of OVIWUN Modification of or additions to that equipment may cause the vehicle to operate other than intended WARRANTY We guarantee this kit to be free from defects in material and workmanship at the time of purchase This warranty does not cover any component parts damaged by use modification or deterioration resulting from the application of adhesives or other products not specified in the Instructions In no event shall our liability exceed the original purchase p
57. n 3 Remove the thumbscrew in the cross tube in the upper compartment of the Upper Body Slide the Duct Assembly out of the cross tube Remove the fan see instructions above for blade replacement Remove the four screws holding the motor in place Gently pull the electrical wires through the lollipop arm fairing Remove the motor Discard the damaged Duct Assembly 0 Reverse the above procedure to install the new Duct Assembly aoe Secs PARTS ORDERING If you discover some damage to one or more parts on the vehicle you can order replacements parts directly from us You will find a list of parts in Appendix A You can also call us at the number below or email us at parts trekaero com CONTACT INFORMATION You can contact us by phone web email writing us or visiting us Our phone number is 209 368 5800 our webpage is at www trekaero com You can email us at info trekaero com the general questions or comments parts trekaero com for parts questions or orders service trekaero com for service questions sales trekaero com for sales and ordering You can write us at You can visit us at Trek Aerospace Inc Trek Aerospace Inc PO Box 748 23987 N Hwy 99 Hanger 21 Acampo CA 95220 0748 Acampo CA 95220 USA USA 44 SECTION 7 ADVANCED FLIGHT CONTROL MODIFICATIONS SETTING THE DEFAULT GAINS The default gains are factory set If the machine loses its default gains you will need to reload the fac
58. ng the battery the motor controllers uNav and Stargate will go through the boot procedure The ducts will move and you will hear a series of single beeps from the motor controllers RF interference may cause one or both of the fans to spin Are the red LED on the uNav and red yellow and green LEDs on the Stargate on Are the LEDs on the Stargate flashing on and off Double check the polarity of the batteries and connect the second battery into the bus bar in one smooth and definite operation 58 The Final Steps Tuck the bus bar into the lower bay Replace the back cover Check the controls a Lift the machine GENTLY SLOWLY and SLIGHTLY pitch the machine forward and backwards The ducts should move in response to your pitch movement They will be attempting to keep the machine level b Repeat the motion in yaw turning the vehicle GENTLY SLOWLY and SLIGHTLY to the right and left c IF THE MACHINE DOES NOT RESPOND FOLLOW THE SHUT DOWN PROCEDURE AND START OVER Your OVIWUN is now ready to fly 59 POST FLIGHT Lock the collective throttle in the down position Remove the rear cover Pull out the bus bar Disconnect both batteries and store safely so the connectors do not touch anything Never place the exposed tabs on or near conductive material Check the power state by looking at the LEDs on the Nav and Stargate They should be off Gently and
59. ontrol code from the OVIWUN support CD located in the Code folder You may modify the gains by editing the control h file Use the make all function to create a new hex file and upload the hex file using the instructions outlined above in the Setting the Default Gains section of this manual OPEN SOURCE CODE Open source code is available from the following link http sourceforge net projects micronav This link contains Stargate code for a basic Kalman Filter AHRS solution using uNAV uNAV firmware and ground station code 45 SECTION 8 PAYLOAD ADDITIONS AND MODIFICATIONS PAYLOAD VOLUME OVIWUN has been designed to accept various payloads in its cargo pod The cargo pod provides 1 45 liters 88 cubic inches of payload space The base of the pod is 13 x 13 cm 5 1 x 5 1 inches Internal depth of the pod is 6 cm 2 37 inches The cargo pod easily detaches from the airframe by loosening four thumbscrews WEIGHT POTENTIAL OVIWUN with a nominal 500 gram 1 1 pound payload and the provided twin battery pack has a hover endurance of nearly 20 minutes Higher payloads can be carried at reduced endurance times The maximum payload OVIWUN can lift is slightly more than 2950 kg 6 5 pounds To allow for maneuvering and atmospheric condition margins Trek Aerospace recommends that the user does not exceed a payload of 1500 grams 3 3 pounds For increased endurance additional battery packs may be installed as shown
60. or and line up the screw holes with the motor mount Be sure to align the cutout for the motor wires Three screws hold the center body it in place Use the T7 Torx wrench to tighten the screws Attach the spinner Place the spinner over the prop and line up the screws Three screws hold it in place Use the T7 Torx wrench to tighten the screws Connect the motor controller to the motor Three wires are connected by press fittings They should slide together easily Hold the wire on either side of the press fitting and slide gently until they pop The fitting itself should not show just the covering Motor replacement is complete 68 pPNAV amp STARGATE REPLACEMENT Removing the units First make sure the machine is inactive If they are not removed remove the batteries ESD WARNING The Stargate Processor Board Daughter Card and uNav are electronic devices and therefore can be damaged by Electrostatic Discharge ESD While handling these devices follow ESD prevention procedures and use an ESD wrist strap There are four thumbscrews which attached the Stargate to the airframe They are located in the top to the bottom bay Turning the screws clockwise loosens them Remove the four thumbscrews and set them aside Each of the thumbscrews has short spacer Loosen the BECs from the Velcro holding them in place on the righ
