JetCat P1000 BasicTechnicalInformation 2021-03-03
JetCat P1000 BasicTechnicalInformation 2021-03-03
Content
INTRODUCTION ............................................................................................................................................................. 3
FUNCTIONAL DESCRIPTION ..................................................................................................................................... 3
CONTROL OPTIONS / ELECTRICAL INTERFACE .................................................................................................................. 4
Engine Control Options.............................................................................................................................................. 5
JETCAT P1000-PRO ENGINE FEATURES/FUNCTIONS ....................................................................................................... 6
TECHNICAL DATA ........................................................................................................................................................ 7
PERFORMANCE DATA ...................................................................................................................................................... 7
FUEL /OIL ........................................................................................................................................................................7
ELECTRICAL .................................................................................................................................................................... 8
Power supply .............................................................................................................................................................. 8
Generator function / AC-DC converter ...................................................................................................................... 8
Diagram DC/DC converter power output, with 3-cell Lipo battery as engine battery .............................................. 9
Diagram DC/DC converter power output, with 4-cell Lipo battery as engine battery ............................................ 10
Diagram DC/DC converter power output, with 6-cell Lipo battery as engine battery ............................................ 11
3-PHASE GENERATOR OUTPUT OPTION .......................................................................................................................... 12
Diagram: Generator performance data vs engine rpm (500W) ............................................................................... 13
Diagram: Generator performance data vs engine rpm (800W) ............................................................................... 13
Diagram: Generator performance data vs engine rpm (1600W) ............................................................................. 14
DELIVERY CONTENT ...................................................................................................................................................... 15
OPERATING CONDITIONS ........................................................................................................................................ 15
OPERATING CONDITIONS FOR ENGINE START ................................................................................................................. 15
OPERATING CONDITIONS FOR ENGINE OPERATION ......................................................................................................... 15
OPERATING LIMITATION ................................................................................................................................................ 15
TIME TO INSPECTION ..................................................................................................................................................... 15
FUEL SYSTEM .............................................................................................................................................................. 16
BEARING LUBRICATION AND COOLING SYSTEM ............................................................................................................. 16
A) Lubrication via oil mixed to fuel .......................................................................................................................... 16
B) Lubrication via separate oil pump ....................................................................................................................... 16
FUEL PRIMING, INTEGRATED PRIMING VALVE FEATURE................................................................................................. 17
BLEEDAIR PORT, PRESSURIZATION OF FUEL TANK ......................................................................................................... 17
CONTROL SYSTEM ..................................................................................................................................................... 18
IGNITION SYSTEM ...................................................................................................................................................... 18
APPENDIX ...................................................................................................................................................................... 18
INSTALLATION DIMENSIONS OF THE ENGINE .................................................................................................................. 18
ENGINE PICTURES .......................................................................................................................................................... 19
500W Generator ....................................................................................................................................................... 19
800W Generator (option) ......................................................................................................................................... 19
ENGINE DIMENSIONAL DRAWING.................................................................................................................................. 20
500W GENERATOR (STANDARD) ................................................................................................................................... 20
800W GENERATOR (OPTION) ......................................................................................................................................... 20
CONNECTIONS ON THE ENGINE , OVERVIEW ................................................................................................................... 21
Fuel Connection Diagram, Standard ....................................................................................................................... 22
Fuel Connection Diagram, pressurized fuel tank ..................................................................................................... 23
SYSTEM CONNECTION DIAGRAM EXAMPLE WITH PRO-INTERFACE ............................................................................... 24
Introduction
The JetCat-P1000-PRO type turbo-jet engine is designed as a propulsion unit for RC-aircraft and/or drones.
The engine can be lubricated by fuel with oil ad mixture, alternatively oil can be delivered via a separate miniature oil
pump, which removes the necessity to add oil to the fuel.
The engine is equipped with a BLDC starter/generator, 2x BLDC fuel pumps, 3x fuel solenoids and electronic control
system (FADEC type).
