Merlin 160G Instruction Manual - jets
Contents
1. Nominal thrust M90K gt SON Guaranteed 140N Guaranteed 160N 15C and sea level M100K gt 100N Max RPM 152 000 rpm 130 000 rpm 118 000 rpm Idle RPM 42 000 rpm 35 000 rpm 32 000 rpm Idle thrust AN 0 8lbf 6N 1 1lbf 7n 1 3lbf EGT max rpm 550 650 C 600 700 C 550 700 C Fuel consumption 0 33 l min at 90N 0 5 l min at 140N 0 58 l min at 160N Fuel oil Kerosene 4 oil 3 5 is OK 100 Synthetic 2T motorcycle oil or turbine oil TCW3 NOT AUTHORIZED Engine Description The engine is a turbojet of a single shaft design specifically designed to power RC aircraft The engine starts automatically thanks to an installed electric starter situated in the front The starting sequence is controlled by an electronic unit that initiates the starting sequence and controls the parameters of the engine within the design limits The engine uses a system of direct liquid preheating ignited by a long life ceramic glow plug situated inside the engine After the initial preheat the liquid fuel is gradually introduced The fuel should contain a small percentage 4 of oil and uses part of this fuel to lubricate its two ceramic high speed bearings The fuel for the engine is provided from a fuel tank through a small electrical pump The engine speed between idle and maximum is controlled by varying the speed of the fuel pump through an electronic controller called an ECU electronic cont2. UserOff The engine has been shut down because it has received the shut down command from the transmitter FailSafe The engine has been shut down because of loss of the control signal from the transmitter After 0 5s of detecting a loss or invalid RC signal the ecu sets engine power to idle and if after another 1 5seconds a valid signal is still not received the engine is shut down LowRPM The engine has been shut down because the RPM has dropped below a minimum Cause could be lack of fuel air bubbles problem with the batteries or defective RPM sensor FlameOut The engine has been shutdown because the temperature has dropped below the minimum of 100 C Usually is a thermocouple failure RCPwFail Lack of power from the radio receiver Other useful information and installation tips Fuel System Always use appropriate containers to store fuel It is advisable to install an anti bubble system to the fuel supply circuit The simplest one is a felt filter clunk installed into the fuel tank This helps maintain consistent fuel flow and greatly reduces the possibility of air getting into the suction side of the pump circuit which could cause stoppages To prevent the felt element sliding out of position a washer is fitted between it and the feed tube as seen A BVM UAT is another contemporary method of reducing the possibility of air bubbles in the engine fuel line This is a very important aspect of the operation of an
3. Merlin 90 100 140 160 Instruction Manual Version 3 1 2011 powered by Merlin 140 e _ JES HITS Torrent d en Puig 31 08358 Arenys de Munt Barcelona Spain Tel Fax 34 93 7950113 www jets munt com E mail info jets munt com Copyright 2011 Jets Munt SL All Rights Reserved Welcome Congratulations on the purchase of your new Jets Munt Merlin gas turbine engine Jets Munt are dedicated to the design and production of engines to the highest standards of quality and reliability to bring you the customer the very latest next generation engine designs The Merlin is the result of an intensive effort of design and tests by the Jets Munt staff During the development period we made extensive use of the latest Computational Flow Dynamics programs allowing us to optimise the engine performance characteristics PLEASE READ The Jets Munt SL responsibility is limited exclusively to the repair of the engine and accessories which are outlined in the conditions of warranty Before unpacking the engine please read the manual and agree to the conditions of warranty Customer satisfaction is important to Jets Munt SL Technical support is available trough your local dealer and trough email Jets Munt S L Torrent d en Puig 31 08358 Arenys de Munt Barcelona Spain Web site www jets munt com E mail info jets munt com Fax 34 93 7950113 Legal and Disclaimer The engine design and the contents of this manual are copyrigh