61. or back through the vane until they are free of the vane Using a 2 mm Allen wrench remove the four screws holding the motor to the motor mount Note There are four washers on each screw one under the screw head and three between the motor and motor mount The motor should fall free Motor removal is complete 67 REPLACING THE MOTOR Make sure the machine is inactive If they are not removed remove the batteries Mount the motor first You will need the 2 mm Allen wrench There are four screws holding the motor to the motor mount Note There are four washers on each screw three between the motor and motor mount and one under the head of the screw Get all four screws started and then tighten in rotation Carefully feed the wires from the motor back through the vane Leave a small amount of slack do not pull the wires tight Place the collet shaft over the motor shaft Place the collet pressure fitting on the collet shaft large end down Place the spinner back plate on the collet shaft flange side down Place the prop on the collet shaft Screw the top of the prop collet on the collet shaft Tighten using a 3 32 Allen wrench as a lever Hold the prop in place and get a good tight fit Note that the screw holes in the spinner back plate must be positioned to mate with the spinner Attach the center body Place the center body over the mot
62. ork your vehicle to the corners yaw in the next direction and repeat until you have successfully completed the task From this point forward you can determine various flight patterns that challenge your abilities without overtaxing them Once you are thoroughly familiar with the vehicle you can begin operating the vehicle under increasing wind conditions Good luck and have fun 56 APPENDIX C OPERATIONS CHECKLISTS PRE FLIGHT Ground Check Is the area you are planning to operate in large enough Is it clear of any loose objects to be blown around Have you removed any loose objects of clothing Have you removed any metal from your fingers rings and wrists watches Is there a safe place to exit to should it be necessary Are observers aware of the danger and do they have an emergency plan Pre Flight Vehicle Check Are all the batteries transmitter and vehicle fully charged Remove the vehicle from the case and install the landing skids Conduct a visual check of your OVIWUN unit Look for any nicks scrapes gouges or other signs of wear and tear Inspect the ducts and fans with particular ardor These should be repaired before any flight Check that the frequency of the receiver and the transmitter are the same Check the surrounding area for any possible RFI Are there other people operating any RC controlled vehicle in the vicinity Are you operating on a unique fre
63. ot encountered that many problems As you operate your OVIWUN and encounter different issues please let us know what happened the conditions under which it happened and what your remedy was We will catalogue those issues and include them and the remedy in future issues of the manual Send an email to sevice trekaero com Problem Vehicle is non responsive to commands We have discovered that you really need to top off the batteries before each flight and keep track of the flight times As the batteries wear down the vehicle loses its ability to implement your commands So if you are out there flying around and the vehicle begins to falter land and check your batteries Be sure to check the charge in the transmitter as well Problem Does not boot The most common problem seems to be that during the pre flight when plugging in the batteries the machine does not boot The lights on the Stargate and uNav may be on but the vehicle is not responsive to your moving it around The only solution we can offer now is to unplug the batteries and start over This works nearly every time BATTERY MAINTENANCE You should inspect your battery packs before and after each flight You should look for frayed wiring discoloration bubbles in the protective cover burn marks and anything else that would indicate the battery has been damaged If you find the battery has been damaged in any way REPLACE IT 1 If your Lithium Polymer Battery pack
