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Throttle Jockey REV MAX
Instructions
Safety Warning
• When using the Throttle Jockey for the first time or making changes to the throttle servo throw, always perform the calibration operation.
• Always perform a range check after installing the Jockey.
• When starting the model, always keep the throttle below 25%.
• Set the failsafe of the throttle channel to the stop position of the engine.
Model Avionics “Throttle Jockey REV MAX” Instructions
Introduction
The Throttle Jockey REV MAX is a digital rotor speed limiter for Model Helicopters. This is the latest evolution of the Throttle Jockey for intermediate, advanced and extreme flyers. This system yields the best performance tradeoff between power and rotor overspeed. When the rotor system is at or below the target rpm, the limiter passes throttle control to the radio system. It engages only when an overspeed condition is detected. The pilot must setup traditional flight mode throttle curves for 3D flight. In testing, the use of super servos did not yield any performance improvements, so any high-quality servo will suffice.
The Limiter is designed to limit the engine speed between 9500 and 20500rpm.The actual head speed can be calculated by dividing the engine speed by the main gear ratio.
Rotor rpm = engine rpm / gear ratio
For example, a 9:1 gear ratio would yield a limited head speed range of 1055 to 2253 rpm.
The Model Avionics website (
http://www.modelavionics.com) includes the latest information, setup tips for various radio systems and an on-line ATV calculator.
Key Features
• Set the target RPM from your transmitter or by an on-board POT.
• High Resolution pulse and generation system.
• Low Power
• Small and lightweight.
• Outstanding customer support and service.
• Fail-out feature on low battery conditions – Limiting ceases on a low battery condition passing control back to the receiver.
Radio System requirements
The wiring of this Limiter is compatible with JR, Futaba, Hi-Tec, Graupner, Robbe and the current style blue plug Sanwa/Airtronics radio systems. A spare channel for setting the target RPM is not necessary.
Standard Servos
The Limiter will work with any servo in the Futaba, JR and Sanwa ranges (and many other makes). The connectors should be oriented so that the Black (Futaba) / Brown (JR) wires are at the bottom.
Connections
From left to right, the connections are as follows:
SRV Throttle Servo Output
THR Throttle Channel Input
AUX Auxiliary Channel Input (Optional)
SNS RPM Sensor input (magnetic OR optical)
ACC Accessory Output (For future Model Avionics Accessories)
Modes of Operation.
The Throttle Jockey REV MAX can be operated in one of two operational modes; Manual or Remote mode. In remote mode, the AUX channel is used to remotely set the target RPM from the transmitter. In manual mode, a small POT (beneath the hole marked ‘MAN’) is used to set the target RPM. This mode is used when the radio system does not have a spare AUX channel.
The Throttle Jockey automatically detects the mode of operation.
Calibration
During calibration, the Jockey measures the limits of the auxiliary and throttle channels. Once calibrated, the Jockey stores the measurements in non-volatile memory.
Calibration only needs to be performed when first installing the Jockey, changing throttle servo throws or after transferring the Jockey to a new machine.
REMOTE mode Calibration Procedure
MANUAL mode Calibration Procedure
• Setup the throttle servo operation so the travel (ATV) is a close to +/-100% as possible. • Setup the throttle servo operation so the travel (ATV) is a close to +/-100% as possible.
• Set the Aux travel (ATV) to +/-100%, make sure that any mixing to the Aux channel is turned off. Ŧ • Rotate the rpm POT fully anti-clockwise.
• Set the throttle and trim to the low (stopped) position <- Important! • Set the throttle and trim to the low (stopped) position <- Important!
• Turn on the transmitter and then turn on the receiver. • Turn on the transmitter and then turn on the receiver.
• During the first 3 seconds, toggle the AUX switch twice • During the first 6 seconds rotate the rpm POT fully clockwise.
• The SET led will flash green indicating that the Jockey has entered its calibration phase. • The SET led will flash green indicating that the Jockey has entered its calibration phase.
• With the throttle trim all the way down raise and lower the throttle stick over its full range. • With the throttle trim all the way down raise and lower the throttle stick over its full range.
• Exit calibration by toggling the AUX switch twice. • Exit calibration by rotating the rpm POT fully anti-clockwise.
• The SET led will stop flashing indicating that it has stored the radio parameters. • The SET led will stop flashing indicating that it has stored the radio parameters.
To verify correct calibration, verify that the SET led is OFF when the throttle stick is below 25% and ON when the throttle stick is above 25%. Ŧ For Futaba systems set the AUX ATV to 90/90
Setting the Target RPM
If the AUX channel was connected during calibration, the target RPM can be set remotely (REMOTE MODE). If calibration was performed without the AUX channel, the target RPM is set using the rpm POT (MANUAL MODE). Switching between Manual and Remote modes will require re-calibration.
Setting the Target RPM in Manual mode
The position of the rpm POT determines the target RPM. If the POT is turned fully anti-clockwise, the target RPM is set to 9500rpm. If the POT is set fully clockwise, the target RPM is set to 20500rpm. The POT can be set anywhere in this range. The position of the POT proportionally corresponds to a RPM setting between 9500rpm and 20500rpm. After calibration, start with a low initial setting and slowly progress to higher values until the desired RPM is achieved.
Setting the Target RPM in Remote mode
The AUX channel input is usually assigned to a slider, pot or two or three position switch. The ATV of this channel controls the active state of the Jockey as well as the target engine rpm. If the ATV in either direction is set to less than 5%, regulation is disabled. An ATV setting between 5% and 100% sets the target speed. The relationship between ATV and rpm above 5% depends on the radio system type. ATVs above 100% are possible, but to use them, the TJ must be calibrated using these higher settings. Settings above the calibrated ATVs are ignored. Always use symmetrical ATVs on the AUX channel, this allows the Jockey to correctly calculate the midpoint.
