Operating Instructions Operating Instructions Featuring
Contents
1. Page Specifications Connections and Controls Information on usage and security Sensor Switch Guarantee conditions DO ON 1 Functions of the Dual Power Control system The backer is intended exclusively for use in modelling and the sole approved application is in radio controlled models It must be powered by a D C current source corresponding to a five cell NiCd or NiMH battery or two Lithium ion or Lithium Polymer cells 7 4 Volts Never connect the unit to a mains PSU For each of the 7 most important channels of your model aircraft you can connect a maximum of four servos directly to the battery backer without any problems re garding the servo signal voltage In each case the signals for the 7 channels are amplified by a two way amplifier to a level which ensures that the stated number De PowerBox Systems POWER BOX 40 24 Competition of servos can safely be connected to the receiver via the PowerBox 40 24 Compe tition even when long cables are in use A special circuit is employed which de couples the individual outputs of each servo socket from each other that is why it is possible to connect up to 4 servos without any one servo affecting the others linear controller 6 0V 0 1 battery 1 Fi electr swich 1 tet PF k E l i de coupling supp diode 1 switch t tension sensor switch 1 micro Er minimum voltage external i memory display 1 LED2. motely i e via the backer This ensures that the receiver works under earth condi tions similar to those prevailing when calibrated at the factory For safety reasons there are two micro processors at the core of the backer s cir cuit controlling the entire process independently of each other Both batteries are connected to the two de coupling diodes via a pair of linear regulators which are also independent of each other The regulators double as electronic switches The micro processors control the two regulators switches generating a very accurate supply voltage for servos and receiver s The processors also control the LED chains which display battery capacity and minimum values as well as the external LEDs PowerBox Systems P OWER BOX 40 24 Competition 5 Sensor Switch fixing bolt flat cable for the connection on the PowerBox red LED for signaling SET key for activation the activation status Switching key battery 1 2 green LED s for signaling Switching key switching battery 2 status fixing bo The SensorSwitch illustrated here can be ai cessible location using the two screws suppli It tached to the model in any easily ac ed Take care that there is no chance for combustion residues to soil the switch motor The SensorSwitch does not actually switch he current to the servos and receiver the switching process is carried out by the two independent electronic switches on the backer
3. 1 minimum value sensor minimum voltage external micro memory display 2 LED 2 processor 2 sensor switch 2 servo signal amplifier with interference blocking 24 connections for servos 7 connections for receiver 4 switch supply tension de coupling ce N y diode 2 linear controller oe electr switch 2 Fee 60V 4 0 1 When long servo leads are used there is a danger of RF interference signals reach ing the receiver by that route but the integral servo signal amplifiers also effectively prevent this by blocking the interference For this reason ferrite rings are not re quired for de coupling the servo cables when this backer is used A further important performance feature of the PowerBox 40 24 Competition is its extremely accurate linear stabilisation circuit for the power supply to the receiver s and servos The stabilisation circuit takes the form of two independent voltage regulators each of which is capable of supplying a current of up to 20 A at a volt age of 5 90 V accuracy 0 1 V This means that the unit is the first ever to pro vide a power supply which fulfils the maximum stated voltage tolerance specified by all RC manufacturers If you wish to use batteries other than NC or NiMH types e g Lithium lon or Lith ium Polymer batteries the PowerBox 40 24 Competition is the outstanding cho
4. and the SensorSwitch serves only to actuate these switches The ad vantage of this arrangement is that the actual completely protected from dirt and vibration Switch buttons is fitted with double contacts switch is inside the model where it is Nevertheless each of the Sensor for secure operation The single recessed SET button is used to prepare and carry out a switching proc ess holding the SET button pressed in arms the sensor and the red LED lights up The two batteries can then be switched on individually using the two remaining buttons marked I and Il Note that the SET Py oe button must be held pressed in when PowerBox Systems POWER BOX 40 24 Competition you switch them on The two green LEDs light up to indicate the switched state of the batteries i e the battery is switched on if the green LED lights up To switch the batteries off the SET button must again be pressed until the red LED lights up This prepares the switching process and arms the sensor The buttons marked I and or Il can then be pressed to switch the batteries off The green LEDs go out and the receiving system is completely switched off When switched off the system draws an idle current of a mere 5 pA which corresponds to a fraction of the self discharge rate of normal batteries The ribbon cable attached to the SensorSwitch should be connected to the red multi pin socket on the right hand side of the