64. quency Check that the fans are secure and rotate freely within the ducts Examine the control linkages They should be straight and be connected The screws holding the linkage should be tight Verify that the wires from the motor controllers to the motors are tightly connected Remember the black and white wires on the 1 side of the vehicle are reversed on purpose Check the weights in the cargo bay They should be positioned and securely attached Make sure the receiver antenna and other wires are free and not pinched Check the duct retaining thumbscrews They should be tight Check that the RC receiver is securely fastened Make sure that the battery elimination circuits are securely fastened to the sides of the airframe Check to see that the Stargate and uNav are secure Place the batteries in the center of the airframe but do not plug them in Z WARNING DO NOT PLUG THE BATTERIES IN YET 57 Transmitter Set the controls on the transmitter The collective throttle stick should be down toward the bottom the transmitter and locked into this position The collective throttle trim control should be set at 50 Center zero out the other three trim controls Roll trim control MUST BE ZEROED out before the vehicle is booted up before EVERY flight VR 1 amp 2 should be set to zero centered Flight Mode swi
65. quency synthesizer module allows you to transmit on any of the fifty 72MHz channels with the twist of a dial The Spectra module is mounted in the back of the receiver KI SEM Tat DIIY 27 RECEIVER A Hitec RCD 3500 Supreme Receiver in included in your kit This is an 8 channel receiver operating at 72MHz and it has a range of 5 500 feet Each receiver is fitted with a single crystal BATTERY CHARGER Your OVIWUN kit comes complete with an AstroFlight 109D Lithium Polymer Li Poly charger discharger and an AstroFlight Model 120 power supply The manual for the charger is included in your kit The following is a brief summary of its features it is important that you read and thoroughly understand the manual before attempting to charge your Li Poly batteries Charges 1 to 9 Celb Diccharges 1 to 9 Cells 50 ma to Ampa Rens on 12 Votis 126 Peth made le ESN ASTRO 109 ASTRO 120 Before using your AstroFlight 109 please read the instructions carefully The Astro Model 109 Lithium Charger is specially designed to charge and discharge Lithium Polymer battery packs This charger can handle the batteries packaged with your OVIWUN vehicle The cells in the battery pack have been arranged in parallel to increase the battery pack capacity 28 It is very important to use a charger that was designed specifically to charge your Lithium Polymer Li Poly batteries The Model 109 Lithium charger use
66. rator check you out on the operation of the vehicle before you begin Quarterly we offer training classes on operating the vehicle Go to www trekaero com OVIWUN Training html to get information on classes 11 INITIAL TESTING AND CHECK OUT WARNING You should always check your vehicle in a safe environment You should have a clear area sufficient to operate the vehicle and get away from your vehicle should it become uncontrollable There should not be any obstacles loose materials or objects which may be blown away by the thrust from the fans or ingested by the fans You should not have any loose clothing or jewelry which may be ingested by the fans or flung into your face obscuring your vision You should remove any metal from your fingers rings and wrists watches Only once you have such an area are you prepared to begin testing and checking out your OVIWUN unit 1 10 11 Remove the batteries from the case and make sure they are fully charged They have been charged and tested prior to shipping however they should always be tested for a full charge before beginning any test or flight See battery charging section of this manual and the manual for the battery charger for details Remove the vehicle from the case and install the landing skids If you have not already done so see assembly instructions above Gently and smoothly remove the back cover from the vehicle Check the frequency of t
67. rice of the kit We reserve the right to change or modify this warranty without notice SECTION 2 ASSEMBLY AND INITIAL SET UP UNPACKING Power Supply Sang enor Charging Cord for Transmitter Lithium Polymer Batteries 2 OVIWUN comes packaged in two boxes The storage shipping box pictured above and a box of support materials The storage shipping box includes everything needed to fly right out of the box 1 Anassembled OVIWUN unit which includes a The basic airframe b Two brushless electric motors c Servos 2 pieces d Two motor controllers e Basic flight control software installed Two 14 8 4000 mAh Lithium Polymer battery packs AstroFlight Model 109 Lithium Charger Discharger Astro 120 Power Supply Landing rails Hitec Eclipse 7 Advanced Digital Radio Control System with the Hitec Spectra Module installed The box of support materials includes Ambicom Compact Flash Card ModelWL1100C CF CBNM 06 Cable Crossbow Stargate Support CD GlobeTek ITE Power Supply Model GT A81051 0505UW2 Stargate Daughter Card Logitech QuickCam Pro 4000 Crossbow MNAU100CA Support Packet MNAV100CA Supprt CD b GPS Antenna c Power Lead d RS32 Adapter Black white amp grey cable e RS32 Adapter Black green amp yellow cable 8 Owners Manual Packet Eclipse 7 Owner s Manual Model 109 Lithium Charger Discharger Owner s Manual Model 120 Power Supply Owner s Manual Hit