The engine may be modified based on customer specific requirements and to meet different operating / installation
conditions.
Functional description
The JetCat P1000-PRO is a single-shaft engine comprising a single-stage radial compressor, annular combustion
chamber, single stage axial turbine and fixed exhaust nozzle. At the compressor intake, there is a brushless starter
/generator mounted which enables starting from the board network and allows for electrical power generation during
engine run. Intake air is compressed in the radial compressor stage, proceeds through the radial and axial diffuser into
the combustion chamber where it is mixed with vaporized fuel. Combustion gases generated by fuel burning in the
combustion chamber expand through the single state axial turbine and the exhaust nozzle to the atmosphere. The gas
exiting the exhaust cone produces the required thrust. The rotor of the engine is mounted on 2 ball bearings
lubricated by a fuel/oil mix.
The JetCat-PRO engine series provides the highest level of integration and maximum ease of installation.
All peripheral systems necessary for the engines operation are fully integrated below the engines front cowling.
Therefore, besides the supply battery, the fuel tank, there are no further
external subsystems required!
Serial communication interface Rx/Tx (3,3V TTL or +/-12V RS232, RS485 optional). Baud rate: 2.4-115k
CAN-Bus (2.0A-11bit or 2.0B-19bit. Bitrate: 125K-1Mbit/s adjustable)
2x Servo PWM inputs for throttle/engine control
Analog input for engine control (Start/Stop/Thrust control)
The system allows to use a single control interface for engine control and data reporting or any mix, depending on user
requirements.
The control signals are fed out on a pigtail cable terminated by a 15-pin SUB-D connector (other connector types
available on request).
The power supply is made via a second pigtail cable with a XT60 connector for direct battery/power supply connection.
Other power connector types possible upon request.
Connector A
SUB-D 15pin connector data/control. Or
customer specific connector
Connector B
XT60-power connector. Or customer
specific connector
Technical data
Performance data
Applicable under ISA conditions (15 °C, ambient 101.325 kPa, v = 0 m/s)
Fuel /Oil
Jet A1 or equivalent mixed with 3-5% of turbine oil.
Alternatively, Diesel fuel can be used.
Fuel purity must comply with class 10-11as per GOST 17216-71 or 7-8 as per NAS 1638
Oil types: JetCat turbine oil, Mobil Jet Oil II, Aero Shell 500, or Exxon 2388 (or equivalents)
Electrical
Power supply
Supply voltage 10 to 35V DC (ideal: 3-4s LiPo battery with 5000mAh)
The chemistry (LiPo, LiFe, Lion, NiCad, Lead, NiMh), the cell count
and capacity (mAh) of the actual used battery is user selectable!
Min battery capacity required for start: > 400 mAh.
With the generator option, although not recommended, battery
can be totally disconnected after engine start-up. The system
then can fully run on its own power generated as soon as the
engine has been started up!
Average energy requirement per start: 400mAh; peak current 25A @12VDC
Peak power consumption (at start): 220W for max. 40s
Power consumptions when running: 24W at idle ; 85W at max thrust.
The integrated power supply unit consists of the integrated three-phase generator, a rectifier, and a switched step
up/down DC-DC power converter. This system will provide enough power to all internal consumers of the engine
(ECU, pumps, solenoids) once the engine has been started up. Excess power is used to automatically re-charge the
supply battery. The generator output voltage is rectified, and precision regulated to a constant output voltage via an
integrated DC/DC converter. The output voltage and current are automatically matched to the selected (programmed)
battery type and size. Therefore, the output voltage of the DC/DC converter is adjustable by the control system in a
broad range from 10 to 30VDC.
The DC/DC converter can supply a maximum current of 15,6A. It can maintain a constant output voltage up to this
limit. If the current limit should exceed this or a lower programmable limit, the output voltage will drop.
Output current limiting function: Depending on selected battery type/size not to over current the attached supply
battery on charging, the system monitors the current flowing in the supply line, by this the current flowing back to the
supply battery can be limited to a safe limit when charging/buffering a connected battery.
