User Manual and Instructions Model RRC² - Rocket
Contents
1. output Otherwise the unit is operating in redundant apogee mode and it will then fire the channel 2 output immediately following the channel 1 output After the unit has fired both output channels it transitions into report mode Report mode After deployment of the recovery system the unit will report the peak altitude it measured during flight The LED will continue to flash at its fast rate of 5 times per second The piezo beeper will continuously annunciate the peak altitude by beeping out the individual digits of the measurement Depending on the peak altitude the unit will annunciate 3 4 or 5 digits For example let s say the rocket flew to a peak altitude of 1230 feet The unit would beep as follows Beep pause Beep Beep pause Beep Beep Beep pause Beeeeeeeeeeep long pause repeat Test Mode Operation and Diagnostics The unit can also be placed into a test mode to verify the basic integrity of the unit and also to ground test e matches igniters ejection charges or recovery system designs To place the unit into a test mode toggle either SW 1 or SW 2 during the power up and initialization period according to the test you d like to run Toggling SW 1 will set the unit into input test mode Toggling SW 2 will set the unit into output test mode The unit will continue to operate in the test mode selected until it is powered off IMPORTANT After selecting a test mode you must power off the unit prior to f2. Check continuity and resistance of the ejection charges e Mount and secure the electronics in the payload section or altimeter bay e Make final wiring connections to the electronics e Prepare and pack the recovery components parachutes wadding heat shields e Assemble the rocket and check all deployment coupling junctions ensuring a snug and adequate fit e Arm the electronics and verify switch positions and ejection charge continuity e Disarm the electronics prepare and load the rocket motor At the Pad e Place the rocket on the launch rod or rail e Arm the electronics and re verify switch settings and ejection charge continuity e Insert the igniter in your rocket motor and connect the launch system wiring e Verify continuity of the motor igniter if possible e Snap a few photos then RELISH IN THE CULMINATION OF ALL YOUR WORK AND PREPARATION Product Warranty Missile Works Corporation has exercised reasonable care in the design and manufacture of this product and warrants the original purchaser that the RRC Rocket Recovery Controller is free of defects and that will operate at a satisfactory level of performance for a period of one year from the original date of purchase If the system fails to operate as specified then return the unit or units within the warranty period for repair or replacement at our discretion The system must be returned by the original purchaser and be free of modification or any other physical damage which re
3. be used Another commercially available powder is called Pyrodex which should not be substituted for black powder The following formula represents a general rule of thumb for calculating the required amount of black powder for a given airframe Factors such as a tight fitting nose cone or coupler shear pins as well as a tight fitting parachute or streamer can affect the performance of an ejection charge It s always better to have a little extra black powder as not enough could possibly result in deployment failure Black Powder grams Compartment Diameter inches X Compartment Diameter inches X Compartment Length inches X 006 Unless you ve got a reloading scale the easiest method to measure black powder is to purchase a set of black powder measuring cups from your local firearms dealer It s a great idea to ground test your recovery system components Always ensure when testing that adequate precautions have been taken to accommodate ejecting nose cones couplers parachutes harnessing etc Launch Day Now that you have methodically designed and built your rocket and its recovery system it s time to fly There s usually lots of activity on a launch day with other fliers and other rocket flights It s best to prepare your rocket carefully and not to bypass any critical steps The following list is a guideline of the necessary steps you should take in the preparation of your RRC 2 At the prep table e Load test the battery e
4. of the rocket airframe however it can be placed at a convenient spot inside the airframe as well There are several options you can use for the power switch A small 3 pole slider switch A locking toggle switch A normally closed phono jack open circuit when a phono plug is inserted closed circuit when removed A pair of wires run through the airframe that are twisted and taped together then fed back into the airframe Figure 5 Standard Wiring diagram Apogee deployment charge Main deployment charge On Off switch For the most failsafe wiring scheme to minimize the possibility of premature firing of the ejection charges wire in a pair of normally closed phono jacks or disconnect switches in series with the leads of the deployment charges The phono jack or switch serves as a disconnect between the unit and the deployment charges Note Although the aforementioned failsafe wiring scheme provides the most secure means for prevention of premature firing of ejection charges it s the opinion of Missile Works Corporation that the use of any extra mechanical switches or connections increases the likelihood of failure due to poor or flight induced intermittent connections Mounting Considerations IMPORTANT Please note the orientation of the unit in the rocket airframe The RRC was designed to be placed in the airframe with the battery towards the nose cone This improves the CG CP relationship of the rocket vehicle and optimizes
