FOXTECH Halo-6000 EFI Generator for Hybrid Drone User Manual

Halo-6000
EFI Generator for Hybrid Drone
User Manual
V1.0 2021.12

Safety Code

Before using this product, please read this manual carefully and be familiar with the meaning. Only by correctly operating and maintaining the product can we ensure its safe and effective operation. In case of any irresistible accidents such as disability, death, fire, and so on due to improper use, it has nothing to do with the product and the manufacturer. If the user refits, all irresistible accidents after refitting have nothing to do with the manufacturer.
General Safety Precautions

• When disassembling the motor and control system, cut off the power supply first.
• The motor shall be kept clean and free from obstacles. All dirt on the motor shall be cleaned regularly to keep the motor clean and dry.
• Exhaust gas discharged by the engine has certain toxicity, and do not inhale or contact engine exhaust gas.
• This manual is an important part of the system. Without written approval, it is strictly forbidden to copy any content of this manual.

Description of Halo-6000

Preface
First of all, thank you for your trust in our brand! Welcome to use the aviation hybrid system (UAV) provided for you. Please read this manual before you use it. This manual provides guidance on the use, troubleshooting, and maintenance of Halo-6000. This manual does not provide a maintenance guide for electrical components. When it is determined that the electrical components have failed, please do not repair them. The whole assembly must be replaced. Other damage may be caused by trying to repair the faulty electrical components. Please read the safety rules in this manual carefully and follow all the requirements and precautions in this manual.

Functions and Technical Features

According to the requirements of multi-rotor UAVs, the developed Halo-6000 is 58V (14S Li battery).
The engine uses two-cylinder and two-stroke gasoline as fuel. It adopts 32-bit MCU of vehicle gauge level, precise injection ignition, adaptive plateau correction, intelligent self-learning, and has passed the environment and EMC tests. Besides, it has the characteristics of high output power and low fuel consumption. The motor adopts the heuristic integrated external rotor motor, which is integrated with the engine, making the hybrid system have the advantages of small volume, lightweight, low noise, and high power-mass ratio. The controller has the protection functions of overvoltage, under-voltage, over-temperature, and over-speed. Halo-6000 has the excellent quality, strong power source, long-term high-power output, and long service life.

Main Technical Parameters

Not include coolant, gasoline, fuel tank
4| Dimension（L x W x H)| mm| 312×288×206|
5| Average Fuel Consumption| L/h| 5.7|
6| Applicable Models| | Multi-rotor|
7| Applicable Power  Voltage| VDC| multi-rotor UAV, VTOL fixed-wing aircraft|
8| Altitude| m| ≤2000|
9| Operating Ambient  Temperature| °C| -20 ~ 50|
10| Start Mode| –| One Key Starting|
11| Mixing Ratio of Lubricating Oil and
Gasoline| –| 1:25| Please use the brand oil suggested by the
manufacturer.

Caution:

1. We suggest you use 25L gasoline to run in the generator for the first time of using the Halo-6000 at the ratio of 25:1(gasoline: engine oil). For everyday use, a ratio of 40:1(gasoline: engine oil)is suggested.
2. Please confirm that the technical parameters of the UAV match the parameters of this hybrid system before use, so as to meet the operational performance of the UAV, Prevent damage caused by improper configuration.
3. Failure to use the oil and engine-fuel ratio suggested by the manufacturer will cause engine damage. The manufacturer will not be liable for any consequences caused by using oil not suggested by the manufacturer.