68. ry placement can affect the center of gravity of the vehicle They should be centered left to right side to side and front to back in the lower bay 12 WARNING Do not plug the batteries in Yet 12 Turn on the transmitter 13 Set the controls on the transmitter a The collective throttle stick should be down toward the bottom the transmitter and locked into this position b The collective throttle trim control should be set at 50 Center zero out the other three trim controls Roll trim control MUST BE ZEROED out before the vehicle is booted up before EVERY flight VR 1 amp 2 should be set to zero centered Flight Mode switch should be centered Rudder D R and Elevator D R switches should be in the down position Channel 7 and Aileron D R switches should be in the down position Flight Condition Switch should be forward towards the front of the transmitter Gear Switch should be in the forward position towards the front of the transmitter With the Gear Switch in the forward position the vehicle operates in the PD mode the back position the vehicle operates in the PID mode 14 Extend the transmitter antenna 15 Double check is the collective throttle stick in the down position Is it locked If not this is your last chance to do so If the collective throttle stick is not in the down position your motor controllers will go into the programming mode when you boot up and your unit may need to
69. s a proprietary 8 bit microprocessor to perform all of the necessary mathematical computations required to insure foolproof charging and discharging Lithium Polymer battery packs A two line digital display indicates the status of the charging sequence and shows you the charge current the number of cells in the battery pack the battery voltage the duration of the charge and the actual number of milliamp hours of charge put into the battery pack A built in voltage converter boosts the input from 12 volts to 40 volts so that battery packs containing one to nine cells can be charged This charger is designed to be powered from 12 to 15 volt regulated power source Note A fully charged 4 cell pack will have a voltage of 16 60 to 16 80 volts WARNING Never use an automobile battery charger as a power source it could damage your new Model 109 Lithium Charger Also included in your OVIWUN kit is an Astro Model 120 power supply The power supply is rated 13 8 Volts at 12 5 Amps and is used to operate the Astro Model 109 Lithium Charger It runs on 110 Volts Remember the battery charging and discharging guidelines provided in this manual are just an overview To ensure safely when handling your Li Poly batteries is imperative that you familiarize yourself with the specific charger and manual that came with your OVIWUN vehicle 29 SECTION 4 VEHICLE OPERATION MINIMUM EQUIPMENT T7 Torx wrench Allen wrenches sizes 7 64
70. s cuve dese T E RE TE 10 SOFTWARE SET UPB ovis wn vee E ES e EE E aS 11 INITIAL TRAINING RECOMMENDATIONS n na 11 INITIAL TESTINGAND CHECK OU Thie e AA ea a i eaa E EE EE E E 12 SHUTDOWN PROCEDURE pamaina ee aa aE E EAE A A E 14 SECTION 3 SYSTEMS DESCRIPTION ccsssssssssssssssscssssscssresssscssecsesesssscssrescsscsssesasesssacsssesesssssceseres 15 VEHICLE SPECIFICATIONS eaa a aa ia ie 15 VEHICLE CIMITATION S aee a e a aa e e a Ea 16 a e ae RE ae a a E Piee EE EEE Ea TATS 17 AEE AEE E EE EE 18 ara S EE rE Ea ARAE TAE EEEE DE eaaa EE a EE TS 18 SERVOS a nr E a A E E a EAE EEEE 19 MOTORS iat a a E aA AEA A E E eaa aa a E eaa TANE 20 SPEED CONTROLLERS a ea E TES 21 ELECTRICAL SYSTEM E E E e a a EE r EA E Ee 22 BAC LERY TET E ties 22 NAVIGATION amp GUIDANCE pie 23 CROSSBOW SUNA V Seve ERTER E 23 CROSSBOW S STARGATE A EERTE 24 PLIGHT CONTROL SY STEM Zicea cities
71. s make sure to test for possible interference with the onboard systems 48 APPENDIX A DETAILED PARTS LIST OVIWUN DUCT EXPLODED VIEW A 49 OVIWUN DUCT SUB ASSEMBLY OVIWUN Duct Sub Assembly 50 AIRFRAME GLASS VIEW B DESCRIPTION OF PARTS ON AIRFRAME GLASS VIEW Part No Onion Description Trek Part Number Quantity 1 GPS Antenna 03 9001 xxA 1 RF Receiver 03 9001 05 1 3A MNav 03 9001 48 1 3B Stargate 03 9001 49 1 4 Motor Controller 03 9001 02 2 5A 6V BEC 03 9001 59 1 5 5 03 9001 58 1 6 Battery Pack 03 9001 14 2 6 7 Battery Bus Bar 03 9001 60 1 8 Servo see detail below Below 2 9 Front Landing Strut Support 03 9000 11A 1 10 Aft Landing Strut Support 03 9000 11B 1 11 Landing Strut 03 9000 11C 2 12 Cargo pod 03 9001 61 1 13 pNav Serial Input Feed Inc 03 9002 48 1 51 SERVO EXPLODED VIEW DESCRIPTION OF PARTS ON SERVO EXPLODED VIEW 2 Per Vehicle Quantity gt WN 52 PARTS ON OVIWUN NOT PRESENTED IN EITHER A GLASS OR EXPLODED VIEW DESCRIPTION OF PARTS ON AIRFRAME NOT DETAILED 53 APPENDIX B LEARNING TO FLY OVIWUN A PRIMER STUDENT BEGINNING FLIGHT LESSONS CAUTION If you are a beginner you should seek assistance from an experienced OVIWUN pilot You should be aware that although the propellers are inside the ducts they are turning at a very high
