Sport Speed Control

SPORT SPEED C ONTROL THIS TWO-PART FEATURE will describe build test use electronic Sport Speed Control SSC motor controller intended Electric installations using six 16 cells sustained motor currents up 35 amps short-term currents up 50 amps SSC uses classic analog circuitryit newer digital circuit types uses readily available parts available everyone Radio Shack Digi-Key New Creations RIC hobby shop requires no special programmed components SSC parts leaded devices using standard circuitassembly techniques much easier modelers newer smaller surface-mount techniques SMT Digital Multi Meter DMM some simple test accessories combined detailed checkout procedures will help assure top-notch performance Although SSC larger heavier parts-intensive newest commereially made digital speed controllers actually about same size weight speed controls just few years ago project recommended modelers have some electronic soldering assembly experience Sport Speed Control measures about 8 x 14 x 21 inches weighs about 22 ounces consists two interconnected subassembliesthe Signal Board Power Plate stacked foam separator held together heat-shrink wrap SSC easily mounted Velcro strip material SSC features smooth nonlinear voltage transfer characteristic morenearly linear power transfer optional delayed brake optional Battery Eliminator Circuit BEC 76 Model Aviation b Kopski Second significant assembly level Signal Board layered parts place Make sure Use Assembly Sequence double-check Fully assembled Signal BQard Individual wires will go Power Plate cable receiver use up 12 cells also features easy minimally interactive -two screw tuneup match stick throw transmitter SSC glitch free upon motor/receiver power-up provided throttle stick off position efficient high rate design An unusual feature optional adjustable motor cutoff prevent deep-discharging motor battery BEC controller needs motor cutoff circuit permit continuing safe operation radio can used whether use BEC feature number cells over design range believed feature can actually extend motor battery cycle life Signal Board uses preprinted hole board no PCB layout etching needed Most components mounted board Power Plate piece hobby shop aluminum sheet mounted power MOSFETs motor diode regulator few other parts heavy battery motor wires also part subassembly subassemblies individually testable before being interconnected Five light-gauge flexible wires used interconnect Signal Board Power Plate Note component parts numbers grouped different number series parts lOs specific basic control circuit operation Components numbered 40s associated motor power drive Thus lOs 40s necessary optional parts Components numbered SOs make up motor cutoff circuitry circuit permits safe BEC operation and/or otherwise precludes deep discharge motor pack during motor pack rundown Its operation precisely adjustable cover six 16 cells optional using BEC want deep-discharge protection case simply eliminate 50s pans jumper IC2a pins 4 5 replace R56 wire jumper Components numbered 60s associated optional brake function generally useful folding props wish can simply omit series parts replace C61 wire jumper Unless pressing need economy simplicity weight savings build complete SSC circuit start its lot harder add optional stuff later Besides can always individually disable two circuit functions during tuneup built-in can readjust SSC invoke operation later desired Everything Sport Speed Control has designed top performance readily available parts have built several SSCs three have built others function described Parts substitutions value changes discouraged case responsibilityokay Electrostatic Discharge ESD static spark heard felt can destroy electronic components other kind circuit assembly often work grounded piece aluminum foil use grounded soldering iron minimize potential problem SIGNAL BOARD ASSEMBLY Please follow well-practiced Assembly Sequence First Wires Assembly Detail drawings photos making sure right part goes right location right time especially important because some parts located right over others fixing mistake can unpleasant Cut holeboard size make sure PC land patterns correctcount holes important smooth edges round corners slightly Cut conductors Xs enlarge selected holes #55 drill shown Use pin vise hold drill bit drill copper side good control over task Polish copper lands install 12 bare wires shown Check out carefully once ICs installed wires disappear sight Begin installing parts per Assembly Sequence sure get IC orientation correct well polarized parts like tantalum capacitors diodes Check recheck THEORY OF OPERATION Refer Schematic Diagram internal SSC signal control circuitry powered 1C41 low-overhead five-volt regulator located Power Plate assembly powered motor battery same five volts also serves optional BEC supply power receiver servos Two other important internal operating voltages 32-volt tp4 line 8- 9-volt tp3 line Both voltages derived five volts Pefitaps busiest component Signal Board CMOS timer 1C3 1C3 configured astable asymmetric clock running about 22 kHz high rate pall SSC IC3 conjunction C7 C8 Dl D2 forms charge-pump producing nine-volt tp3 voltage MOSFET gate drive derived higher voltage assures very low FET ON