FOXTECH Halo-6000 EFI Generator for Hybrid Drone User Manual

User Manual for FOXTECH models including: Halo-6000, EFI Generator for Hybrid Drone, Halo-6000 EFI Generator for Hybrid Drone

韦道军 (WEI DAOJUN)

Halo-6000

Halo-6000 EFI GENERATOR USER MANUAL

Foxtech Thor 210 Gasoline-electric Hybrid Heavy Load hexacopter for transportation

Halo-6000 - Foxtech

9 mar 2022 — Engine Model. 247AI. Type. Double cylinder, two-stroke, EFI engine, water-cooling system. Displacement（mL）. 124. Rated Power（kW）@7000 r/min.

File Info : application/pdf, 23 Pages, 2.13MB

Foxtech-Halo-6000-user-manual-2

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

Contents

Safety Code

Description of Halo-6000

Preface

Functions and Technical Difficulties

Main Technical Parameters

Before Operation

Wiring Diagram

Operation

Usage and Operation

Maintenance

Faults and Maintenance Method

Others

Transport and Storage

Unpacking Instructions

Appendix

List of Accessories

List of wearing parts and maintenance

Safety Code

Halo-6000 EFI Generator User Manual

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 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.
©2021 FOXTECH All Rights Reserved 1

Halo-6000 EFI Generator User Manual

Functions and Technical Features
According to the requirements of multi-rotor UAV, 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, makes the hybrid system having the advantages of small volume, light weight, low noise and high power-mass ratio. The controller has the protection functions of over voltage, undervoltage, over temperature and overspeed.
Halo-6000 has excellent quality, strong power source, long-term high-power output, and long service life.

Main Technical Parameters

No. 1 2 3

Items Rated Voltage Rated Power

Weight

Unit VDC kW
kg

DimensionL x W x H) mm

Average Fuel

Consumption

Applicable Models

Applicable Power

Voltage

Altitude

Operating Ambient

Temperature

Start Mode

Mixing Ratio of

Lubricating Oil and

Gasoline

L/h
VDC m °C -

Parameter Index 58
6.0@ Sea Level
9.2
312×288×206 5.7

Remarks
Include: radiators, water pipe, water pump, fuel pump etc; Not include: coolant, gasoline, fuel tank

Multi-rotor multi-rotor UAV, VTOL fixed
wing aircraft 2000 -20 ~ 50

One Key Starting 1:25

Please use the brand oil suggested by the manufacturer.

Halo-6000 EFI Generator User Manual Tab. 1 Main Technical Parameters of Halo-6000

Caution: 1. We suggest you to 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 UAV match the parameters of this hybrid system before use, so as to meet the operational performance of 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.

Engine Model

247AI

Type

Double cylinder, two-stroke, EFI engine, water-cooling system

DisplacementmL

124

Rated PowerkW@7000 r/min

7.3

Rated Speedr/min

7000

Rated Max. Speedr/min

7500

Idle Speed r/min

5000

Oil

Jaso FC or iso-l-egc and higher 2T oil

Gasoline Label Number

95# gasoline is required

Tab. 2 Main technical parameters of engine configuration

Before Operation

Halo-6000 EFI Generator User Manual

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 engine harness and electrical parts is shown in Figure 1

Plug in instructions: The red and black end connector is connected with the "+" pole on the oil pump; The blue and red end connector is connected with the upper "-" pole of the oil pump

Oil Pump

Connecting aircraft CAN cable Red: fault indicator

Water Pump Cylinder block Temperature Sensor

Connect the fan

Fig. 1

Halo-6000 EFI Generator User Manual The wiring of electrical wiring harness and electrical parts is shown in Figure 2

Rectifier bridge

1connect the aircraft CAN Connector
2JST-02T-JWPF-VSLE Plug White lineCAN_L Blue lineCAN_H Green line: Serial port
Serial port Connect to engine CAN Connect to aircraft CAN
redfault indicator greenoperation indicator
connect to the receiver