72. s not a toy It is capable of causing serious injury and or damage if not assembled operated and or maintained properly While the vehicle is less dangerous than some RC helicopters or fixed wing airplanes it can still cause serious injury We strongly suggest that you find a knowledgeable OVIWUN operator or an experienced helicopter pilot to assist you VEHICLE OVERVIEW OVIWUN is a first generation radio controlled electrically powered dual ducted VTOL research aircraft There is a pair of ducts approximately nine inches in diameter mounted on the upper end of the airframe Each duct contains a fan consisting of three blades which produce thrust in the vertical direction The fans counter rotate eliminating the torque that is normally associated with a single rotor The ducts and fans tilt individually about a common axis for pitch and yaw control Roll control is achieved by modulating the speed of the individual motors within the ducts The vehicle is powered by two 450 watt electric motors This vehicle generates approximately twelve pounds of thrust at full power This gives this vehicle the unique characteristic of being able to lift more than twice its own weight The vehicle including installed batteries weighs less than six pounds yielding a maximum payload greater than six pounds While OVIWUN can do this when substantial control authority is needed it is not recommended to do so for extended periods of time A line of
73. sight seven channel radio operates the Beta version of the vehicle Future versions will contain autonomous operation including flight planning and changing operating parameters on the fly The vehicle is shaped similar to a truncated pyramid At the top are two ducted fans Each duct is attached to the airframe with a control arm giving them a lollipop look when detached from the machine The aircraft is about 26 wide 14 tall and about 16 deep The body of the airframe is constructed out of fiberglass The airframe is divided into two major components The upper part of the airframe contains the workings of vehicle while the lower detachable part is the payload bay The entire vehicle stands on two landing skids The all up weight of vehicle is less than six pounds This includes the standard batteries necessary to operate the vehicle The batteries include two 14 8 volt 4000 mAh Lithium Polymer battery packs There is a radio receiver on the vehicle in the upper part of the airframe The range of the machine is currently limited to the distance of the radio signal you are using to control it With the supplied radio that is approximately 5 500 feet The operating endurance is approximately 20 minutes with a one pound payload As you increase the payload the endurance will decrease Currently we recommend a maximum payload of three pounds This allows you sufficient excess power to easil
74. son altitude control is achieved By altering fan speed differentially a rolling motion created There is no pitch control per se for the airframe The aircraft hangs from the duct assembly always maintaining a nearly vertical position In hover the fans generate 55 of the lift The remaining 45 is created by the induced airflow over the ducts In forward flight the increased airflow over the ducts generates even more lift This is analogous to translational lift on conventional rotary wing aircraft The effect is that less power and lower fan speeds are required to maintain level flight at moderate forward flight speeds than are required to hover Conversely if you transition to forward flight without reducing power OVIWUN will climb SERVOS Your OVIWUN unit comes equipped with two HiTec HS 945MG Digital High Torque Servos At the heart of the HS 945MG unbreakable gear train is the MP Gear The MP Gear is made utilizing a revolutionary production technique that injects a high impact plastic around a metal pinion gear to form an unbreakable first gear By utilizing this gear Hitec has successfully reduced the amount of drive train noise that is common in metal gear servos while at the same time added considerable strength to the gear train Information supplied by HiTec RC USA Inc Trek Aerospace is not responsible for content 19 m Features oO Coreless Motor c Lon
75. specifically designed for Li Poly batteries their optimal charge rate is 1C fast charging on a NiCd NiMH or other charger will damage the cells permanently SAFETY PRECAUTIONS FOR LITHIUM POLYMER BATTERY PACKS 1 Lithium Polymer batteries should not be fast charged their optimal charge rate is 1C Do not charge at a mA higher than the capacity of the battery 2 Never charge your Lithium Polymer Battery pack at any rate unattended 3 Only charge Lithium Polymer Battery pack with a charger designed specifically for Lithium Polymer chemistry Your kit includes the AstroFlight 109 battery charger This is our recommended charger WARNING fast charging on a NiCd NiMH charger will damage the cells permanently 4 It is extremely important to double check the correct polarity when connecting cell packs to the charger or to your vehicle 5 Never place exposed tabs on conductive materials if a tab is torn off the battery is no longer useable 6 Li Poly cells can ignite because of unmatched cell capacity or voltage cell damage charger failure incorrect charger settings improper discharge or other factors Always check your batteries for damage before and after each flight 7 Always use the correct charging voltage Read and understand the manual for the AstroFlight 109 charger that was provided with your vehicle 8 To prevent permanent damage not over discharge your Lithium Polymer cells This can be avoided by ensuring proper