Tab. 2 Main technical parameters of engine configuration

Before Operation

Wiring DiagramSystem Controller and PMU
Please wire in strict accordance with Fig. 1 and Fig. 2. If the connection is wrong, the system components may be damaged.
1.1 The wiring between the engine harness and electrical parts is shown in Figure 1
The wiring of the electrical wiring harness and electrical parts is shown in Figure 2

Operation

Usage and Operation

1. Halo-6000 is configured as shown in Fig. 3

2. The installation dimension of Halo-6000 is given in Fig. 4

Installation Method

3.1 Install the hybrid system to the appropriate position of the UAV. The damping pad is connected with the aircraft mounting mount, as shown in Figure 5 below
Caution The factory default is hoisting, other installation methods will cause shock vibration damper damage
3.2 Cooling system installation and water pipe connection is shown in Figure 6 below
3.2.1 Install the fixed water-cooling radiator.
3.2.2 Installation of fixed water jacket: the water jacket must be placed at the highest point of the cooling system.
3.2.3 Installation of the fixed water pump.
3.2.4 Connect the water pipe. Water pipe of Ø8 Ø12 Water pipe of Ø12 Ø16

The red arrow marks the direction of the coolant circulation flow, and the distribution clamp is used at the end of each inlet and outlet.
3.2.5 Precautions for filling water
Water injection is required before starting the water pump, After the water pump is started, fill the water between the high and low scales of the Water jacket.
3.2.6 Precautions for use of coolant
a) Unscrew radiator cap,
b) Slowly fill the coolant into the water jacket. Be careful not to let the water bubble.
c) After supplying coolant, tighten the water jacket cap.
d) Check the connector of the cooling water rubber hose for looseness, damage or other faults. If the sealing performance of the water pipe is poor, the cooling water may be consumed excessively.
The radiator shall be installed under the propeller. If it is installed in other positions, the forced-air cooling fan shall be added, and the fan power supplied by ECU shall be less than 100W.
3.3 The oil pump installation and oil pipe connection are shown in Figure 7 below

3.4 Operation method of engine fuel pipe exhaust
When the engine is started for the first time or the oil return pipe is not filled with oil, exhaust treatment shall be carried out before starting the engine. The specific operation methods are as follows: connect the gasoline bubble in series at the end of the oil return pipe, press it several times to exhaust the air in the pipe, so that the fuel fills the whole oil supply pipeline. At this time, remove the oil bubble and start the engine normally.
4. Preparation method of gasoline and lubricating oil
Use 95# or higher grade gasoline, Jaso FC grade or iso-l-egc grade or higher 2T engine oil (Mott 710 is recommended), and use a proportioning pot to prepare according to the engine fuel ratio of 1:40 (engine oil: gasoline). It is strictly prohibited to use vehicle 4-stroke engine oil.
The specific preparation steps are shown in Figure 8 below. 5. Inspection items before use
5.1 Check whether the connectors of the range extender and controller are connected and installed in place.
5.2 Make sure there is enough fuel in the fuel tank and the fuel pipe is installed correctly.
5.3 Spark plugs shall be checked before use. Spark plugs with excessive carbon and oil stains shall be replaced or cleaned.
5.4 Check the steering gear mechanism, check whether the steering gear rod ball head is flexible, and repair it if it is stuck.
5.5 Check the position of steering gear and throttle, and check whether the steering gear operates normally and whether the throttle position is correct.
5.6 Check the motor to see if it rotates normally.
5.7 Check the oil pipe. The oil pipe shall not directly contact with heat sources such as engines or motors. Meanwhile, excessive bending of oil pipe shall be avoided.
5.8 The ignition coil head should be pressed firmly to check whether the connector is loose.
5.9 There is no obvious bubble in the tubing.
5.10 Check the anti-loosening mark of the connecting bolt, and there shall be no dislocation.
Check whether the exhaust funnel is loose. In case of shaking, be sure to tighten the fixing bolts of the exhaust funnel.
6. Precautions for starting the engine
6.1 Before starting the engine for the first time, the air in the oil inlet pipe needs to be discharged to make the oil inlet pipe full of oil and free of bubbles
6.2 For the first use, the generator should be powered on before adding coolant. After power is on, the electrical water pump will continue to run for about 100s. If the water jacket is not fully within 100s, the generator shall be re-powered. Repeat until the air in the pipeline is drained. The pipelines can be squeezed properly until there is no obvious bubble upwelling in the water jacket; Generally, this operation is not needed during subsequent startup, just observe the liquid level of the water jacket, and add coolant when it is too low.
6.3 After each power on, the steering gear will execute the self-learning program for about 8s. Operate the remote control to make the system indicator light normally on (the remote control needs to be unlocked).
6.4 The engine must be idle for 30 seconds after starting, so that the crankshaft, piston and connecting rod can be more fully lubricated.
6.5 Multiple start failures may cause the spark plug to be flooded. In this case, replace or dry the spark plug and try to start again. 7. Function description of monitoring software 7.1 Software installation instructions
Open the software installation package with an installation package attached.