5. successful recovery Onboard Battery Connections The RRC is designed to be operated with a standard 9 volt alkaline battery Always purchase and use premium alkaline batteries 9 volt Nicad batteries may also be used however the voltage of this battery type can range from 7 2 to 8 4 volts A higher voltage Nicad is more desirable as 7 2 volts is on the very edge of operational acceptance When your battery voltage is too low the continuity circuit will fail to operate and will not report beep the status of the ejection charges This is a good indication that it s time to change your battery IMPORTANT Always load test your battery prior to flight to ensure adequate power for reliable operation and ignition of the ejection charges To load test a battery you will require a DC multimeter capable of DC amp measurement with a 10 amp capability A 9 volt battery can easily source in excess of 5 amps Briefly connect the meter leads across the battery terminals to measure the DC current capacity If the measurement is close to or drops below 2 amps do not use the battery Some batteries have built in testers however it is still recommended that a meter be used for testing The battery clip hardware is designed to hold the battery tightly The best method is to first push the battery inside the clip without connecting the battery terminals see Figure 3 Once the battery is clipped into place push the battery forward into the circuit board
6. the battery clip design The payload section or electronics bay used for the RRC must be a sealed chamber with a static pressure equalization port The sealing of the chamber is necessary for several reasons e Isolation of the electronics from the ejection charge heat residue and over pressure e Isolation from the aerodynamic pressure and vacuum effects on the rocket airframe during flight e Provides uniform static pressure equalization to ambient flight conditions IMPORTANT Inadequate sealing of the payload section or electronics bay or exposure of the electronics to ejection charge heat residue or pressure will cause the RRC to malfunction Static Pressure Ports Equally as important as sealing the electronics bay or payload section is the proper location sizing quality and quantity of static pressure ports Always try to locate a static port on the airframe where it is not obstructed by any object that may cause turbulence upstream of the airflow over the port Also try to locate the static port as far away as possible from the nose cone or body transition sections The rule of thumb is a 1 diameter hole for every 100 cubic inches of bay volume Bay Volume Calculations The first step to sizing of the static port hole is to compute volume use the following formula Volume cubic inches Bay Radius inches x Bay Radius inches x Bay Length inches x 3 14 With the known volume of the electronics bay or payload section c
7. Beep Continuity on channel 1 2 Short Beeps Continuity on channel 2 3 Short Beeps Continuity on channel 1 amp 2 The unit also monitors the barometric sensor for a change of 300 feet in elevation to determine the launch of the rocket After this change the unit transitions into mach delay mode if selected or apogee detection mode Mach Delay mode When either SW 3 or SW 4 is in the ON position the unit will enter the mach delay mode The LED flashes again at its fast rate of 5 times per second There is no audible sound from the piezo beeper After the expiration of the mach delay if selected the unit transitions into apogee detect mode Apogee Detection Mode At this point the RRC has detected launch and is in flight The LED continues to flash at its fast rate of 5 times per second The piezo beeper will beep at a fast rate of 1 2 second During this mode the unit is sampling for apogee indicated by an increase in pressure When this pressure increase is detected the unit transitions into deployment mode Deployment mode Now that the unit has detected apogee it will fire the channel 1 J1 output The LED will continue to flash at its fast rate of 5 times per second There is no output from the piezo beeper If the unit was set to operate in standard dual deployment mode it will continue to sample barometric pressure until it is either 1000 800 500 or 300 feet above the initial launch elevation before firing the channel 2 J2
8. F SW 4 ON or 12 seconds SW 3 ON SW 4 ON of total delay It is recommended to use the mach delay at velocities of 0 8 mach or above Modes of Operation The RRC has several distinct modes throughout the course of its normal operation These modes of operation are easily identified by the piezo beeper and the status LED Power up switch position annunciation After initially powering on the RRC unit it will annunciate beep the positions of all 5 switches in numerical order 1 through 5 with a series of 0 s and 1 s A zero is a long beep a 1 is a short beep A switch in the OFF position will beep as a 0 and a switch in the ON position will beep as a 1 The LED flashes at a fast rate of 5 times per second This annunciation allows you to double check the altimeter switch settings once inside the rocket Baro initialization mode After the switch position annunciation the unit goes through a 15 second initialization and start up delay The LED flashes at a fast rate of 5 times per second There is no audible sound from the piezo beeper This start up delay allows stabilization of the electronics and establishes an initial barometric history Pre launch mode After the 15 second power up and initialization delay the unit goes into the pre launch mode The LED will flash at a slow 2 second rate and the piezo beeper will indicate the continuity of the ejection charges as follows Long Beep No continuity on either channel 1 Short