76. sssssessseserssssecssrescsscssscsasssssesssnenesssesscseseees 49 OVIWUN DUCT EXPLODED VIEW Arrat n ET R EE RN E A 49 OVIWUN DUCT SUBA SSEMBL Yesin N N TE n 50 AIRFRAME GEASS VIEW Birete ccs sess e nR EKE T N N ANT RE ES 51 SERVO EXPLODED VIEW nisen g E E EE E AA E RRAN EE ETAR 52 PARTS ON OVIWUN NOT PRESENTED IN EITHER A GLASS OR EXPLODED VIEW 53 APPENDIX B LEARNING TO FLY OVIWUN A PRIMER csccsssssssssscscssresssscsssesesscsssesenessenes 54 STUDENT BEGINNING FLIGHT LESSONS eee cesses 54 APPENDIX C OPERATIONS CHECKLISTS 57 PRE PLIGUT O EEEN A E E S POST FLIGH YD 60 STORAGE AOE evden deduceuresdeveescosteeevercctccsseesestetureveeveeds 60 APPENDIX D SERVICE AND MAINTENANCE CHECKLISTS 62 BAT TERY CHARGING E E E 62 DUCT REPLACEMENT 65 MOTOR REPLACEMENT 67 amp STARGATE REPLACEMENT EE T 69 CONTROL SERVO REPLACEMENT teiten e EEE EE A E A onan ey 71 LANDING SKID amp STRUT REPLACEMENT niunie n e a e n Ria 72 AIRFRAME REPLACEMENT TA EE E seta
77. t Radio Frequency Interference RFI interference So 31 CAUTION Do not run or tape the antenna alongside any carbon fiber components as this may cause unexpected radio interference 17 Double check is the collective throttle stick in the down position Is it locked If not this is your last chance to do so If the collective throttle stick is not in the down position your motor controllers will go into the programming mode when you boot up and your unit may need to be returned to the factory for reprogramming CAUTION Have someone restrain the vehicle while you complete the next four steps They should do so by holding the machine firmly on the ground by placing a hand on the machine between the ducts and pressing down Z WARNING The vehicle will be active with the next step Have the vehicle in a clear and open space If the switches are improperly set and procedures not followed the fans may start without any warning 18 Ensure that the batteries are properly charged and are free from defects or damage A fully charged 4 cell pack will have a voltage of 16 60 to 16 80 volts 19 After double checking the polarity the first battery should be connected to the bus bar in one smooth and definite operation Avoid multiple touches of the connectors Immediately after connecting the battery the motor controllers uNav and Stargate will go through the boot procedure The ducts will move and you will h
78. t and left of the bay Pull the forward so they are hanging out of the bay Holding the Stargate by the right and left edges gently and carefully slide the Stargate forward Be careful of the servos hitting the uNav When disconnecting the following items hold the Stargate by the edges Do Not put your thumb on the top of the NAV as you can break the board Disconnect the 5V BEC from the Stargate by holding the connector at the Stargate and gentle pulling it from the press fitting Disconnect the 6V BEC from the NAV by holding the connector at the uNAV connector bar it is attached to the number two position and gently pulling it from the press fitting Disconnect the RC Receiver from the uNAV It is attached to the number 5 position Disconnect the servo 2 from the uNAV It is attached to the number 10 position Disconnect the motor controller 2 from the NAV It is attached to the number 11 position Disconnect the motor controller 1 from the NAV It is attached to the number 12 position Disconnect the servo 1 from the uNAV It is attached to the number 14 position There are two screws 2 56 which attach the uNAV to the Stargate Each screw has a nut a spacer and washer Hold the nut while loosening the screws Once the nuts have been removed you are now ready to replace either unit 69 Replacing the Units
79. t with this electrolyte scrub the area with soap and water If the electrolyte splashes into your eyes flush with water and seek immediate medical attention 62 If your Lithtum Polymer batteries are involved in a crash drop or excessive heat a Remove the Lithium Polymer Battery pack from the vehicle b Carefully inspect the pack for shorts in the wiring or connections If in doubt replace the battery pack with a new one Inspect cells for punctures dents cracks tears and splits Examine cells for leakage or an electrolyte smell e If your batteries have been damaged dispose of damaged cells cells packs as follows a Discharge with the pack in a safe area use your battery charger to discharge the pack to the recommended cut off voltage Usually 3 0 volts per cell CAUTION pack may get hot b Allow to cool and then puncture each cell in the battery pack and immerse in salt water for several hours c Apply electricians tape over the terminals and place in a sealed plastic bag d They are then safe to dispose of in your regular trash Always handle your batteries with care They can deliver high currents if shorted Remove any rings or other metal before handling your batteries Shorting by a ring can result in the loss of a finger Always store cells packs in a secure location where they cannot be shorted dropped