After loading, the directory selection interface will be displayed. In this interface, you can select the software storage location, and click “next” to install until it is completed.

The installation is complete.

7.2 Software operation instructions Find “GX_6. exe” on desktop and double click to enter the operation interface.
If the connection fails, check whether the serial port cable is correct, restart the software and system, and try again.
First, supply power to the system and connect the serial port harness. When using the software, do not click other buttons before opening the serial port.
Running
8.1 System controller receiver signal pulse width definition

1. Receiver transmission pulse width, 1.1ms (reserved), 1.5ms (start) and 1.9ms (shutdown), with a cycle of 20msFig. 9
2. The remote controller is equipped with a three-position switch (1.1ms is idle and not used).

1. Start or idle First, turn the three-position switch of the remote control to the “superscript” position, then turn it from the “superscript” position to the “subscript” position, pause for 2 seconds, and then turn the three-position switch of the remote control to the “bid winning” position to start the range extender (if it is not started, repeat the above methods).
2. Power generation operation After the engine is ignited and idling, the range extender does not need any manual operation, and the
the system automatically enters the power generation state.
3. Stop Running When the range extender is in operation, turn the three- position switch of the remote control from the “bid winning” position to the “subscript” position to stop, and the system will stop automatically.
8.2 To start the Halo-6000, please first confirm whether the three-position switch of the remote control is normal
8.3 Turn the three-position control switch of the remote control to the “bid winning” (as shown in Figure 9) position for operation,
Observe the bus voltage, ensure that the drone voltage is stable at 57V ± 2V
8.4 Observe the drone voltage and operate stably for about one minute to warm up the engine
8.5 In case of maneuver or gust during flight, the bus voltage will drop, which is a normal phenomenon.
If the drone voltage drops rapidly and continuously and is lower than 53V, special attention shall be paid, and it shall be immediately lowered for maintenance if necessary;
8.6 Running out of fuel will cause serious damage to Halo-6000r. Optionally, use the oil level sensor to monitor the remaining fuel to ensure that the operation is stopped before running out of fuel.
9. Stop Running
9.1 After the continuous flight, Halo-6000 needs to be cooled. Therefore, after landing, maintain idle speed for the 30s. After the engine is shut down, do not turn off the power supply and keep the water pump running for 3min.
9.2 ** After the booster runs, some parts are at high temperatures. After the booster stops running, please do not touch the booster to avoid scalding.
Gasoline is a volatile flammable and explosive liquid. At the end of the day or during long-distance transportation. The remaining fuel in the oil tank shall be drained and properly stored in the oil drum to avoid danger!**

Maintenance

1. For routine maintenance items (after each operation), the warranty will not be given if the maintenance manual is not followed
1.1 Check whether the plug of the controller circuit is in good contact, and check whether the oil pipe and water pipe are loose or leaking.
1.2 Check if the controller is damp and keep it dry.
1.3 Check the motor for dirt and moisture, remove dirt, and keep it clean and dry.
1.4 Check the air filter, remove the dirt, and keep clean to prevent foreign matters or dust from entering the engine inlet.
1.5 Check whether the fixing bolts are loose, and no loose bolts are allowed.
1.6 Check whether the steering gear rod ball is stuck. If it is stuck, oil can be applied temporarily and replaced later.
2. Regular Maintenance(Carry out regular maintenance and parts replacement according to Appendix 3)
2.1 After the Halo-6000 runs for 50h, check the carbon deposit on the spark plug. If the carbon deposit is serious, remove the carbon deposit or replace the spark plug.
2.2 Check whether the fuel pipe has aging, hardening, and cracks. If so, be sure to replace it to avoid potential safety hazards.
2.3 Check the motor for dirt, remove sundries and keep it clean and dry.
3. Maintenance Before Long-Term Shutdown
it is necessary to carry out comprehensive maintenance for the Halo-6000 before storage if the system is out of service and will not be used for a long time. This can avoid some parts’ failure caused by the long-term shutdown and maintain the system performance.
Caution: The manufacturer shall not be responsible for the system damage caused by untimely maintenance.