9. Owens Cross Roads AL 35763 Tel 916 391 2674 Tel 205 725 4226 Fax 916 391 2783 Fax 205 725 4811 Model Resistance Test Current Firing Current Wire Color Daveyfire 28B 1 6 0 3 ohms 20 ma 0 020 amp max 370 ma 0 37 amps min Daveyfire 28BR 1 6 0 3 ohms 20 ma 0 020 amp max 370 ma 0 37 amps min Daveyfire 28F 1 6 0 3 ohms 20 ma 0 020 amp max 1 00 amp min 2 ohms nominal 25 ma 0 025 amp max 500 ma 0 5 amp min Red Blue Ejection charges The ejection charge consists of a small quantity of black powder which when ignited produces enough gas pressure to expel the recovery system from the body of the rocket You can either make your own ejection charges or purchase commercially available ejection charge systems Robby s Rockets provides two ejection charge systems one single use the other a reloadable system Refer to Table 4 for more information Table 4 Commercial Ejection Charge suppliers Robby s Rockets Disposable Ejection Charges L E S Kits Loadable Ejection System P O Box 171 10 prewired AG 1 bulbs in cardboard Reusable aluminum charge holder 10 Elkhart IN 46515 tubes 1 gram measuring cup end caps prewired AG 1 bulbs 1 gram measuring 219 679 4143 and mandrel cup end caps and mandrel There are several methods for constructing your own ejection charges First you ll need to acquire some black powder locally It is recommended that you use FFFF 4F grade however FFF 3F powder can
10. User Manual and Instructions Model RRC Rocket Recovery Controller Revision C 1 System Overview The RRC Rocket Recovery Controller provides two stage barometrically controlled deployment of rocket recovery systems and equipment Two stage or dual deployment is preferable to single parachute or streamer recovery systems for high power rocketry Recovery of large heavy rockets with a small parachute or streamer alone does not supply enough drag to safely recover the rocket without damage An adequately sized parachute deployed at a high altitude may cause the rocket to drift out of the launch area making recovery difficult if not impossible Two stage or dual deployment recovery systems either separate the rocket airframe into two sections or eject a small drogue parachute or streamer at apogee allowing the rocket to descend at a rapid yet controlled rate When the rocket descends to a predetermined altitude above its initial launch elevation it then deploys the main parachute allowing the rocket to make a safe landing Specifications Operational range 0 25 000 ft MSL Test Current 80 ua Arming mode barometric Firing Current 1 25 amps 1 sec Minimum altitude for arming 300 ft AGL Dimensions 1 30 W x 5 9 L Battery onboard 9V Nominal Battery load 15ma Weight 3 4 oz w battery Main deployment ranges Hi 1000 500 ft AGL Lo 800 300 ft AGL W Handling Precautions These units are sensitive to damage from ESD electro stati
11. alculate the required nominal diameter for a single static port with the appropriate formula If volume lt 100 cubic inches Single Port Diameter inches Volume 400 If volume gt 100 cubic inches Single Port Diameter inches 2 x SQRT Volume 100 x 0 04908 3 14 If using a multi static port configuration calculate the diameter for each static port Multi Vent Diameter inches SQRT Single Vent Diameter of holes 3 14 The static port requires smooth clean edges around the opening Although a single static port is adequate multiple ports null out undesirable pressure effects caused by strong wind gusts or unstable flight profiles When using multiple static ports always use a minimum of three Always space them equally around the rocket airframe and keep them all in line horizontally IMPORTANT Improper sizing of the static port s could induce adverse operation of the unit Undersized ports will cause a pressure equilibrium lag and subsequent late event operation Oversized ports tend to increase the risk of premature deployment due to pressure anomalies during boost caused by atmospheric conditions airframe turbulence or velocity induced pressure spikes E matches and Ejection Charges The topic of e matches and ejection charges is often overlooked and not given a proper evaluation The ejection charge is as critical a component as the electronics Improper selection or application of e matches can result i