80. tch should be centered Rudder D R and Elevator D R switches should be in the down position Channel 7 and Aileron D R switches should be in the down position Flight Condition Switch should be forward towards the front of the transmitter Gear Switch should be in the forward position towards the front of the transmitter Double check is the collective throttle stick in the down position Is it locked If not this is your last chance to do so If the collective throttle stick is not in the down position your motor controllers will go into the programming mode when you boot up and your unit may need to be returned to the Trek Aerospace factory for reprogramming Z CAUTION Have someone restrain the vehicle while you complete the next four steps They should do so by holding the machine firmly on the ground by placing a hand on the machine between the ducts and pressing down Z WARNING THE VEHICLE WILL BE ACTIVE WITH THE NEXT STEP Have the vehicle in a clear and open space If the switches are improperly set and procedures are not followed the fans may start without any warning Batteries Double check the polarity of the batteries and connect the first battery to the bus bar in one smooth and definite operation Avoid multiple touches of the connectors or touching the connectors on anything that can carry a charge Immediately after connecti
81. the damaged cells per the instructions below 17 Dispose of cells packs as follows a Discharge with the pack in a safe area use your battery charger to discharge the pack to the recommended cut off voltage Usually 3 0 volts per cell CAUTION pack may get hot b Allow to cool and then puncture each cell in the battery pack and immerse in salt water for several hours c Apply electricians tape over the terminals and place in a sealed bag d They are then safe to dispose of in your regular trash 18 Handle all cells packs with care as they can deliver high currents if shorted Shorting by a ring for example can result in the loss of your finger 19 Always store cells packs in a secure location where they cannot be shorted dropped overheated to 140 F 60 C or handled by children 20 Follow the manufacturer s recommendations for proper long term battery storage BATTERY CHARGER BASICS ASTROFLIGHT 109 There are two power cords on the AstroFlight 109 charger discharger The four foot long cord with the alligator clips is the input cord and should be connected to the Astro Model 120 power supply The short cord is the output cord and is fitted with an Astro Zero Loss Connector 526 Connect the output cord to the Lithium Polymer battery being charged or discharged The charger has a current adjust knob on the front panel Charging current can then be adjusted between fifty milliamps and eight amps Discharging current
82. the uNAV It is attached to the number 5 position The ground wire is to the outside Connect the 6V BEC to the uNAV by holding the connector at the uNAV connector bar it is attached to the number two position and gently pushing unit it seats The black ground wire is to the outside Connect the 5V BEC to the Stargate by holding the connector gently pushing unit it seats The black ground wire is to the inside This unit is not reverse polarity protected Make sure you have it right if you do not you will blow the board There is a jumper on the Stargate next to Connector 1 on the NAV It needs to be set to the inside position That is the exposed lead should be that closest to the rear of the uNAV Holding the Stargate by the right and left edges gently and carefully slide the Stargate into the bay Be careful of the servos hitting the uNav There are four thumbscrews which attached the Stargate to the airframe They are located in the top to the bottom bay Loosely attach the screws to the Stargate by turning them counter clockwise Once all four of the thumbscrews are in place you can tighten them down Do not forget the short spacer as it will make removing the unit later easier Replace the BECs using the Velcro to holding them in place on the right and left of the sides of the bay Ok you are back in business
83. tically begin During Discharge the digital display will indicate battery voltage duration of discharge in hours minutes and seconds and the milliamp hours delivered from the Lithium Polymer battery to the electronic load in the charger When Discharge is complete the discharging will automatically stop As long as the pack remains connected the display will be frozen with the values of final discharge voltage and the number of milliamp hours taken from the pack To go back to charging 39 remove the battery pack wait for the display to say waiting for battery and then connect the next battery Error Messages Over voltage error The Over Voltage Error message is displayed if a battery pack with more than 39 volts is connected to the charger The Over Voltage Error may be displayed if the battery is disconnected while being charged and the charger attempts to charge an open circuit This is very likely to occur if the charging current is higher than three amps The Over Voltage Error will be displayed during Mode 2 or Mode 3 if the battery voltage goes above 4 3 volts per cell based on the cell count detected in Mode 1 If you see the Over Voltage error message it means that charging has stopped and the charging sequence if frozen Please remove the lithium battery pack and disconnect the alligator clips from the 12 volt power source Then set the charge current to minimum and reconnect the lith