resistance greater operational efficiency 1C3 two external resistors also produce internal 32-volt tp4 power line buffered IC lb DC value rests exactly top edge asymmetric sawtooth timing waveform appearing 1C3 pins 2 6 planned relationship allows easy tuneup SSC adjustments deliberately incorporated asymmetly sawtooth waveform responsible nonlinear response SSC linearizes stick thmw/motor power input relationship Gone limp feeling low end touchiness high end thruttle stick thiow signal input circuitry made up Qi ICla associated passive components circuitry accepts incoming positive-going throttle pulse signals produces varying DC level representative throttle stick position amplifies level shifts further filters voltage use below SSC properly adjusted voltage varies just above tp4 voltage below about half value over range throttle stick throw voltage range encompasses peak-to-peak sawtooth voltage swing present 1C3 pins 2 & 6 Comparator IC2b noninverting input pin 7 driven 1C3 sawtooth waveform inverting input pin 6 receives stick-controlled DC voltage just discussed Whenever DC voltage pin 6 lower instantaneous sawtooth waveform pin 7 IC2b output pin 1 goes high does 22 kHz clock rate should clear resulting output pulse width can anywhere between zero 100% duty cycle throttle stick moved full OFF full ON fixed rate variable duty cycle waveform what ultimately varies motor input voltagevia motor drive FETS Q41 thru Q43 Q2 Q3 buffer IC2b pin 1 waveform assure high quality high amplitude drive signal FET gates maximum efficiency minimum FBI heating same time maintaining controlled edge speeds minimize radio interference motor cutoff circuitry consists hystersis-connected comparator IC2a associated components circuitry monitors raw motor pack voltage compares reference level derived five volt regulator pack voltage reaches pre-determined level set R52 IC2a retards DC signal drive comparator IC2b via DS 1 thereby reducing drive motor actual use motor power retardation occurs gradual pulsing manner clearly advises pilot its soon time land brake circuit consists IC2c IC2d associated components brake activates two seconds following OFF throttle command delay allows some energy associated rotating machinery burn offmaking life brake P-FET Q61 much easier IC2c inputs fixed voltage tp4 derivative stick controlled DC level off ICla pin 1 During SSC adjustment low throttle trimmer R6 can set either avoid assure brake activation fully-down stick position either case additional stick deflection needed initiate motor power-up no power-ON / brake-ON conflict example brake adjusted ON lowest throttle stick position brake will go OFF some advance stick further advance stick will allow power input motor An on-board brake lite D62 provides visual indication proper R6 adjustment respect brake function Thus brake adjustment easily done ground assurance proper operation air September 1999 77 Item 2 3 SIGNAL BOARD ASSEMBLY SEQUENCE Description Cut board outline notch sand edges smooth Cut conductors 10 X locations Enlarge 13 open square holes #55 bit polish copper lands 4 Install 12 #24 wires flat board solder solid dots 5 Set place 3 ICs trim package flash easy end-to-end fit A/R 6 Install R14 36K & R16 10K solder making sure ICs flush board 7 Install R12 18K D51 1N4148 locate diode high resistors solder 8 Install C9 & C62 both 100 pF solder 9 Install R61 470K insulated wire 1C2 pins 1014 & bare wire 1C2 pin 8 solder 10 Install Rl 127K & R13 20K solder 11 Install C2 22 uF & C7 47 uF solder 12 Install D62 LED note flat cathode end solder cathode lead 13 Install D61 1N4148 R63 1K noting bottom R61 wire extends over D62 anode under board solder 14 Solder remaining IC pin locations 15 This completes stacked part assembly reaffirm work before proceeding 16 Install Qi 2N3904 Q2 2N3904 solder 17 Install Q3 2N3906 & associated wire solder 18 Install C51 01 uF solder 19 Install R6 100 Ohm pot & R7 68K solder 20 Install R9 lOOK pot solder 21 Install R52 50K pot solder 22 Install D63 1N5242 R62 10K solder 23 Install RIS 51K & R17 120K solder 24 Install R54 51K & R57 10K solder 25 Install R55 56K & R56 56K solder 26 Install Dl & D2 both SDIO3ACT solder 27 Install R53 12K & associated wire Dress top resistor wire close body solder 28 Install C3 & C4 both 47 uF solder 29 Install C61 22 uF Cl 047 uF solder 30 Install RI & R2 both 47K solder 31 Install R3 47K R4 47K solder 32 Install R8 22K dressing top lead under R6 body solder 33 Install R5 100 Ohms & RiO 68K shaping top lead latter A/R solder 34 Install CS 1000 pF associated wire solder 35 Install C6 22 uF C8 47 uF solder 36 Install R18 10K & R51 15K solder 37 Install remaining bare wire jumpers solder appropriate 38 Install SSC-receiver cable piece aileron extension strain relief loop-thru solder 39 Install five flexible six-inch-long colored wires shown solder 40 Trim leads bottom board 41 Lightly block-sand bottom board 180-220 grit 42 Solvent-clean bottom board 43 Inspect assembly touch-up solder needed resand reclean reinspect A/R 44 Strip tin five flying leads preparation test Keep components low board unless noted allow some wire lead show between board part careful damage parts bending leads sharply excessively near component body sure solder location until