4. radio manual for this before you start DO NOT use the digital trim in any case Aligning transmitter with ecu As the display does not photograph well we have reproduced the display readings as a green box Turn on the transmitter and receiver The opening screen should show as below If the temp probe is not connected it will show as O C T ambient temp Note there are four buttons on the display two on the left and two on the right hand side The left buttons move to the different screens and the right buttons are used to change the values stored Press the second left button and scroll through the menus until you find the one showing Press the button and the ecu will show the Radio parameters menus Press the right hand button to confirm that you really want to programm the radio The screen will change to On your transmitter raise first the trim to full and next the throttle stick to full in this order Ensure stick is firmly against the stop Now holding the stick against the stop press the right button to store the signal from your TX into the ECU The screen will now change to struction manual V3 0 Pag 10 Move the trim or switch the engine cut switch to on and throttle stick back to zero and again press the right hand button The display will now change to Leaving the throttle stick in the minimum position raise the throttle trim to the full up position or swi
5. NSIDE THE ENGINE If there is flame then set full throttle to engage the starter and blow out the flame USE SHORT BURSTS OF STARTER Using the starter for long time can destroy the starter motor In the case that the start up procedure has been aborted due at starter failure then it will be necessary to apply the CO2 fire extinguisher A white smoke from the engine is a good indication here mean that there is no fire inside First engine runs e Confirm your test stand is securely fixed to a bench or heavy table Keep your ear defenders within easy reach and a CO2 fire extinguisher handy VERY IMPORTANT ON KEROSTART ENGINES e Fill the gas and fuel tanks Do not forget to filter the fuel and to mix the oil e Confirm all batteries are freshly charged and connected up e Check there is a temperature reading on the data terminal e Ensure the running area is clear of onlookers especially the prohibited zone of a 10 metre radius 180 arc from engine centre around the rear e Verify that the fuel tubes are full of fuel and purged of all air if not carry out the fuel prime sequence as described here Priming the fuel system Both fuel lines need purging of all air after initial installation Take extra care when priming them ensure fuel is primed only up 5cm before to reach the engine too much fuel inside engine will cause excessive flaming during start sequence Priming is achieved by a special menu on the ecu Set the trim to low a
6. at the factory and the settings should be left as default The ECU plugs into your receiver throttle channel and is powered from the identified receiver rechargeable battery The ECU is pre programmed and only requires simply setting to your radio All ecu connections are color coded and easily ECU Data Terminal The data terminal plugs into the ECU via the lead supplied The display should be used only for starting and test running This socket also doubles as digital connection to a computer Do not fly the plane with the display connected as there is a potential for interference The function of the buttons is described later in the ECU setup Engine installation Electrical connections RPM Sensor The RPM sensor used by the ECU to read the engine RPM is mounted in the front of the engine this is underneath the black cover EF 90 140 160 Instructio Temperature Probe thermocouple The engine mounting provides an attachment for the temperature probe using the two nuts provided The temperature probe has been carefully shaped and installed at the factory to align with the small hole in the exhaust cone When connecting the temperature probe plug be sure to get the plug in the correct orientation one wire has a white sleeve and this should be positioned as indicated on the ECU Because it receives the magnetic impulses of the rotor it is important to assure that other electrical devices that can gen
7. brication system and subsequent bearing damage 3 Ensure the fuel is free from moisture water is heavier than fuel and will settle at the bottom of the container 4 Use good quality aircraft turbine oils e g Aeroshell 500 Exxon 2380 Mobil JetOil IT Mobil DTE Light turbine oil or 2T 100 synthetic oil with a specification JASO FC or better DO NOT USE TCW 3 oil 5 The fuel must be mixed with oil in the ratio of 4 oil to 96 fuel ratio 1 24 Too little oil will shorten the bearings life You can use higher content of oil 5 6 without any problem for the engine to share the same fuel with other engines Please remember to always handle fuel and oils with care Avoid all direct contact with skin in case of contact wash all affected areas with soap and warm water immediately Feed Pipes All the pipes must be Polyurethane or nylon as provided by Jets Munt or Tygon like the ones used by gasoline engines Do not use Tygon on the pressure side of the fuel pump Silicone tubing must not be used anywhere in the installation as it is dissolved by fuel and oil If in doubt take a small piece of tube and submerge it in kerosene for a few days and verify that its characteristics have not changed Maintenance 1 Always keep the engine and its accessories clean and dry 2 Regularly check wires for chafing or insulation breakdown etc 3 Regularly check fuel pipelines for chafing and or leaks at joints 4 Check the temperature probe is correct