5. backer Although this connection is secure and firm it is worth noting that disconnecting the SensorSwitch has no ef fect on the actual switched state of the device Nevertheless it is good practice to deploy the ribbon cable in a location where vibration is low Don t let it simply dan gle it is much better to fit some form of strain relief a small piece of double sided foam tape between cable and fuselage sometimes works wonders Our new Sen sorSwitch system offers you the very highest level of security as there is abso lutely no chance of switching the system off accidentally nor of compromised reli ability due to vibration The SensorSwitch fulfils yet another task it is used to display the value of the two minimum voltage memories This is the procedure after the landing press both power on buttons I and Il simultaneously whilst holding the SET button pressed in The two LED chains on the backer then display the minimum voltage of both bat teries i e the lowest values which occurred during the previous flight Carrying out this check enables you reliably to detect batteries which are defective in poor con dition or of inadequate capacity for the model aircraft in question Since the checks are carried out using the externally mounted SensorSwitch there is not even any need to open the canopy The minimum values are reset when both batteries are switched off i e the low voltage recording process restarts for the next
6. flight The SensorSwitch is available in the colours black or grey and one or other is very likely to blend inconspicuously with the colour scheme of your model The in ner packing of the SensorSwitch includes a template for the switch aperture en suring that it is quick and easy to mount the SensorSwitch accurately on your model PowerBox Systems POWER BOX 40 24 Competition 6 Guarantee conditions During the production process each battery backer undergoes a series of visual and technical tests We take the maintenance of the highest quality standards very seriously and this includes bought in items That is why we are able to grant a 24 month guarantee on all our battery backer systems valid from the initial date of purchase The guarantee covers proven material faults which will be corrected by us at no charge to you We wish to emphasise expressly that we reserve the right to replace the unit if a repair is impossible for economic reasons Proof of the commencement and progress of this guarantee period is the purchase receipt Repairs which our Service Department carries out for you do not extend the guarantee period Misuse and maltreatment such as reversed polarity excessive voltage the ef fects of damp fuel external mechanical influences or physical damage invalidate the guarantee The guarantee does not cover any additional claims such as con sequent damage Goods must be returned to us post paid we will not accept C
7. of high current sockets located at one end of the backer Before you connect the two packs itis vital to ensure that they are wired with correct polarity as the backer is not protected against re versed polarity If one of the batteries let alone both is connected with reversed polarity the backer will be ruined ERST Connecting diagram We can supply you with ready made batteries fitted with High current plug genuine high current connectors If you prefer to make up d the connecting leads yourself you require two of these l polarised high current connectors for the batteries you will find them in the accessory bag Please note that the cables must be soldered the right way round and are eee embossed on the rear face of the connector Please 4 1 take great care to observe these markings when soldering the cables and double check your work so that there is top view 4 PowerBox Systems POWER BOX 40 24 Competition absolutely no chance of reversed polarity Take the trouble to produce sound sol dered joints and insulate each of the and joints with a piece of heat shrink sleeving baseplate with flat cable mounting holes of the sensor switch _ 24 connetions _ for servos and sensor to call the minimum voltage memory botteny boney 7 receiver an CE ok channels intelligent en cee recon ot ae voltage POWER BOX 407 24 d contoller for A intelligent battery 1 volt
8. sockets to one receiver and four to the other receiver Select the channels for each receiver whose signals are to be amplified or which you wish to separate from the receiver for reasons of safety The ferrite rings in the backer s connecting leads help to eliminate RF interference carried by long servo leads but they also de couple the receiver s earth from the earth of the backer and all the components connected to it batteries servo leads servos This ensures that the receiver s operate under the conditions for which the RC manufacturer calibrated them Registered Design No 202 02 003 7 In practi cal terms the earth surfaces of a receiver represent the counterbalance or base point of the aerial These standard earth conditions should not be altered by more than a small amount otherwise the receiver s optimum tuning may be affected That is why we have fitted a de coupling ferrite ring in each of the servo leads to the receiver This is a relatively complex production procedure but the effect is that full range is obtained with all standard commercial receivers and that is certainly worth the trouble Most RC manufacturers calibrate their receivers using a simulated load of one or two servos connected to the unit and that is why many professionals have adopted the standard practice of leaving at least one servo connected directly to the receiver at all times For this reason it is not advisable to connect all receiver channels re