component leads location Note can nip off component leads following solder statement Assembly Sequence Some wire jumpers shaped loops either clear some component serve test point meter clip sure install loops depicted Use small sewing needle pin vise probe holes already have wires its difficult get last wire pin will easily smoothly push clear path last component lead also helps cut component lead angle help insertion crowded hole sure soldering results bright shining solder cone completely surrounding leads associated PC land no cold joints gaps please encourage pause Assembly Sequence step 15 verify work point before continuing components wires have soldered place clean conductor side acid brush solvent such acetone Hold assembly must brush underneath allowing solvent drip down away assembly Clean until traces solder flux have disappeared blot dry board gently blow dry hair dryer Inspect finished board lens now can most-easily see questionable joints land-to-land solder shorts tiny whiskers may jump adjacent conductors Nip off leads already cut close gently blocksand 180- 220-grit bottom board assembly leveling operation important no wire projections reach thru foam separator contact Power Plate assembly two subassemblies stacked Reclean solvent needed Dont reluctant reinspect work rework it often takes two three trips around circuit get everything just right Make absolutely sure leads component top side board properly dressed touch other SIGNAL BOARD CHECKOUT AND PRELIMINARY TUNEUP following test steps check operation Signal Board Signal Board Power Plate assembly combined will likely have immediate safe proper operation SSC Items will need perform testing include DMM fresh nine-volt alkaline battery matching battery snap connector small test clips leads 300-ohm resistor test leads equipped micro mini test clips use DMM cutoff portion aileron extension other half became SSC-receiver cable will also need transmitter operating receiver calibrated servo driver such Pulse Mini Lab June 1998 MA Portions test sequence unidirectional Please perform tests methodically order given expected result obtained troubleshoot assembly fix problem before proceeding Place Signal Board component-side up clean nonconducting surface Hold five leadout wires safely spread apart tape Strip tin wire ends aileron cable cutoff solder 300-ohm resistor positive lead Connect accessory cable SSC-receiver cable tape stuff safely work surface Set R6 low R9 high pots about midrange R52 fully counterclockwise will quietly chck end range Set DMM ohms function selecting range accordingly measure Receiver cable negative positive about 23k ohms Receiver cable negative signal open very high ohms Receiver cable positive signal open Receiver cable positive red positive leadout wire short small fraction ohm Receiver cable negative black negative leadout wire short Receiver cable negative tpl test loop board short Unless specifically stated otherwise tests follow DMM negative test lead connected tpl positive DMM test lead placed instructed Meter positive white leadout Q5 drive open 78 Model Aviation r positive yellow leadout MotBatt about 17k ohms Meter positive green leadout FET drive open Change 11MM read DC Volts using 20- 30- volt scale connect DMM positive red positive leadout Connect negative nine-volt battery lead receiver cable negative Connect positive battery lead input end 300-ohm test resistor Snap mating connector onto ninevolt battery Immediately observe about five volts DMM Write down exact value referred below reference voltage brake lite BL should above okay temporarily connect DMM negative positive leads across 300-ohm resistor Observe nominal fourvolt reading test verifies nominal l3mA current drain Signal Board Reconnect DMM negative lead tpl Connect positive DMM lead tp4 observe voltage about 064 x reference voltage usually about 31 33 volts verifies important circuit internal bias level readings assume fresh battery thai has very close nine-volt terminal voltage Continued page 84 -4-V+-V 0i H -4 -4 + x II t I- --44x It 44-1 TI -41-t WVC* V+-4-4-4-4-4-4-4-4-4-4-4-4 1T4-T-V-V*t -V-4 n -11 4-T1T1 -t-f I-t-4V-V-VVV x -V-VT **VV -4tI-V tVV-VI-V tili G / x EEl -4x-4--4-4-4-4 --4in TOP VIEW BOTTOM VIEW NOTES X UCTOR CUT OPEN SO DRILL HOLE SOLID DOTS ER NOW DASHED WIRE R ICs SOLID WIRE IDE OF ICs ELECTRONIC SPORT SPEED CONTROL -SIGNAL BOARD FIRST WIRES September 1999 79 First critical assembly level Signal Board Board outline Signal Board methodical checkouttypical several steps wire locations enlarged holes must right help assure proper operation mated Power Plate Sport Speed Control its shrink-wrap cover about size weight controls few years ago MOO BAIT 0ca 150242 P51 15K 1p2~ P54J P52RO71K 50K2 1C2 ROR 58K CSI 85301 12K s 54145 RR 100 Cl 047 02 22 P1 47KP447K 01 3004 52 4-74 02\ P5100 P8100K P768KRIO 288K 2 V P11 27K Cl LM304 P822K Cs 47 CA 47 78 P12 18K 081 1N414Rblake lit PSILEO 062 470KP631K -CR122o 1C2cP8210K 14111024 VCR2 1C2LM2381L 1007 00USD BOX POWER PLATE POSY ELECTRONIC SPORT SPEED CONTROL SCHEMATIC DIAGRAM TO MOT ow 5V red t 2a t 2b -GND_____ black R57 1K -1R55 56KF TO GATES green D63R155iK R17120K IC 347K CS iCOOp C5101- R54 115k Qi 56K D62 LED TOQ5R6210K R631KC6122D614146 white- SIG GND 5 - Ri 47K 5 32 tp4 3904 R5 100 R4 47K G t5 R6 100 Q2R185R5250KR9100KR768K 390410K \ tp3NOTES DASHED WIRES T WIRES OPEN SQUARES DRILL HOLES PC LANDS ALL ON-BOARD WIRES ARE BARE #24 SOLID EXCEPT 1C2 PIN 10-14 #26 FLEXIBLE INSULATED CABLE TIE DOWN WIRE D INSULATED FIVE INDIVIDUAL LEAD OUT WIRES ARE #26 COLORED INSULATED ELECTRONIC SPORT SPEED CONTROL SIGNAL BOARD ASSEMBLY DETAIL 80 Model Aviation 0 gno S5I -I MOTOP 220K 041 H 061 PP 8040 P3 47K 0414243 IPL 3700 black MOT SPIT F4 4-40x1/2 socket cops sell $435/i 00 gllffl1ffl111 oiioy steel $665/i 00 stoinless S750/50 aluminum fair prices sensible quontities fos teners need model building coil write fox free catalog Micro Fasteners 110 Hillcrest Rood Flemington NJ 08822 e-mail microf@blastnetInternet 800-892-6917 908-806-4050 fax 908-788-2607 http//microfastenerstnm Sport Speed/Kopski Continued page 79 Measure tp5 1C3 read about 8 x reference voltage Use short bare wire held positive meter test lead clip probe IC pin directly carefully verifies charge pump waveform asymmetry Move DMM positive lead tp3 observe about 8-9 volts verifies charge pump voltage output Disconnect temporary test cable SSC-receiver lead ninevolt battery leads Take care let battery leads short together Connect DMM positive lead green leadout wire FET drive Connect SSC receiver cable servo driver such Pulse Mini-Lab powered receiver throttle-channel output Power receiver servo driver supply throttle command about midrange Note Signal Board temporarily being powered receiver servo driver BL should out Observe DMM reading usually several volts Vary throttle command observe DMM reading vary several volts BL may may come ON low throttle settings using transmitter/receiver option keep transmitter antenna collapsed two feet away Signal Board stuff connected Set throttle signal full OFF Adjust low trim pot R6 until BL just comes brake function response delayed work slowly give time respond Advance throttle slowly observe BL go out Continue slowly advancing throttle observe DMM reading begin rise Advance throttle full ON observe DMM reading several volts Vary high pot R9 over its range note highest DMM readingusually about nine volts Move throttle stick two clicks down full up adjust R9 until level just begins drop highest value Return throttle full OFF readjust R6 until BL just comes Repeat cycle iteration should require two cycles obtain desired result confirms adjustability motor voltage control over range tuneup just described works radio Ive tried covers usual RC pulse signal range 11 12 mSec low throttle 18 19 mSec high throttle frame rates 40 50 Hz However have programmable transmitter possible throttle signal range may have set sufficiently outside normal parameters adjustments will work youre sure throttle stick programming please confirm using servo thottle location verify normal servo motion measure adjust throttle stick action device such Pulse Mini Lab Turn off receiver servo driver power carefully cut tp2a / tp2b test loop middle jumper wire Cutting jumper activates cutoff circuit Trim two resulting wires about /y /ls inch stands vertically board Tp2b can accessed future allow setting cutoff voltage specific battery packs Connect DMM positive lead red leadout wire reapply receiver servo driver power signal Note exact DMM readingthis nominal 48-volt supply value Calculate half DMM readingthis number will used below Move DMM positive lead tp2b Set throttle full OFF BL should come ON DMM should read zero volts Connect nine-volt battery negative lead black negative leadout positive battery lead yellow Mot V leadout being very careful make polarity mistake DMM reading should rise little four volts Advance throttle just past BL goes OFF Slowly adjust R52 CW until DMM reading drops about 27 volts Continue turning R52 slowly meter reading will continue drop slowly some point around half value determined above little less BL should come has nothing brake circuit operation see below Back up R52 note requires about 3/4 turn BL go back off DMM should now read about 200 millivolts higher half value verifies motor cutoff circuit hystersis Shut off power disconnect test equipment Reset R52 fully counterclockwise completes Signal Board preliminary checkout motor cutoff function does normally activate BL actual use just did during tuneup Motor cutoff operation takes form pulsing motor voltage too fast slowresponding [delayed] brake circuit follow actual application BL will operate adjusted OFF throttle variation technique just used verify proper motor cutoff circuit operation will used later set circuit up chosen number motor cells month Completion Sport Speed Control Bob Kopski 25 West End Dr Lansdole PA 19446 84 Model Aviation anufacturing & B ROD Distributing Co. Inc largest supplier control-line airplanes ADJUSTABLE WEIGHT Box Adjustable Weight Bones answer question ot change amount weight utter airptane built Flyers hnOw changing amount weight can dramatically attect airplanes trertormance BH-775 1/4 no size weights159 also available Catalogue 1*9 Send $400 Brodaks 100 Park Avenue iebsels PA 15320 Phone 724-966-2726 724-966-0670 9I yuui titn home center hobby shop Complete pe e ,.5,y c or. roe sc list oniy $995 * $500 S/H send check money Order name address Flight Table c/a JH Products PC Boo 1975 Burtenon TX 7t097-1975 Adccinsaesrarirssncesrrneas a0e3Seees celveroOsnsycrdrrscl n5OSderrr2wcrrgaars erramorrssrsrcflnroicn@fashnrr WHY ARE YOU PAYING MORE FOR LESS Compare Tee-Sara other similar-looking products cost arid customers about 30% No140 Mini T-Sar Sandpaper 4V2$375 No 141 Tee Sar 11 in$350 No 142 Tee Sar 22 in$525 Ottror mini tonic neal/aSIa Write cad cata/oS Applied Design Corp zJI@ 3101 375-4120 Fax 310 378-1590 P0 Box 3384 Torrance CA 00510