8. d exhaust duct is required it should be of sufficient diameter and strength for optimum engine performance 9 Extreme care should be exercised to ensure that no foreign object loose parts of the model or debris are allowed to enter the compartment where the engine is installed We recommend testing the engine ona test stand prior airframe installation You should have a clear idea of how to arrange the components needed to run the engine inside the model The main issue is the fuel tank you will need to arrange the CofG in the centre of the tank and adjust the receiver and ECU batteries to achieve the correct location Do not be tempted to move the fuel pump into the area between the tank and the engine as this can cause interference with the rpm pickup and presents a potential hazard in event of fuel leaking from the pump In the event of the temperature probe wire being too short it is correct to extend this with a good quality servo extension lead use a gold plated connector version With this arrangement a error of around 10 C is sometimes seen on the temperature display but this is of no consequence in normal starting and running Electronic Control Unit ECU gP Merlin 90 140 160 Instruction manual V3 0 Pag 6 The Xicoy ECU supplied with the engine is custom designed for the Merlin engine and must not be changed for any other as this may result in improper control of the engine Your engine has been set up and run with this ECU
9. e thrust throttle curve Linear Expo Intermediate Check the capacity of battery used Test the starter Glow Plug valves and Pump Check the failsafe counter time and pulses of wrong RC signal Check and set the maximum airspeed if pitot tube and sensor installed Reduce the maximum power Increase the Idle Rpm Adjust the glow plug voltage The engine come from factory with this voltage adjusted for reliable starts and long life of the glow plug element Increasing the voltage beyond the necessary will cause the failure or shortening of the life of the element Do not change the voltage please contact to Jets Munt first Adjust the pump power at startup The fuel flow during ignition phase must be finely tuned for each engine pump combination and this is done at factory during test In the case that after some run time the pump become loose and the starts become too aggressive reduce the value by 2 units at time until normal starts are reached again Please refer to the FADEC manual http www espiell com FAD10 pdf for further information gP Merlin 90 140 160 Instruction manual V3 0 Pag 18 Engine Kill Switch It is good practice and in some countries mandatory to have an alternative means of shutting off the engine in emergencies independent of the ecu A simple method to achieve this is by putting a switch in the battery line to the ECU operated by a mini servo mounted to a ply plate The plate is drilled fo
10. erate magnetic fields e g servo battery cables pump etc mount at least 100mm away from the engine Both the RPM pickup and thermocouple may need extending to reach the ECU A standard good quality servo extension can be used there those for JR radios have the same color code and this helps avoid any errors when plugging in Power cord The power for the starter and Glow plug is supplied trough a 3 wire twisted lead with MPX connectors Supplied length is of 50cm if it is necessary to extend it use 1mm cooper section lead Engine installation Fuel system Install the fuel system components as seen in the picture EF 90 140 160 Instruction manual V3 0 Pag 8 Start Gas Valve The starting fuel valve is of gold color and must be connected to the Gas valve ecu socket in any orientation polarity will always be correct Respect the direction of flow as marked in the valve body Note that in the output the nipple is for 3mm tube Fuel valve The fuel valve can be connected to the respective ecu socket in any orientation polarity will always be correct an Fuel filter YE The fuel filter must be installed close to the input port on the pump to prevent any particle to enter in the pump and to damage it Use a suitable length of the 4mm 6mm M160 clear tubing supplied and keep the tubing on the suction side as short as possible Direction of flow inside the filter is not important but should be always t