Faults and Maintenance Methods

1 Common fault and maintenance methods are shown in Table 3 below

No.| Description| Check Item| Cause of Failure| Maintenance Method
---|---|---|---|---
1| System
cannot be
started.| Air filter| Under the heavy working condition| Clean the filter with fuel
2| Oil Supply
System| Wrong lubricating oil model| Use the original lubricating oil
3| Tubing bubble or no oil| Press the oil bubble several times to absorb oil
4| Wire Harness| Poor contact of the connector| Check the circuit and connect it again
5| Spark Plug| yellow or weak light| change the spark plug
6| Reed valve
failure| Damaged reed valve diaphragm| Replace reed valve
7| Speed
fluctuation,
voltage
fluctuation,
smoke| Spark Plug| The spark plug is loose| Tighten the spark plug
8| Fuel| Water in fuel or fuel quality
Poor quality, fuel storage more than 2 months| Change the fuel
9| Lubricating Oil| Poor quality of lubricating oil| Change to the original lubricating oil
10| Oil Way| The oil supply is not smooth, there are bubbles in the yellow oil pipe, or the oil filter in the oil tank has not been replaced for more than 50 hours.| Drain the air from the oil inlet pipe. Open the filler cap to make the top of the fuel filter close to the top of the oil level. Power on and drain the air. In some cases, tilt the fuel tank properly.
11| | Control Circuit| The control circuit or sensor is damaged.| Contact the manufacturer.
---|---|---|---|---
12| Insufficient Power Output| | It’s time for maintenance.| Contact the manufacturer.
13| Air Filter| The air filter element is too dirty.| Clean the filter element with gasoline.
14| Spark Plug| Remove the spark plug and press it in the red coil. Contact the ignition head of the spark plug with the engine block, and turn the starting head. If the ignition light is yellow or weak, replace the spark plug.|
15| The voltage drops rapidly after take-off| Battery| Low battery voltage| Before takeoff, turn the three-position-switch to “run” and wait for about 1 minute.
16| miscellaneous| | Mechanical parts are damaged.| Contact the manufacturer.

Caution: This system does not support low power consumption. When the system is not in use, please remove the battery or set a switch to cut off the electrical connection between the battery and the system. The system does not support hotplugs. The controller will be damaged by a hot plug-in case of use and maintenance.
2. Controller Indicator Definition
2.1 Red indicator light: The light is not on in a normal state, and is always on in case of system failure
The fault list of the red fault indicator is shown in Table 4 below

Failure

|

Fault light mode

---|---
1. Sensor Failure| 1. throttle position| ——| –| | | |
2. liquid level sensor| ——| –| –| | |
3. water temperature sensor| ——| –| –| –| |
4. motor temperature| ——| –| –| –| –|
5. atmospheric pressure sensor| ——| –| –| –| –| –
2. ignition failure|

——

|

——

|

–

| | |
---|---|---|---|---|---|---
3. speed failure| ——| | | | |
4. voltage failure| –| | | | |
5. power failure| on| | | | |

Note”—-” represents that the red fault light flashes slowly by 0.5s every time”-” represents that the red fault light flashes rapidly by 0.2s every time.
2.2 Green indicator light: It is a running indicator light, and its working state is divided into fast flash (100ms) slow flash (500ms) constant light.
Flash: system initialization process;
Slow flash: after initialization, wait for receiving the start command;
Light on: after receiving the start command, you can start the engine through the starter.