SPORT SPEED C ONTROL THIS TWO-PART FEATURE will describe build test use electronic Sport Speed Control SSC motor controller intended Electric installations using six 16 cells sustained motor currents up 35 amps short-term currents up 50 amps SSC uses classic analog circuitryit newer digital circuit types uses readily available parts available everyone Radio Shack Digi-Key New Creations RIC hobby shop requires no special programmed components SSC parts leaded devices using standard circuitassembly techniques much easier modelers newer smaller surface-mount techniques SMT Digital Multi Meter DMM some simple test accessories combined detailed checkout procedures will help assure top-notch performance Although SSC larger heavier parts-intensive newest commereially made digital speed controllers actually about same size weight speed controls just few years ago project recommended modelers have some electronic soldering assembly experience Sport Speed Control measures about 8 x 14 x 21 inches weighs about 22 ounces consists two interconnected subassembliesthe Signal Board Power Plate stacked foam separator held together heat-shrink wrap SSC easily mounted Velcro strip material SSC features smooth nonlinear voltage transfer characteristic morenearly linear power transfer optional delayed brake optional Battery Eliminator Circuit BEC 76 Model Aviation b Kopski Second significant assembly level Signal Board layered parts place Make sure Use Assembly Sequence double-check Fully assembled Signal BQard Individual wires will go Power Plate cable receiver use up 12 cells also features easy minimally interactive -two screw tuneup match stick throw transmitter SSC glitch free upon motor/receiver power-up provided throttle stick off position efficient high rate design An unusual feature optional adjustable motor cutoff prevent deep-discharging motor battery BEC controller needs motor cutoff circuit permit continuing safe operation radio can used whether use BEC feature number cells over design range believed feature can actually extend motor battery cycle life Signal Board uses preprinted hole board no PCB layout etching needed Most components mounted board Power Plate piece hobby shop aluminum sheet mounted power MOSFETs motor diode regulator few other parts heavy battery motor wires also part subassembly subassemblies individually testable before being interconnected Five light-gauge flexible wires used interconnect Signal Board Power Plate Note component parts numbers grouped different number series parts lOs specific basic control circuit operation Components numbered 40s associated motor power drive Thus lOs 40s necessary optional parts Components numbered SOs make up motor cutoff circuitry circuit permits safe BEC operation and/or otherwise precludes deep discharge motor pack during motor pack rundown Its operation precisely adjustable cover six 16 cells optional using BEC want deep-discharge protection case simply eliminate 50s pans jumper IC2a pins 4 5 replace R56 wire jumper Components numbered 60s associated optional brake function generally useful folding props wish can simply omit series parts replace C61 wire jumper Unless pressing need economy simplicity weight savings build complete SSC circuit start its lot harder add optional stuff later Besides can always individually disable two circuit functions during tuneup built-in can readjust SSC invoke operation later desired Everything Sport Speed Control has designed top performance readily available parts have built several SSCs three have built others function described Parts substitutions value changes discouraged case responsibilityokay Electrostatic Discharge ESD static spark heard felt can destroy electronic components other kind circuit assembly often work grounded piece aluminum foil use grounded soldering iron minimize potential problem SIGNAL BOARD ASSEMBLY Please follow well-practiced Assembly Sequence First Wires Assembly Detail drawings photos making sure right part goes right location right time especially important because some parts located right over others fixing mistake can unpleasant Cut holeboard size make sure PC land patterns correctcount holes important smooth edges round corners slightly Cut conductors Xs enlarge selected holes #55 drill shown Use pin vise hold drill bit drill copper side good control over task Polish copper lands install 12 bare wires shown Check out carefully once ICs installed wires disappear sight Begin installing parts per Assembly Sequence sure get IC orientation correct well polarized parts like tantalum capacitors diodes Check recheck THEORY OF OPERATION Refer Schematic Diagram internal SSC signal control circuitry powered 1C41 low-overhead five-volt regulator located Power Plate assembly powered motor battery