11. haust temperature is of around 80 C the data terminal reading will change to SWITCHOVER during this phase the fuel will be routed to main injectors and the speed of the rotor will be progressively increased to 10 000 RPM Once this phase is finished the reading will be FUEL RAMP In this phase the engine receives fuel only trough its normal fuel input and internal glow plug will be disconnected The fuel flow and starter power will be increased automatically to increase the RPM up to idle RPM Before arriving to idle the Ecu will automatically disconnect power to the starter When the rotor speed reaches idle the screen will change to running and the engine speed is stabilized The engine is running Control of engine power rpm is now handed back to the transmitter and controlled by the position of the throttle stick Increase decrease the throttle slowly verifying that the engine accelerates decelerates Take special care around the engine intake keep your hands at a safe distance along with any other objects as they can be easily ingested Engine shut down procedure To shut down the engine lower the trim and the stick Is recommendable that before shutting down the engine please restrain the model then raise the throttle stick to approximately 25 allowing temperatures to stabilize for around 5 seconds before carrying out the shutdown procedure WHAT TO DO IN THE CASE OF AN EMERGENCY During the start sequence the Ecu will be
12. he same after first use Do not run the engine without the fuel filter Finally connect the fuel pump the fuel valve and the battery to the ecu as shown It is strongly recommended that after a new installation or modification on the fuel system to disconnect the fuel hose from the engine routing it to a appropriate container and run the pump few seconds using the pump test function on the ecu so that some fuel clean all the possible dirt particles that could have entered in the system during installation ECU Engine Control Unit Set Up The ECU supplied is a special software version of the FADEC Autostart made by Xicoy Electronica SL It is a reliable unit and is supplied programmed for the Merlin The engine has already been set up and tested using the same ECU and pump supplied so there is very little to adjust in order to get the engine running Confirm you have connected the ECU input to the throttle channel of your receiver the ecu battery is fully charged and connected and the Data Terminal is plugged into the ECU Remove all rates mixes and g Merlin 90 140 160 Instruction manual V3 0 Pag 9 throttle travel settings in the transmitter The setup assumes the use of a transmitter with manual trims If you use a TX with digital trims is essential to use the switch in the TX programmed for the function Throttle cut or engine cut which normally has the effect of producing the trim down function Check your
13. in charge of everything controlling temperature and RPM The only thing the user can do is to abort the sequence by lowering the trim in the case that something abnormal excessive flames in the exhaust etc Merlin 90 140 160 Instruction manual V3 0 Pag 14 If a problem is detected first Move the trim to the low position to abort the sequence If there is a fire in the engine and the problem is because the starter has failed or the engine is seized not turning IMMEDIATELY APPLY THE FIRE EXTINGUISHER through the intake side of the engine never trough the exhaust If there is a fire but the rotor remains free to spin and the starter is OK raise the trim and stick to the full power position this will connect the starter manually to ventilate the engine and extinguish the fire The throttle channel acts as a starter switch USE SHORT BURSTS OF STARTER Using the starter for long time can destroy the starter motor List of ECU message codes Here is a list of possible messages shown on the data terminal screen and their meaning TrimLow Indicates that the signal received from the transmitter corresponds to the lowered trim that is to say engine OFF Ready Indicates that the engine is ready for starting and that the transmitter signal corresponds to IDLE green LED lit StickLol This indicates that the throttle stick is in a position above IDLE the engine will not start with the stick in this position Glow Test Verificati