12. c discharge and should always be handled in a properly grounded environment ESD damage is not covered under your warranty W Never directly handle the unit when it is armed and connected to live pyrotechnic charges as this may cause the premature detonation of the charges W Always allow the unit and the battery system to adjust to ambient temperature conditions prior to connecting arming and flying Avoid exposure of an armed unit to high intensity light including direct sunlight heat cold wind or other extreme environmental conditions Always prepare your rocket and recovery system components with the unit powered off Never cycle the power switch off then immediately back on Always allow at least 10 seconds prior to restoring power Operational Overview Figure 1 depicts the general component layout of the RRC Rocket Recovery Controller The unit is designed for several different modes of operation Selection of these modes is made by the switches located on the circuit board Figure 1 General component layout of the RRC Battery Microcontroller Pressure sensor LED FA lt Ji Output 1 is Q J2 Output 2 J3 Power switch Piezo Beeper Switch Bank The switches are labeled 1 through 5 accordingly switch 1 being the leftmost switch as illustrated in figure 1 The ON OFF position is also labeled with the ON position being UP the OFF position being DOWN The following table describes the switch func
13. charges in the output test mode Another useful accessory for testing the outputs are 12 volt DC panel lamps The lamps will allow you to observe the proper operation of the outputs without the use of pyrotechnic devices An LED with a current limiting resistor can be used in place of a lamp however you have to observe the diode polarity when connecting to the output terminals refer to Figure 1 for orientation of terminal polarity A 470 ohm resistor is suggested when using an LED Connect the LED for output testing as depicted in Figure 2 Figure 2 Output Test connections with LED on i NA J2 Barometric Limits Alarm The unit also features a barometric limit alarm This alarm mode is easily identified by the continuous actuation of the piezo beeper While the unit is in the pre launch mode it tests the barometric sensor reading for basic integrity If the reading is below 0 MSL or above 14000 MSL the alarm will sound This extreme reading indicates a failed sensor unless of course your attempting to launch from those base elevations in which case you cannot do so IMPORTANT Do not fly the unit if it activates the baro sensor alarm Wiring Mounting and Construction Considerations There are several factors to consider when it comes to the construction mounting wiring and arrangement of the RRC in your rocket airframe Careful planning during the construction and preparation of your rocket will improve your chances for a
14. light or additional testing Input Test mode After toggling SW 1 the unit will enter the input test mode This mode verifies the integrity of all the inputs to the microprocessor Whenever an input is in the ON position the unit will beep out a digit to indicate operational integrity of the input see Table 2 The test mode scans and reports the inputs starting with the lowest value first SW 1 Lower value switch positions and inputs take priority over higher position switches and inputs Table 2 Input Test mode beep indications 1 Beep SW 1 in the ON position 5 Beeps SW 5 in the ON position 2 Beeps SW 2 in the ON position 6 Beeps J1 continuity 3 Beeps SW 3 in the ON position 7 Beeps J2 continuity 4 Beeps SW 4 in the ON position Output Test Mode After toggling SW 2 the unit will enter the output test mode This mode can be used to test the integrity of both outputs J1 and J2 and to also ground test your pyrotechnic e match igniter flashbulb ejection charge or ground test deployment of your entire recovery system The test mode begins by beeping the piezo beeper at a fast rate of 5 beeps per second After 10 seconds of countdown the unit will fire the J1 output This is followed immediately by firing the J2 output this functions identical to the deployment firing sequence used in the redundant apogee mode IMPORTANT Always exercise caution when using live pyrotechnic
15. n failure of the recovery system and total loss of the rocket The following text will make some very specific recommendations which you should seriously consider when selecting constructing and ultimately flying with electronic deployment systems IMPORTANT Always ground test the type of e match you ll be using under actual flight conditions prior to committing to flight Improper selection of a pyro initiator device will result in a malfunction Always use an initiator that is suited for the test and firing conditions of the RRC unit e g do not use a match with very low or high current requirements Always check your e match igniter or flash bulb devices for continuity and proper resistance prior to using them under testing or actual flight conditions Selecting an adequate E match The RRC has been tested and flown with several commercially available e matches It has also been successfully tested and flown with AG 1 flashbulbs and custom made 003 nichrome bridgewire ejection charges This however is a just a small sampling compared to what is commercially available When selecting an alternative e match supplier refer to the Specifications section for the typical test current and firing current of the RRC Refer to Table 3 for adequate commercial e match suppliers for the RRC Table 3 Recommended E match suppliers Daveyfire Inc OXRAL Inc Luna Tech 7311 Greenhaven Dr Suite 100 PO Box 160 Sacramento CA 95831 3572