same five volts also serves optional BEC supply power receiver servos Two other important internal operating voltages 32-volt tp4 line 8- 9-volt tp3 line Both voltages derived five volts Pefitaps busiest component Signal Board CMOS timer 1C3 1C3 configured astable asymmetric clock running about 22 kHz high rate pall SSC IC3 conjunction C7 C8 Dl D2 forms charge-pump producing nine-volt tp3 voltage MOSFET gate drive derived higher voltage assures very low FET ON resistance greater operational efficiency 1C3 two external resistors also produce internal 32-volt tp4 power line buffered IC lb DC value rests exactly top edge asymmetric sawtooth timing waveform appearing 1C3 pins 2 6 planned relationship allows easy tuneup SSC adjustments deliberately incorporated asymmetly sawtooth waveform responsible nonlinear response SSC linearizes stick thmw/motor power input relationship Gone limp feeling low end touchiness high end thruttle stick thiow signal input circuitry made up Qi ICla associated passive components circuitry accepts incoming positive-going throttle pulse signals produces varying DC level representative throttle stick position amplifies level shifts further filters voltage use below SSC properly adjusted voltage varies just above tp4 voltage below about half value over range throttle stick throw voltage range encompasses peak-to-peak sawtooth voltage swing present 1C3 pins 2 & 6 Comparator IC2b noninverting input pin 7 driven 1C3 sawtooth waveform inverting input pin 6 receives stick-controlled DC voltage just discussed Whenever DC voltage pin 6 lower instantaneous sawtooth waveform pin 7 IC2b output pin 1 goes high does 22 kHz clock rate should clear resulting output pulse width can anywhere between zero 100% duty cycle throttle stick moved full OFF full ON fixed rate variable duty cycle waveform what ultimately varies motor input voltagevia motor drive FETS Q41 thru Q43 Q2 Q3 buffer IC2b pin 1 waveform assure high quality high amplitude drive signal FET gates maximum efficiency minimum FBI heating same time maintaining controlled edge speeds minimize radio interference motor cutoff circuitry consists hystersis-connected comparator IC2a associated components circuitry monitors raw motor pack voltage compares reference level derived five volt regulator pack voltage reaches pre-determined level set R52 IC2a retards DC signal drive comparator IC2b via DS 1 thereby reducing drive motor actual use motor power retardation occurs gradual pulsing manner clearly advises pilot its soon time land brake circuit consists IC2c IC2d associated components brake activates two seconds following OFF throttle command delay allows some energy associated rotating machinery burn offmaking life brake P-FET Q61 much easier IC2c inputs fixed voltage tp4 derivative stick controlled DC level off ICla pin 1 During SSC adjustment low throttle trimmer R6 can set either avoid assure brake activation fully-down stick position either case additional stick deflection needed initiate motor power-up no power-ON / brake-ON conflict example brake adjusted ON lowest throttle stick position brake will go OFF some advance stick further advance stick will allow power input motor An on-board brake lite D62 provides visual indication proper R6 adjustment respect brake function Thus brake adjustment easily done ground assurance proper operation air September 1999 77 Item 2 3 SIGNAL BOARD ASSEMBLY SEQUENCE Description Cut board outline notch sand edges smooth Cut conductors 10 X locations Enlarge 13 open square holes #55 bit polish copper lands 4 Install 12 #24 wires flat board solder solid dots 5 Set place 3 ICs trim package flash easy end-to-end fit A/R 6 Install R14 36K & R16 10K solder making sure ICs flush board 7 Install R12 18K D51 1N4148 locate diode high resistors solder 8 Install C9 & C62 both 100 pF solder 9 Install R61 470K insulated wire 1C2 pins 1014 & bare wire 1C2 pin 8 solder 10 Install Rl 127K & R13 20K solder 11 Install C2 22 uF & C7 47 uF solder 12 Install D62 LED note flat cathode end solder cathode lead 13 Install D61 1N4148 R63 1K noting bottom R61 wire extends over D62 anode under board solder 14 Solder remaining IC pin locations 15 This completes stacked part assembly reaffirm work before proceeding 16 Install Qi 2N3904 Q2 2N3904 solder 17 Install Q3 2N3906 & associated wire solder 18 Install C51 01 uF solder 19 Install R6 100 Ohm pot & R7 68K solder 20 Install R9 lOOK pot solder 21 Install R52 50K pot solder 22 Install D63 1N5242 R62 10K solder 23 Install RIS 51K & R17 120K solder 24 Install R54 51K & R57 10K solder 25 Install R55 56K & R56 56K solder 26 Install Dl & D2 both SDIO3ACT solder 27 Install R53 12K & associated wire Dress top resistor wire close body solder 28 Install C3 & C4 both 47 uF solder 29 Install C61 22 uF Cl 047 uF solder 30 Install RI & R2 both 47K solder 31 Install R3 47K R4 47K solder 32 Install R8 22K dressing top lead under R6 body solder 33 Install R5 100 Ohms & RiO 68K shaping top lead latter A/R solder 34 Install CS 1000 pF associated wire solder 35 Install C6 22 uF C8 47 uF solder 36 Install R18 10K & R51 15K solder 37 Install remaining bare wire jumpers solder appropriate 38 Install SSC-receiver cable piece aileron extension strain relief loop-thru solder 39 Install