14. ly positioned 5 Check the engine and mounting for loose fittings and secure if required 6 Ensure the fuel system is kept free from dust and dirt inclusion and that fuel is carefully filtered gP Merlin 90 140 160 Instruction manual V3 0 Pag 17 Battery charging and care The engine come with a LiPo 2 cell batteries You can use any type and capacity of battery but only of 7 2 7 4V nominal voltage minimum recommended capacity is 2000mAh 20C type Never use a 3s 11 1V battery Special care should be taken with LiPo technology and they should be charged with a Lipo charger using a regular NiCd charger could cause the battery exploding or taking fire Always follow the charger manufacturer recommendations The ecu will not start the engine if the batteries show low voltage but once the engine is running the ecu will keep it running until the batteries are completely empty and so this can cause the battery to discharge below its safe voltage Running Time Counter Using the second left hand button scroll through the menu s to the INFO menu This screen contains a timer which shows The total running time of the engine in minutes Tot The time in seconds of the last engine run Last The total number of starts cycles CY Use this screen to keep track of your total running time and starts Extra ECU functions The ecu provides several menus that allow doing some tests and personalizing some settings like Adjust th
15. nd go to Info menus and next to Pump test Click on on off to start stop the pump manually Please observe fuel line to engine very carefully and push the off button to shutoff as soon as fuel reaches engine Repeat the same operation on the burner line by the appropriate menu IMPORTANT The prime procedure should be done only to fill the fuel tubes and filters in the case of a first installation or in case of disassembling of the tubes Do not run the prime function so that the engine becomes flooded by fuel as this will cause an uncontrolled fire at next startup gP Merlin 90 140 160 Instruction manual V3 0 Pag 13 Starting the engine Set the throttle stick down and the trim up Idle Confirm that the green LED in the ecu is illuminated and the screen shows Ready Ready to start Move the stick to 50 and then back to idle again The Ecu will begin the startup sequence as described below First the internal glow plug will be energized After 6 10 seconds depending on the engine temperature and battery charge the starter will be powered up to have the rotor turning at slow speed 2000 3000 RPM Once the rotor is at speed the pump and solenoid valves will be energized in pulsating mode Few seconds later the kerosene will ignite and the exhaust temperature will begin to increase The rpm and pump power will increase automatically During this phase the data terminal will display IGNITION When the ex
16. o loose items of clothing ties etc or equipment which can readily be sucked into the engine intake even from adjacent to the engine 4 Always operate your engine in open air away from confined spaces as the engine exhaust contains gases which can cause asphyxiation and nuisance smells 5 Do not touch the engine whilst it is running Turbines rotate at a very high rpm and the engine casing and exhaust can reach very high temperatures Ensure anything affected by heat is kept well clear of the engine and exhaust during operation g Merlin 90 140 160 Instruction manual V3 0 Pag 4 6 Never use the engine near to sources of flammable gases liquids or materials 7 Keep unauthorized persons spectators children and animals well away from the starting area at least 30ft or 10 meters away 8 Always handle turbine fuel and oil with care as they are highly flammable Store them in appropriate labeled containers Never dispose inappropriately We recommend the use of suitable disposable protective gloves for the mixing of turbine oil fuel Merlin Specifications M90K M100K M140K M160K Dimensions Outer Diameter 90mm Outer Diameter Outer Diameter Length 230mm 102mm Length 111mm Length 230mm 308mm Weight 980grams engine only 1 300grams engine 1 800grams engine 1150gr including pump ecu and fuel valves only 1450gr including pump ecu and fuel valves only 1950gr including pump ecu and fuel valves
17. on of glow plug StartOn Test of the starter Ignition Gas ignition phase Preheat Phase of heating of the combustion chamber after detecting the ignition Switchover Phase of switching the kerosene feed from igniter to normal injectors FuelRamp Phase of acceleration until idle speed Running Engine working correctly pilot have full control of engine power Stop Engine off Cooling Starter operating to cool the engine GlowBad Defective or disconnected glow plug StartBad Defective starter insufficient RPM reached during start RPM sensor disconnected Low RPM Engine speed below the minimum HighTemp Excessive temperature FlameOut Exhaust Temperature below the minimum Diagnoses During engine operation the Ecu measures and stores all the engine operating parameters recorded during the last the 51 minutes of operation These measures can be downloaded later to a PC to study the behaviour of the engine in flight and to diagnose any possible problems Also after each cycle of operation the Ecu stores the last cause of shut down and the values of RPM temperature and pump power In order to access these measures it is gP Merlin 90 140 160 Instruction manual V3 0 Pag 15 necessary to shut down and power up the Ecu Set the trim down trimLow and push the left button on the display The Ecu will show the cause of shutdown and the parameter values at the moment of shut down These are as follows Diagnosis messages