16. nders the system inoperable Upon repair of replacement of the unit Missile Works Corporation will return the unit postage paid to the original purchaser Product Disclaimer and Limit of Liability Because the use and application of this equipment are beyond our control the purchaser or user agrees to hold harmless Missile Works Corporation and their agents from any and all claims demands actions debts liabilities judgements costs and attorney fees arising out of claimed on account of or in any manner predicated upon loss or damage to property of or injuries to or the death of any and all persons arising out of the use this equipment Due to the nature of electronic devices the application and environments for those devices the possibility of failure can never be totally ruled out It is the responsibility of the purchaser or user of this equipment to properly test and simulate the actual conditions under which the device is intended to be used to ensure the highest degree of reliability and success Rules to live and fly by 1 Before you use the RRC Rocket Recovery Controller make sure you have read and understand all the instructions operations and warnings contained herein 2 Do not alter the system in any way as this voids the warranty and could render the system inoperable or unreliable 3 Always fly within the guidelines established by either the National Association of Rocketry or the Tripoli Rocketry Association whenever yo
17. terminals Next bolt on the battery end clip hardware included with your RRC 4 screw 2 4 nuts washer amp lock washer as shown in Figure 4 Secure the end clip firmly against the battery Figure 3 9 volt battery insertion side view Figure 4 Battery end clip placement side view goer aeneh large hole on top Push forward gt Fe TE 4 nuts E l w oe Sah Washer lt 4screw External Battery Connections Though the unit is intended to operate with an onboard 9 volt battery the user may elect to power the RRC with an external battery source The voltage requirement for this battery source is 7 5 to 9 volts DO NOT EXCEED 9 VOLTS A standard 9 volt battery clip with wire leads easily mates to the onboard 9 volt battery clip note when connected in this manner reverse the wire leads to maintain the correct polarity The user must also adequately size the current capacity of the battery system Nominal load during operation is about 15 ma and during output firing the unit requires upwards of 2 amps IMPORTANT Inadequate sizing of an external battery system will damage or cause the unit to malfunction Always pre test your external battery system design prior to launch Wiring Connections Figure 5 depicts the standard wiring connections J1 connects to the apogee deployment charge J2 connects to the main deployment charge J3 connects to an external user supplied power switch This switch is best located on the exterior
18. tions and the corresponding modes of operation Table 1 Switch functions and positions Switch 2 Switch 3 Switch 4 Switch 5 Func Main deployment Dual Deploy selection High or Low range altitude selection or Redundant Apogee selection selection Main deployment Stage 2 J2 Main Redundant apogee 4 seconds of 8 seconds of Lo range Stage 2 On deploys at 1000 ft deployment operation delay time is delay time is J2 deployment Pos SW 5 OFF or Stage 2 Main fires at added to the added to the altitudes are 800 ft AGL SW 5 apogee and overrides mach delay timer mach delay timer selected 800 or 300 ON SW 1 amp SW 5 setting total total ft based on SW 1 Stage 2 J2 Main Standard two stage 0 seconds of 0 seconds of Hi range Stage 2 Off deploys at 500 ft deployment operation delay is added to delay is addedto J2 deployment Pos SW 5 OFF or Stage 2 Main altitude the mach delay the mach delay altitudes are 300 ft AGL SW 5 selected by SW 1 amp timer total timer total selected 1000 or ON SW 5 settings 500 ft based on SW 1 IMPORTANT The Mach Delay and High Low range settings SW 3 4 5 MUST be made prior to powering up the unit They are read at power up ONLY Set ALL switch positions prior to turning the unit on Standard two stage deployment Two stage recovery of high power rockets is preferable as previously described in the Overview section of this document Operational progression of standard t
19. u participate in hobby rocketry activities Missile Works Corporation PO Box 1725 Lyons CO 80540 Tel 303 823 9222 On the World Wide Web www missileworks com Copyright 2000 2005 by Missile Works Corporation All rights reserved
20. wo stage deployment is as follows Initial launch boost and coast phases of flight Apogee of flight detected airframe separation or drogue chute streamer deployed Rapid controlled descent phase to pre programmed second stage deployment level Main parachute deployment and touchdown Single Stage Redundant Apogee Deployment Single stage deployment has its own set of advantages when the launch site size or weather conditions permit main parachute deployment at apogee They are much simpler in design and are simpler to operate and prepare Redundant apogee mode fires both charges at apogee 1 sec apart Single stage deployment operation is as follows e Initial launch boost and coast phases of flight e Apogee of flight detected main parachute streamer deployed e Slow descent and touchdown Mach Delay timer For high performance rocket flights approaching or exceeding the speed of sound mach the unit can be configured to employ a time delay just after lift off is detected This time delay prevents the possibility of premature apogee detection caused by the high low pressure effects present along the rocket airframe during transition into and out of mach During the time delay all barometric samples from the sensor are ignored so these pressure effects cannot falsely trigger the apogee charge After the expiration of time delay normal barometric sampling resumes The unit can be programmed for 4 seconds SW 3 ON SW 4 OFF 8 seconds SW 3 OF
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