five flexible six-inch-long colored wires shown solder 40 Trim leads bottom board 41 Lightly block-sand bottom board 180-220 grit 42 Solvent-clean bottom board 43 Inspect assembly touch-up solder needed resand reclean reinspect A/R 44 Strip tin five flying leads preparation test Keep components low board unless noted allow some wire lead show between board part careful damage parts bending leads sharply excessively near component body sure solder location until component leads location Note can nip off component leads following solder statement Assembly Sequence Some wire jumpers shaped loops either clear some component serve test point meter clip sure install loops depicted Use small sewing needle pin vise probe holes already have wires its difficult get last wire pin will easily smoothly push clear path last component lead also helps cut component lead angle help insertion crowded hole sure soldering results bright shining solder cone completely surrounding leads associated PC land no cold joints gaps please encourage pause Assembly Sequence step 15 verify work point before continuing components wires have soldered place clean conductor side acid brush solvent such acetone Hold assembly must brush underneath allowing solvent drip down away assembly Clean until traces solder flux have disappeared blot dry board gently blow dry hair dryer Inspect finished board lens now can most-easily see questionable joints land-to-land solder shorts tiny whiskers may jump adjacent conductors Nip off leads already cut close gently blocksand 180- 220-grit bottom board assembly leveling operation important no wire projections reach thru foam separator contact Power Plate assembly two subassemblies stacked Reclean solvent needed Dont reluctant reinspect work rework it often takes two three trips around circuit get everything just right Make absolutely sure leads component top side board properly dressed touch other SIGNAL BOARD CHECKOUT AND PRELIMINARY TUNEUP following test steps check operation Signal Board Signal Board Power Plate assembly combined will likely have immediate safe proper operation SSC Items will need perform testing include DMM fresh nine-volt alkaline battery matching battery snap connector small test clips leads 300-ohm resistor test leads equipped micro mini test clips use DMM cutoff portion aileron extension other half became SSC-receiver cable will also need transmitter operating receiver calibrated servo driver such Pulse Mini Lab June 1998 MA Portions test sequence unidirectional Please perform tests methodically order given expected result obtained troubleshoot assembly fix problem before proceeding Place Signal Board component-side up clean nonconducting surface Hold five leadout wires safely spread apart tape Strip tin wire ends aileron cable cutoff solder 300-ohm resistor positive lead Connect accessory cable SSC-receiver cable tape stuff safely work surface Set R6 low R9 high pots about midrange R52 fully counterclockwise will quietly chck end range Set DMM ohms function selecting range accordingly measure Receiver cable negative positive about 23k ohms Receiver cable negative signal open very high ohms Receiver cable positive signal open Receiver cable positive red positive leadout wire short small fraction ohm Receiver cable negative black negative leadout wire short Receiver cable negative tpl test loop board short Unless specifically stated otherwise tests follow DMM negative test lead connected tpl positive DMM test lead placed instructed Meter positive white leadout Q5 drive open 78 Model Aviation r positive yellow leadout MotBatt about 17k ohms Meter positive green leadout FET drive open Change 11MM read DC Volts using 20- 30- volt scale connect DMM positive red positive leadout Connect negative nine-volt battery lead receiver cable negative Connect positive battery lead input end 300-ohm test resistor Snap mating connector onto ninevolt battery Immediately observe about five volts DMM Write down exact value referred below reference voltage brake lite BL should above okay temporarily connect DMM negative positive leads across 300-ohm resistor Observe nominal fourvolt reading test verifies nominal l3mA current drain Signal Board Reconnect DMM negative lead tpl Connect positive DMM lead tp4 observe voltage about 064 x reference voltage usually about 31 33 volts verifies important circuit internal bias level readings assume fresh battery thai has very close nine-volt terminal voltage Continued page 84 -4-V+-V 0i H -4 -4 + x II t I- --44x It 44-1 TI -41-t WVC* V+-4-4-4-4-4-4-4-4-4-4-4-4 1T4-T-V-V*t -V-4 n -11 4-T1T1 -t-f I-t-4V-V-VVV x -V-VT **VV -4tI-V tVV-VI-V tili G / x EEl -4x-4--4-4-4-4 --4in TOP VIEW BOTTOM VIEW NOTES X UCTOR CUT OPEN SO DRILL HOLE SOLID DOTS ER NOW DASHED WIRE R ICs SOLID WIRE IDE OF ICs ELECTRONIC SPORT SPEED CONTROL -SIGNAL BOARD FIRST WIRES September 1999 79 First critical assembly level Signal Board Board outline Signal Board methodical checkouttypical several steps wire locations enlarged holes must right help assure proper operation mated Power Plate Sport Speed Control its shrink-wrap cover about size weight controls few years ago MOO BAIT 0ca 150242 P51 15K 1p2~ P54J P52RO71K 50K2 1C2 ROR 58K CSI 85301 12K s 54145 RR 100 Cl 047 02 