18. r a miniature toggle switch actuated by the servo arm position it so it can only be reset by hand The switch is wired in series with the positive red battery wire to the ECU The servo should be connected to a channel which is operated by a switch on your transmitter so it can be operated quickly The servo travel should be adjusted to ensure it is not stalled at either position Merlin Trouble Shooting PROBLEMS SOLUTIONS There is no reading on the screen 1 Disconnected receiver or the ecu receiver batteries are empty 2 The display is badly connected 3 Problem in the ecu or display The kerosene does not ignite 1 The start gas solenoid valve is not connected properly or installed fuel shut off valve is closed Check fuel flow 3 There battery is discharged 4 Glow voltage or pump power needs adjustment There is little increase of RPM when the fuel ignites 1 The fuel valve is partially open 2 There is air in the line of fuel 3 The filters are blocked The engine reduces the power of it is stopped during starting 1 The ecu has detected temperatures over 800 C due to too slow starting 2 There is low battery or air in the tubes Therefore let it cool and retry Engine does not accelerate to maximum set rpm 1 There is insufficient fuel flow or air bubble entering the engine during the initial start up 2 Low battery capacity The engine loses power in flight 1 The ECU batter
19. rol unit EP Merlin 90 140 160 Instruction manual V3 0 Pag 5 Installation Notes 1 The engine should be mounted using the strap mount supplied or an approved equivalent 2 The temperature probe should be firmly fixed to the engine as supplied and not allowed to rattle against metal parts as this could result in radio interference 3 The signal cables from the engine must be carefully routed away from the engine intake so there is no possibility of accidental ingestion of the wire 4 Fuel pipes should be routed similarly clear of the intake The engine must not be run with the gas pipe open to the atmosphere 5 The fuel pump should be mounted at least 100mm away from the front of the engine The pump can emit magnetic pulses that cause the speed sensor to transmit incorrect rpm information to the ECU The fuel pump should be preferably mounted with the spindle in the vertical position with the motor uppermost In the event of any fuel seeping from the pump this will not pass through the electric motor Note the pump is supplied fitted with built in suppression filter to reduce radio frequency noise 6 The centre of the fuel tank should be mounted laterally as near to the centre of gravity CofG of the model as possible This will minimize the CofG shift as the fuel is used during flight 7 Any air ducting to the inlet of the engine must have sufficient diameter of at least twice of the engine intake diameter 8 If an extende
20. rs not covered under the terms of warranty will be carried out by Jets Munt SL or their appointed agents after agreement of costs Before returning the engine or ancillary equipment for service of repair please contact first to your local dealer or Jets Munt central office to agree action and costs Please do not disassemble this engine You will breach your warranty agreement and you will find it is a precision assembly which you will be unlikely to re assemble without considerable difficulty and specialist equipment Simply slackening the spinner nut of the rotor will immediately lose the delicate balance condition without which the engine may not run without damage to its rotating assembly You are permitted to access under the black cover in event of replacement of the magnetic rpm sensor if repair or replacement is required You may not dismantle the engine further Any further investigation may only be undertaken by Jets Munt This warranty is void if any one or more of the following conditions applies In such a case Jets Munt will accept no responsibility for any damage or any other consequence caused by the Merlin operation 1 The engine cover is dismantled except for the removal of the front black cover to access service connections and the RPM sensor 2 The product has been subject to any form of operation whilst containing incorrect fuel oil or fuel oil mix 3 The product is crash damaged pump is blocked due dirt inge