9. O D shipments We accept no liability for transit damage or the loss of your shipment If you need to make a claim under guarantee send the unit to us at the following address and be sure to include proof of purchase PowerBox Systems Modellbau Deutsch Hindenburgstra e 33 86609 Donauw rth you must include the proof of purchase receipt for your backer the backer must have been operated in accordance with these operating instructions the backer must have been operated within the voltage and current limits stated in the Specification Liability exclusion We are unable to ensure that the battery backer is operated correctly nor that the entire radio control system has been maintained properly For this reason we are unable to accept liability for loss damages or costs which result from the use of the backer or are connected with its use in any way Unless otherwise prescribed by binding law our obligation to pay compensation regardless of the legal argument employed is limited to the invoice value of that quantity of our products which was immediately and directly involved in the event which caused the damage We wish you every success using your new PowerBox 40 24 Competition battery backer and hope you have loads of fun with it Donauwoerth February 2004 eu PowerBox Systems Modellbau Deutsch Hindenburgstra e 33 86609 Donauworth Tel 49 0906 22559 Fax 49 0906 22459 info PowerBox Systems com www Po
10. PowerBox Systems World Leaders in RC Power Supply Systems PowerBox Competition 40 24 Operating Instructions Featuring seven servo pulse amplifiers plus two independent voltage controllers PowerBox Systems POWER BOX 40 24 Competition Dear Customer we are delighted that you have decided to purchase the PowerBox 40 24 Competition from our range Your valuable model aircraft can now be fitted with one of the most capable battery backers available enabling you to couple two bat teries and also monitor the voltage of both packs constantly The unit stores the minimum voltage of both batteries and you can call up this information after each flight The PowerBox 40 24 Competition features an integrated two way signal amplifier for each of seven receiver channels connected to the backer allowing you to connect up to 4 servos to a single output without problem This backer also pro vides a power supply for receiver and servos of 5 9 Volts 0 1 Volts with very accurate linear stabilisation This is generated by an extremely low loss IC controlled regulator 0 12 Volt reduction very low waste heat Although this battery backer is simple to operate you do need to understand cer tain points if you are to exploit its advantages to the full Please read through these instructions and you will quickly feel at home with your new accessory Table of contents Functions of the Dual Power Control system
11. age contoller for battery 2 entrance battery 1 EN N entrance 7 ferrit rings for battery 2 earth decoupling receiver power supply All seven servo leads carry the power supply for the receiver s Please connect the connectors to the channel sockets of the receiver s whose servo signals you wish to amplify the numbers of the servo lead inputs on the PowerBox 40 24 Competition are identical to the connector block numbers The integral amplifiers eliminate servo signal damping distortion and interference even where cable lengths are in excess of two metres You should always connect all the servo leads to the receiver even when fewer than seven control channels are connected to the backer because they all supply current to the receiver This ensures that the power supply to the receiver s is completely reliable PowerBox Systems POWER BOX 40 24 Competition 4 Information on usage and security Naturally it is possible to connect two or if you wish even more receivers to this battery backer If you wish to do this be sure to observe the information sup plied by your RC manufacturer concerning the use of two receivers in a model oth erwise there may be problems with inter action between the two receivers The basic rule make sure that the two receivers are physically separated by a distance of around 20 25 cm The power supply to the receivers is through the seven servo leads of the PowerBox 40 24 Competition e g three servo
12. ice In fact the initial idea of voltage stabilisation was developed specifically with these new technology batteries in mind We have world wide experience with our nae PowerBox Systems POWER BOX 40 24 Competition American partner DURALITE with the result that our design was a unique devel opment and showed the way forward for other manufacturers There are absolutely no problems in using your PowerBox 40 24 Competition in conjunction with the lithium battery types mentioned above We can even alter the voltage display program so that you can gain the full benefit of the new battery technology This provides you with the full security provided by the PowerBox 40 24 Competition Alternatively you can state your intended application when you order your backer and you will then be supplied with the version for Lithium Polymer batteries 2 Specification Operating voltage 2 5V to9V Power supply 2 x 5 cell NiCd or NiMH batteries or 2x Li lon or Li Polymer cells 7 4 V Maximum load 2x20A Voltage loss approx 0 32 V total backer function and voltage regulator Voltage stabiliser 5 9 V 0 1 V for receiver s and servos No load current drain approx 5 ya switched off with SensorSwitch Servo sockets 24 sockets up to 4 servos Temperature range 20 C to 75 C Dimensions 114 x 72x 19 mm incl base plate Weight 135g Weight SensorSwitch 14g 3 Connections and controls The two batteries are connected using the pair
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