The generator is installed in the compressor intake; The rectifier and DC/DC converter are integral part of the front
mounted ECU.
From this output capability, the power required by the engine system itself must be deducted. At idle, the
power consumption of the engine system is around: 24W@idle, at max power it is at around 85W.
System allows for automatic (re-) charge / buffering of connected supply battery. When engine runs, there will be no
energy taken from supply battery.
Diagram DC/DC converter power output, with 3-cell Lipo battery as engine battery
65000 180
60000
170
55000
160
50000
40000 140
35000
130
30000
120
25000
110
20000
15000 100
0 10 20 30 40 50 60 70 80 90 100
engine thrust in %
Diagram DC/DC converter power output, with 4-cell Lipo battery as engine battery
65000 250
60000
240
55000
230
50000
40000 210
35000
200
30000
190
25000
180
20000
15000 170
0 10 20 30 40 50 60 70 80 90 100
engine thrust in %
Diagram DC/DC converter power output, with 6-cell Lipo battery as engine battery
65000 380
60000 370
55000
360
50000
350
40000
330
35000
320
30000
310
25000
20000 300
15000 290
0 10 20 30 40 50 60 70 80 90 100
engine thrust in %
The 3-phase AC alternator output is normally provided on a 3-pin “MT30” type connector (female):
MT30-F AMASS
3-phase AC + Output
alternator
Phase A DC
Phase B
Phase C
DC
- Output
In case the 3-phase generator output is used, the user system must absolutely make sure that the following conditions
are always met:
1) No generator loading during engine start-up or cooling phase To avoid interference with engine start-up
where the alternator is used/ actively powered as a starter motor by the ECU system, the user sided power
conditioning system must be safely disabled until engine has reached idle rpm!
2) Generator loading by external circuitry is limited to below shown diagrams (depending on actual alternator
size installed with engine).
The user system must make sure that these limits are not exceeded at any time, otherwise damage of
generator and/or coupling system may result!
650 40,0
600
35,0
500 30,0
Power (W)
450 25,0
400 20,0
350
15,0
300
10,0
250
200 5,0
15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000
engine rpm (1/min)
45,0
750
40,0
current (A) / voltage (V)
650
35,0
Power (W)
550 30,0
25,0
450
20,0
350
15,0
250 10,0
15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000
engine rpm (1/min)
50,0
1400
45,0
1000 35,0
30,0
800
25,0
600
20,0
400 15,0
15000 20000 25000 30000 35000 40000 45000 50000 55000 60000
engine rpm (1/min)
Generator Power output (W) Generator AC output voltage (V) Generator max current allowed (A)
Delivery content
The engine assembly consists of:
1x engine, including pigtail cables (2x) for power and control/data.
Engine clamp
Operating conditions
Operating conditions for engine start
Operating limitation
Max EGT at starting: 900 °C max. for 3 sec.
Max EGT normal operation: 750 °C
Typical starting time: 55 sec
Restart after unsuccessful start: 5 sec
Restart after previous operation: 30 sec
Time to inspection
50 hours of operation
Fuel system
Fuel is drawn from the external tank via an external to be provided 50 µm filter. There is no further external fuel valve
required. From the engine sided fuel inlet port, the fuel is routed directly into the brushless fuel pump and from there
though a 25um integrated post filter before going into a set of 4x solenoid valves total. One of these valves is
controlling the fuel to the main fuel supply ending up in the combustion chamber as well as the bearing lubrication
system.
The pump/solenoids are controlled by the ECU, depending on the actual operation condition. The engine front
mounted fuel supply manifold comprising the fuel inlet/fuel pump/ post filter and solenoids is machined out of a
single full metal piece, no further pipes or tubing’s.