The highest target rpm is 20500rpm and the lowest rpm setting is 9500rpm. To verify operation, raise the throttle above the 25% threshold and lower the active ATV of the auxiliary channel below 5% and verify the Green LED is off. Alternatively, the ATV at each state of the aux switch can be used to set a different speed target. ATVs greater than 5% set the target rpm. 6% corresponds to 9500 rpm and 100% corresponds to 20500 rpm. On some radio systems, the auxiliary channel can be mixed with the flight mode switch. Different ATVs (or speeds) can be assigned to each flight mode setting using this method. Set the PCM failsafe to 0% for this channel.
Fig: Auxiliary Channel ATV to target Speed
Fig: AUX Rotory Control Fig: AUX Switch
ATV ranges differ slightly between radio manufacturers. The tables below show examples of ATV settings for popular radio systems.
Example 1: Raptor 30: 9.56-1 gear ratio Rotor/ATV Example 2: Engine RPM / ATV
RPM JR FUT HITEC SANWA
1500 76 56 81 78
1550 80 59 85 82
1600 84 63 89 86
1650 88 66 94 90
1700 92 69 97 94
1750 96 72 101 98
1800 99 75 105 101
ATV JR FUTABA HITEC SANWA
10 9480 9600 9420 9420
20 10140 10380 9840 10020
30 10620 11200 10380 10500
40 11280 12240 10920 11100
50 11900 13700 11640 11820
60 12720 15000 12420 12600
70 13500 16500 13200 13500
80 14700 18060 14100 14520
90 16080 18500 15240 15720
100 17340 18500 16620 17160
Throttle channel operation
Make the servo operating range as close to +/-100% ATV as possible.
Use backup throttle curves.
Set the flight mode/stunt/idle up minimum throttle settings greater the 25% so that the Jockey is enabled (SET led on) at all stunt throttle stick positions. (Note that it can still be disabled using the aux channel).
Make sure that the engine can idle reliably when the throttle stick is below 25%.
Set the throttle hold below the enabled threshold so that the Jockey is automatically disabled during autorotations.
Set the PCM failsafe to the stop position of the engine.
Sensor and magnet installation
The Jockey uses a magnetic hall-effect sensor. The magnet is installed on the cooling fan of the engine and the sensor is attached to a bracket which attaches to one side of the engine mount.
Use the supplied Heat Shrink tubing and tie wraps to mount the sensor to the bracket. A dab of Cyno can be used to secure the sensor and tie wraps once the position has been set. The sensor is carefully bent over the top of the bracket with the writing on the sensor facing the fan (Note: The most sensitive side of the sensor is the side with the writing, however, if you have a magnet installed from a previous Futaba GV1 setup, the Jockey sensor needs to be oriented with the side without the writing facing the magnet).
The magnet should be mounted on the underside of the fan at a radius of 28mm (60 size) or 23mm (30 size) from the center of the fan. Drill a 4mm hole 1.5mm deep and epoxy the magnet to the fan. Do not use metallic epoxy such as JB-Weld, it will lower the performance of the magnet. Use a good epoxy with a 20min or greater curing time.
If both magnets are installed to balance the fan in a 2-stroke setup, make sure that the sensor only responds to one of the magnets.
The sensor must be mounted a close to the magnet as possible. The sensor must be less than 2mm away from the surface of the magnet.
The sensor is only sensitive to one pole of the magnet. To check the correct orientation of the magnet, connect the Jockey to the receiver and turn on the transmitter then connect the sensor and pass it in front of the magnet. The Red LED will light as the sensor detects the magnet. After installation, this method can be used to periodically check that the sensor and magnet are in range.
Operation
After power-up, the Limiter waits for a calibration event from the AUX channel or the rpm POT. Normally the Jockey will enter an idle state monitoring the sensor, throttle and auxiliary channels waiting to be enabled. Once enabled the jockey waits for the engine to reach the target speed set by the auxiliary channel state ATV. After 1 second, the Jockey will slowly and smoothly take over the throttle channel, regulating the engine directly. If the target speed is changed during flight (by changing the aux state setting), the Jockey will acquire the new speed target setting.
Rules of limiter engagement
The Jockey will only limit the throttle after ALL of the following conditions have been met:
1. The Sensor, Throttle and Aux channel are operating correctly AND
2. The Jockey has been calibrated AND
3. The Throttle stick is above 25% AND
4. The AUX ATV is greater than 5% (if connected) AND
5. The target speed has been reached.
After limiting has been enabled, the Jockey will pass control back to the throttle channel if ANY of the following conditions occur:
1. The Throttle stick is below 25 % (Throttle stick priority) OR
2. The sensor fails OR
3. The AUX ATV is less than (Auxiliary disable) 5%
If the battery voltage dips below 3.56V, the Jockey will enter a ‘fail-out’ mode where control is passed back to the receiver. The only way to exit the ‘fail-out’ mode is to cycle the power.
Four-stroke engine setup
Four-stroke engines run at about half the speed of a two-stroke engine. Two magnets can be installed 180 degrees apart on the fan. This will cause the Jockey to limit at half the target rpm (4750 to 10250 rpm).
Disclaimer and Limitation of Liability
Specifications are subject to change without notice.
Model Avionics shall have no liability or responsibility to the customer or any other person or entity with respect to any liability, loss or damage, caused or alleged to be caused, directly or indirectly, for equipment sold or furnished by Model Avionics.
Notwithstanding the above limitations, Model Avionics liability for damages incurred by customers or others shall not exceed the amount paid by the customer for the particular equipment involved.
Neither Model Avionics nor this document makes any expressed or implied warranty, including, but not limited to the implied warranties of merchantability, quality or fitness for a particular purpose.
www.modelavionics.com