Others

Transportation and Storage
Handle it lightly during loading and unloading. During transportation, it is strictly forbidden to bump and scratch to prevent rain. The booster shall be stored in a clean, ventilated, moisture-proof, and moisture-proof place. In idle or for a long-time storage

1. Please put the booster in a clean, ventilated, moisture-proof and moisture-proof place.
2. Disconnect the power cord of the controller from the battery. 3. The motor rotor needs to be covered to prevent dust and foreign objects from entering.

Unpacking Instructions

Note: operate with care. When unpacking, the extender shall be placed in the upright direction according to the label of the outer package. After unpacking, check the packing list and the items (including certificate, operation and maintenance manual, products, etc.) according to the packing list. Carefully check whether it is consistent with the real object.

Appendix 1List of Accessories

No.

| Article| Quantity|

Remark

---|---|---|---
1| Operation and maintenance manual of Halo-6000| 1| Standard Configuration
2| Product maintenance of Halo-6000 EFI| 1| Standard Configuration
3| Halo-6000 EFI Generator| 1| Standard Configuration
4| Oil pump| 1| Standard Configuration
5| Water pump| 1| Standard Configuration
6| Water jacket| 1| Standard Configuration
7| Water jacket cover| 1| Standard Configuration
8| T-junction| 1| Standard Configuration
9| Clamp(internal diameter φ10~φ16)| 4| Standard Configuration
10| M13 clamp (for pipe with an internal diameter of φ8)| 8| Standard Configuration
11| Motor controller| 1| Standard Configuration
12| System controller| 1| Standard Configuration
13| PMU(for water&fuel pump)| 1| Standard Configuration
14| 12V output wire of PMU(female connector)| 1| Standard Configuration
15| Input wire of PMU(female connector)| 1| Standard Configuration
16| Water pipe Ø 12 outer diameter Ø16| 1m| Standard Configuration
17| Water pipe Ø 8 outer diameter Ø 12| 3m| Standard Configuration
18| Water pipe Ø 10* outer diameter Ø 14| 1.5m| Standard Configuration
19| Liquid level sensor| 1| Standard Configuration
20| 2*7S 12000 batteries| 1| Standard Configuration
21| Radiator| 2| Standard Configuration
22| Fuel tank| 1| Standard Configuration
23| Fuel Mixer| 1| Standard Configuration

Appendix 2Maintenance List

Part Name| Unit Consumption| Before Start-Up| 25h| 50h| 100h| 150h| 200h| 300h
---|---|---|---|---|---|---|---|---
Air Filter Assembly| 1| Check| Check/ Replace| Replace| | | |
Oil Pump Assembly| 1| | | | | | | Replace
Steering Gear Assembly| 1| Check| | Check/ Replace| Replace| | |
Spark Plug| 1| Check| Check| Check/ Replace| Replace| | |
Reed Valve
Assembly| 1| | | | Check/Replace| Replace| |
Right Hand Connecting Rod Head Of Steering Gear|

1

| | | | Check/ Replace| | |
Position Sensor| ****

1

| | | | | Check/ Replace| | Replace
Oil Inlet Pipe| 1| | | | Check/ Replace| | |
Damping Sleeve
Assembly| 1| | | | | | | Replace
Cylinder Block| 2| | | | | | | Replace
Exhaust Shim| 2| | | | | | | Replace
Cylinder Block Shim| 2| | | | | | | Replace
Piston Assembly| 2| | | | Replace| | |
Piston Ring| 2| | | | Replace| | |
Piston Pin| 2| | | | Replace| | |
Retaining Ring For Piston Pin| 2| | | | Replace| | |
---|---|---|---|---|---|---|---|---
Assembly Of Crankshaft And Connecting Rod| 1| | | | | Replace| |
Needle Bearing For Connecting Rod Small End| 2| | | | Replace| | |
Fuel Injector| 1| | | | | | | Replace
Upper Box| 1| | | | | | | Replace
Lower Box| 1| | | | | | | Replace
Deep Groove Ball Bearing| 1| | | | | | | Replace

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References

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