21. stion electronics or pump are flooded by fuel connection leads are cut or lost its isolation and short circuit reverse polarity on battery etc gP Merlin 90 140 160 Instruction manual V3 0 Pag 3 4 Unauthorized maintenance or modifications have been made to any part of the product including the unlocking of the ecu and changing the manufacturer settings 5 Parts have been damaged by ingestion of foreign objects e g wires sand water etc 6 The engine has been operated incorrectly 7 The product has been misused neglected or inadequately maintained 8 Damage to the engine where blockages in the fuel system have occurred by unfiltered or contaminated fuel Jets Munt Representatives Check the current dealer list on our web page www jets munt com Safety Notes Please remember the engine is not a toy and has the potential to cause bodily harm to you and others if misused The Merlin is a sophisticated piece of machinery and should be treated with a high level of safety when it is in operation The following guidelines should be read carefully and adhered to 1 Always keep a CO2 or similar fire extinguisher of at least 2Kg of CO2 contents close when starting and operating the engine 2 Always protect eyes and ears during the starting procedure 3 Be aware of the extreme intake suction hazard we advise the use of a suitable commercial wire mesh Foreign Object Damage guard to protect the engine intake Ensure you have n
22. t by Jets Munt SL Arenys de Munt Barcelona Spain All rights reserved This manual the pictures and data are property of Jets Munt and cannot be used or reproduced in any way without written permission from Jets Munt SL Disclaimer The Merlin engine is a sophisticated piece of machinery Care should be taken at all times when using the engine It should only be operated by those with the appropriate skills and knowledge to do so This engine is not a toy Incorrect operation or misuse can cause damage to property and bodily harm operators spectators and animals Jets Munt SL accepts no liability for any kind of damage which may occur Jets Munt SL assumes no responsibility for any errors contained in this document and is not liable for any damages resulting from such errors g Merlin 90 140 160 Instruction manual V3 0 Pag 2 It is forbidden the use of this engine outside Radio Control applications specially those that power vehicles that carry people Warranty The warranty period for the Merlin is 2 years from the date of purchase or 25 running hours whichever comes first Warranty is valid solely for the original owner and is non transferable upon resale Warranty includes all supplied parts except the battery and is limited to manufacturing and material defects only Damage or defective operation covered under the warranty terms will be repaired and tested at no cost the original owner other than postage and packaging Repai
23. tch Engine Cut switch to off and again press the button to store the value into the ecu If you have done all steps correctly the green LED located directly above the data terminal socket in the ecu will light up in the ECU when the Idle command is received meaning that trim and throttle stick are set to idle positions on the transmitter Lower your throttle trim and the green LED will go out indicating correct reading of the transmitter engine shut off signal by the Fadec ecu On rare occasions usually when using a Futaba transmitter it has been found that the throttle channel the sense of movement may require reversing Servo reverse and repeat the transmitter alignment Correct reading of throttle by the ecu can be verified in the second screen of the data terminal percentage of the throttle position is shown on 0 in the position of engine stop trim and stick down 100 with stick trim full up and between 10 and 30 at idle This now completes your radio setup and should only need doing again if the radio settings are changed Check that you have the failsafe set on your TX so that the engine will be shutdown in the event of radio failure Never fly with the failsafe set to hold There are many more parameters that can be modified in the ECU but we have specifically programmed your Merlin ecu with the optimum settings further adjustment should not be required and can only be carried out by Jets M