22 P1 47KP447K 01 3004 52 4-74 02\ P5100 P8100K P768KRIO 288K 2 V P11 27K Cl LM304 P822K Cs 47 CA 47 78 P12 18K 081 1N414Rblake lit PSILEO 062 470KP631K -CR122o 1C2cP8210K 14111024 VCR2 1C2LM2381L 1007 00USD BOX POWER PLATE POSY ELECTRONIC SPORT SPEED CONTROL SCHEMATIC DIAGRAM TO MOT ow 5V red t 2a t 2b -GND_____ black R57 1K -1R55 56KF TO GATES green D63R155iK R17120K IC 347K CS iCOOp C5101- R54 115k Qi 56K D62 LED TOQ5R6210K R631KC6122D614146 white- SIG GND 5 - Ri 47K 5 32 tp4 3904 R5 100 R4 47K G t5 R6 100 Q2R185R5250KR9100KR768K 390410K \ tp3NOTES DASHED WIRES T WIRES OPEN SQUARES DRILL HOLES PC LANDS ALL ON-BOARD WIRES ARE BARE #24 SOLID EXCEPT 1C2 PIN 10-14 #26 FLEXIBLE INSULATED CABLE TIE DOWN WIRE D INSULATED FIVE INDIVIDUAL LEAD OUT WIRES ARE #26 COLORED INSULATED ELECTRONIC SPORT SPEED CONTROL SIGNAL BOARD ASSEMBLY DETAIL 80 Model Aviation 0 gno S5I -I MOTOP 220K 041 H 061 PP 8040 P3 47K 0414243 IPL 3700 black MOT SPIT F4 4-40x1/2 socket cops sell $435/i 00 gllffl1ffl111 oiioy steel $665/i 00 stoinless S750/50 aluminum fair prices sensible quontities fos teners need model building coil write fox free catalog Micro Fasteners 110 Hillcrest Rood Flemington NJ 08822 e-mail microf@blastnetInternet 800-892-6917 908-806-4050 fax 908-788-2607 http//microfastenerstnm Sport Speed/Kopski Continued page 79 Measure tp5 1C3 read about 8 x reference voltage Use short bare wire held positive meter test lead clip probe IC pin directly carefully verifies charge pump waveform asymmetry Move DMM positive lead tp3 observe about 8-9 volts verifies charge pump voltage output Disconnect temporary test cable SSC-receiver lead ninevolt battery leads Take care let battery leads short together Connect DMM positive lead green leadout wire FET drive Connect SSC receiver cable servo driver such Pulse Mini-Lab powered receiver throttle-channel output Power receiver servo driver supply throttle command about midrange Note Signal Board temporarily being powered receiver servo driver BL should out Observe DMM reading usually several volts Vary throttle command observe DMM reading vary several volts BL may may come ON low throttle settings using transmitter/receiver option keep transmitter antenna collapsed two feet away Signal Board stuff connected Set throttle signal full OFF Adjust low trim pot R6 until BL just comes brake function response delayed work slowly give time respond Advance throttle slowly observe BL go out Continue slowly advancing throttle observe DMM reading begin rise Advance throttle full ON observe DMM reading several volts Vary high pot R9 over its range note highest DMM readingusually about nine volts Move throttle stick two clicks down full up adjust R9 until level just begins drop highest value Return throttle full OFF readjust R6 until BL just comes Repeat cycle iteration should require two cycles obtain desired result confirms adjustability motor voltage control over range tuneup just described works radio Ive tried covers usual RC pulse signal range 11 12 mSec low throttle 18 19 mSec high throttle frame rates 40 50 Hz However have programmable transmitter possible throttle signal range may have set sufficiently outside normal parameters adjustments will work youre sure throttle stick programming please confirm using servo thottle location verify normal servo motion measure adjust throttle stick action device such Pulse Mini Lab Turn off receiver servo driver power carefully cut tp2a / tp2b test loop middle jumper wire Cutting jumper activates cutoff circuit Trim two resulting wires about /y /ls inch stands vertically board Tp2b can accessed future allow setting cutoff voltage specific battery packs Connect DMM positive lead red leadout wire reapply receiver servo driver power signal Note exact DMM readingthis nominal 48-volt supply value Calculate half DMM readingthis number will used below Move DMM positive lead tp2b Set throttle full OFF BL should come ON DMM should read zero volts Connect nine-volt battery negative lead black negative leadout positive battery lead yellow Mot V leadout being very careful make polarity mistake DMM reading should rise little four volts Advance throttle just past BL goes OFF Slowly adjust R52 CW until DMM reading drops about 27 volts Continue turning R52 slowly meter reading will continue drop slowly some point around half value determined above little less BL should come has nothing brake circuit operation see below Back up R52 note requires about 3/4 turn BL go back off DMM should now read about 200 millivolts higher half value verifies motor cutoff circuit hystersis Shut off power disconnect test equipment Reset R52 fully counterclockwise completes Signal Board preliminary checkout motor cutoff function does normally activate BL actual use just did during tuneup Motor cutoff operation takes form pulsing motor voltage too fast slowresponding [delayed] brake circuit follow actual application BL will operate adjusted OFF throttle variation technique just used verify proper motor cutoff circuit operation will used later set circuit up chosen number motor cells month Completion Sport Speed Control Bob Kopski 25 West End Dr Lansdole PA 19446 84 Model Aviation anufacturing & B ROD Distributing Co. 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