For easy fuel priming, the P1000 engine provides an integrated “fuel prime” solenoid valve
This allows for easy and safe fuel system priming (fill / deaerate fuel supply lines). This is accomplished by “sending
back” the fuel aspirated (via the integrated fuel pumps) back out through the bleedair outlet port. This optional
function can be software enabled and allows an easy and secure way to prime the fuel supply lines without any risk to
accidentally dump fuel into the engine during the priming process.
In addition, an “auto priming function” can be activated which will do the priming automatically prior to every engine
run and/or only if desired.
For this system to work, the only thing required, is to make a “loop back” connection from the engines bleed air
output back into the fuel tank.
(Ventilation)
Engine
Fuelpump
to main valves Fuel inlet fuel tank
Solenoid valve
(fuel prime)
Tank fill
connector
A B Bleed air
output
compessor air
A) tank
pressurisation
B) Drain port
During normal operation, the “fuel prime solenoid” is switched to position A. In this case the bleedair pressure will be
present at the bleedair output port (for optional tank pressurisation). The integrated one-way valves would prevent
accidental flow back from the (pressurised) main tank back into the engines compressor system and/or fuel system.
During fuel priming, the “fuel prime solenoid” is switched to position B. In this case fuel aspirated by the fuel pump
will be send back out through the bleedair port. Fuel will then flow back either into the fuel tank ( “A), tank
pressurisation”) or to a dedicated drain port (“B) Drain port”).
The bleedair port can provide compressed air derived from the engine’s compressor stage.
In order to avoid any possible reverse flow back into the engine, an internal one-way valve is provided on the engine
side. As the bleed air can be hot/warm, the use of a Teflon/PTFE tubing for the first 20cm is recommended!
The pressure on the bleedair port depends on the engine’s operational rpm. On full power a pressure of up to 2,7 bars
can be reached!
In case bleed air is not required/used, please block the outlet by a piece of crimped tubing.
Typically bleed air is used to pressurize the onboard fuel system to avoid degassing/bubbling of the fuel on high
altitude operation of the engine (>5000m).
For full operation of this feature an additional pressure relief valve must be fitted in front of the fuel tank in order not
to over pressurize the fuel tank!
The pressure relief valve should have a recommended relief pressure of 0,3-0,5 bars.
Control system
The engine´s control system (ECU comprises a 32-bit microprocessor, driver circuitry for pumps/solenoids, and the
optional AC/DC converter). It controls safe operation of the engine including engine starting, maintaining required
speed, stopping and cooling of the engine after shutting down.
All above functions/devices are installed at the engine’s frontend, no external equipment required.
The ECU supports controlled acceleration and deceleration of the engine under all conditions. Engine operation can be
controlled and monitored via a serial bus or CAN bus from a master control system. The user software allows the
identification of remaining TBO, statistical data, Engine start/stop control, monitoring of real time parameters like:
rpms, EGT, fuel flow, remaining fuel, voltages, currents etc.
External devices like oil feeder pump, smoke pumps / feeder pumps, light control system, GSU etc.
Ignition system
The integrated ignition system consists of high-pressure fuel evaporation system assisted by an integrated dual high
voltage spark plug ignition system.
The fully integrated ignition system is active only for a limited time until stable combustion is reached.
Appendix
Engine pictures
500W Generator
Expansion connector C
4-pin Molex connector. For
connection of GSU or smoke
pump / oil pump or other
JetCat accessory.
Connector B
XT60-power connector. Or customer
specific connector
Connector A
SUB-D 15pin connector data/control. Or customer specific
connector
Feeder/Hoppertank
Main-tank
Do not use a filter in the suction line to the engine just an UAT air trap or large felt clunk!!!
On engines above 400N thrust two felt clunks in parallel might be needed not to restrict flow, or one high flow felt
clunk from JetCat.
The fuel demands are high, especially on larger engines, and require large tubing interconnecting
the tanks. Use short connections and large diameter tubing’s.
Bl e
ed
air
por
t
No additional Filter in suction line!
To filling connector
Feeder/Hoppertank make sure to close after filling!
Large Mesh/Felt
to reject air bubbles
Main-tank