24. to the engine sound to check for positive sound of ignition check looking from the exhaust that the kero is burning or check for a increase in exhaust temperature in the data terminal A small plume of white smoke from the exhaust means that the fuel is not burning The fuel is pooling inside the engine Abort immediately the start Double check that solenoid valves are installed in the correct sense An extra security measure is to place a manual valve between the last fuel tank and the pump intake line to prevent that during the process of filling the tanks or during storage some fuel can arrive to the engine After a failed start or whatever condition that could cause that fuel be collected inside the engine i e extra priming ALWAYS empty the engine of fuel by tilting the engine nose down Fuel will exit trough intake Do not tilt upwards due at the internal engine construction the fuel cannot exit trough exhaust Merlin 90 140 160 Instruction manual V3 0 Pag 12 Another big difference between gas start and liquid start is that the kerosene can keep slowly burning during long time inside the engine This situation usually happen during an aborted start the start up sequence is aborted by the user or automatically before the engine arrive to idle This can cause that the kerosene inside the engine keep burning for long time and could destroy the engine or the model IF A STARTUP SEQUENCE IS NOT COMPLETED ALWAYS CHECK FOR FLAME I
25. unt SL or your authorized dealer amp Merlin 90 140 160 Instruction manual V3 0 Pag 11 Preparing the engine for running A suitable platform table workbench is now required to clamp the test stand onto Make sure this can be easily transported outside and weight enough to ensure it cannot be blown over by the thrust of the engine Select a clear area for running keep clear of areas with loose leaves sand or other debris that could be picked up or drawn towards the intake Ensure the fuel tank is position well clear of the exhaust area and secured Important notes for kerostart engines PLEASE READ The kerostart system used on this is a reliable and well tested that produce very smooth and trouble free starts However extra care and attention must be paid when starting a kerostart engine The main difference between gas and kerosene is that in the case of a failed ignition the gas dissipates quickly on the air and don t keep inside the engine Kerosene is liquid and if unburned will pool inside the engine and stay there forever The engine can hold a big quantity of kerosene inside This kerosene will be ignited on next successful start up and will be pushed to the exhaust as soon as the airflow inside the engine is sufficient and will be ignited in the exhaust causing a hot start in extreme cases a big fireball that surely will not hurt the engine but can destroy the model To prevent this During the start up listen
26. y is empty recharge 2 The filters are dirty The engine stops in flight 1 The fuel level is low and or there is air in the pipes 2 There is a poor connection between the g Merlin 90 140 160 Instruction manual V3 0 Pag 19 battery and pump 3 Interference 4 Check the last power down cause on the ecu There is excessive vibration and unusual 1 The engine is unbalanced by the noise ingestion of a foreign object Do not use the engine and send it in for service Merlin Log Owner Serial Number Purchase Date Start No Date Model Place Engine Time Flight Time Remarks gP Merlin 90 140 160 Instruction manual V3 0 Pag 20
27. y turbine engine Use a appropriate adapter for the 6mm tube output of the UAT to the 4mm in the inlet side of the fuel pump direction of fuel flow is clearly shown at the top of the pump The clear 4mm tubing is used on the pressure side of the pump Clear tubing helps identify and locate any potential future problems with air leaks EF 90 140 160 Instruction manual V3 0 Pag 16 The fuel pump and ECU can be mounted simply with a pair of tie wraps and or Velcro The best orientation for the fuel pump is vertical Tt is important to ensure any fuel seepage does not reach the motor brushes The fuel feed from the pump to the engine should have sufficient length of the clear tubing fitted to allow the fitment of the electronic fuel shut off valve and the valve should always go on the pressure side When making any fuel or gas line cuts use a sharp blade to make and cut squarely The fuel filter provided should be installed in an accessible place for regular inspection in line between the pump and the engine Fuel and Oil 1 Use CLEAN well filtered Jet Al or kerosene fuel which is available from most airports or paraffin K1 used for greenhouses available from most hardware stores 2 Ensure the fuel is clean and filtered at each stage of mixing and transfer to the model fuel tank Please note the importance of using clean fuel Failure to do so will result in blockages of the fine fuel injectors in the engine or blockage of the engine lu
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