84. tory default settings All support documentation and software are located on the Trek Aerospace OVIWUN support CD If you did not receive a support CD with your unit s call or email Trek Aerospace and one will be provided Re loading the default settings will require an upload to the onboard IMU Instructions for loading lt Oviwun hex gt file are located at the following link http www xbow com Support Support_pdf_files MNAVI00CA_Users_Manual pdf Additionally Crossbow support CDs are shipped with all new units On your OVIWUN support CD locate the Oviwun hex file in the hex folder and follow the instructions laid out in the Crossbow manual Section 5 3 Connect to the uNAV using the Crossbow support tool Loader exe locate the Oviwun hex file and start the upload The unit will be reset to the Trek Aerospace default Do not confuse this Oviwun hex file with the Crossbow uNAV default hex file The OVIWUN will not function and may become unstable if this Crossbow hex file is loaded MODIFYING THE GAINS To modify the OVIWUN software you must first set up the AVR GCC Toolchain on your development system You may purchase a ready to system from Trek Aerospace or setup your own To set up a development system follow the instructions laid out in Section 5 0 of the uNAV user manual After you have installed the development tools on you target computer open programmers note pad Start programmers note pad pn exe and import the c
85. u find this is making operating the vehicle difficult we suggest that you land and let the air settle Please remember that the vehicle is meant to fly no matter how hard you try there will be some movement even when attempting to hover on station The vehicle will always require some form of input to stop the drift or the tendency to turn This is not a sign of something faulty with the vehicle but more the nature of the vehicle As you become more familiar with your vehicle you will find that your hand and eye co ordination will enable input to correct the movement of the vehicle as soon as it starts and this will start to show smooth flight Step 3 Once you become familiar with the basic hovering of OVIWUN you should start expanding your ability by yawing the vehicle slightly to the left or right This is accomplished by moving the left hand stick right and left Always remember that if you have yawed your vehicle and you find you are losing control yaw the vehicle back in the opposite direction so you have the rear of the vehicle pointing at you for easier reference Take off is a little easier than landing This is due to the ground effect turbulence from the ducted fans However spot landing at a modest rate of descent is not as difficult as it might seem 55 As you become more proficient with your OVIWUN find a larger hall so you can expand your ability to control the vehicle during maneuvers On dead calm days you can
86. vement They will be attempting to keep the machine level b Repeat the motion in yaw turning the vehicle GENTLY SLOWLY and SLIGHTLY to the right and left c Ifthe machine does not respond follow the SHUTDOWN PROCEDURE on the next page and start over 21 The vehicle is now ready to fly SHUTDOWN PROCEDURE WARNING Do not turn off the transmitter until told to do so Lock the collective throttle in the down position Remove the rear cover Pull out the bus bar Disconnect both batteries Check the power state by looking at the LEDs on the uNav and Stargate They should be off 6 Gently and slowly move the machine and determine that the ducts are not responding 7 Now turn off the transmitter 8 Remove the batteries from the lower bay and let them cool tae Z CAUTION The batteries may be warm or hot to the touch You are ready to repack your machine in its case 14 SECTION 3 SYSTEMS DESCRIPTION VEHICLE SPECIFICATIONS Propulsion Motor Two 450 w brushless motors Batteries Two 14 8 VDC 4000 mAH Li Poly Dimensions Height to top of fan hub 36 2 cm 14 26 inches Width over ducts 64 7 cm 25 46 inches Length of skids 41 1 cm 16 19 inches Weights Empty with batteries installed 2550 g 5 62 pounds Normal Payload 500 g 1 10 pounds Normal Flight Weight 3050 g 6 73 pounds Maximum Recommended Payload 1500 g 3 31 pounds PERFORMANCE SPECIFICATIONS Maximum Speed 73 kph 4
87. y operate and maneuver the vehicle OPERATING OVERVIEW OVIWUN has been designed to be easy to operate It has advanced computer algorithms located on an onboard computer The onboard computer is a powerful single board computer with enhanced communications and sensor signal processing capabilities There is also a calibrated digital sensor and servo control system designed specifically for use in Radio Control R C vehicles The onboard sensor package includes accelerometers angular rate sensors and magnetometers for use in inner loop control applications as well as static pressure altitude and dynamic pressure airspeed sensors for use in airborne robotics There is even a GPS sensor included so that you can develop your own path planning and navigation The vehicle works much like an R C mini helicopter but without the cyclic or collective SERVICING OVERVIEW Mechanically there is nothing to service on this vehicle The bearings are sealed The control linkages should last for thousands of hours The motors require no lubrication Running the vehicle should provide enough airflow to clean dust out of the engine area The airframe requires no scheduled servicing Repair work on the airframe can be accomplished with fiberglass and epoxy Your should physically check the vehicle for any frayed wiring or other signs of wear before each use and replace any part that appears damaged or worn MODIFICATION POTENTIAL OVIWUN is an experi

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