2Serial port connector5264receptacle
Controller power supply harness
system controller
Motor temperature sensor Steering gear harness
Ignition coil harness

XT150(Receptacle)

Motor Controller

DC-12-IN
PMU(for water&fuel pump)

Relay
XT90H male connector

3connect to the receiver connector 3PIN 2.54mmDuPont row plastic shellreceptacle yellow linereceiver signal line

4Power Cord The connector shall be selected according to the battery configured by the customer or welded by the customer

Connect with ignition coil harness of system controller

Fig.2

Operation

Halo-6000 EFI Generator User Manual

Usage and Operation

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

Fig. 3
2. The installation dimension of Halo-6000 is given in Fig. 4
Fig. 4
©2021 FOXTECH All Rights Reserved 6

Halo-6000 EFI Generator User Manual 3. Installation Method 3.1 Install the hybrid system to the appropriate position of UAV. The damping pad is connected with the aircraft mounting mount, as shown in Figure 5 below
Vibration Damper

Vibration Damper

4 Fig. 5

Vibration Damper Vibration Damper

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 fixed water pump.

3.2.4 Connect the water pipe. Water pipe of Ø8 * Ø12 Water pipe of Ø12 * Ø16

Water jacket

radiator

The red arrow marks the direction of the coolant circulation flow, and the distribution clamp is used at the end of

radiator

Fig. 6
system assembly

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.

Halo-6000 EFI Generator User Manual 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

Oil outlet Oil inlet pipe System assembly

Filling port Fuel tank

Gasoline bubble

Oil inlet pipe

Oil return pipe Oil pump
Fig. 7

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.

Halo-6000 EFI Generator User Manual The specific preparation steps are shown in Figure 8 below.

Add 95# or
higher gasoline to the marking line

Add lubricating oil to the marking line
Mix the fuel in the inverted proportional barrel.

Fig. 8
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 engine or motor. 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 engine 6.1 Before starting the engine for the first time, the air in the oil inlet pipe needs to be

Halo-6000 EFI Generator User Manual

discharged to make the oil inlet pipe full of oil and free of bubbles

6.2 For the first using, the generator should be power on before adding coolant. After

power on, the electrical water pump will continue to run for about 100s. If the water jacket

is not full within 100s, the generator shall be re-powered on. Repeat until the air in the pipe

line is drained. The pipe lines can be squeezed properly until there is no obvious bubble

up welling in the water jacket; Generally, this operation is not needed during subsequent

startup, just observe the liquid level of 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

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.

Open the software installation package with an installation package attached.

Find setup.exe, double click to open, enter the installation interface as shown in the figure and wait until the loading is completed.

The installation is complete.

Halo-6000 EFI Generator User Manual 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.
©2021 FOXTECH All Rights Reserved 11

Halo-6000 EFI Generator User Manual

8. 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 20ms

Fig. 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).

subscript 1.9ms stop

Middlescript 1.5ms start

Superscript 1.1ms reserved

2. Power generation operation After the engine is ignited and idling, the range extender does not need any manual operation, and 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 ±

8.4 Observe the drone voltage and operate stably for about one minute to warm up the

engine

Halo-6000 EFI Generator User Manual

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 continuous flight, Halo-6000 needs to be cooled. Therefore, after landing,

maintain idle speed for 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 temperature. 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

Halo-6000 EFI Generator User Manual

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 cleanto 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.

Remove the spark plug
Fig. 8

Remove carbon deposit

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.
©2021 FOXTECH All Rights Reserved 14

Halo-6000 EFI Generator User Manual 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 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 faults and maintenance methods are shown in Table 3 below

No.

Description Check Item

Cause of Failure

Maintenance Method

Air filter

Under heavy working condition

Clean the filter with fuel

Wrong lubricating oil model

Oil Supply

System

Tubing bubble or no oil

System

cannot be

started.

Wire Harness Poor contact of connector

Use the original lubricating oil
Press the oil bubble several times to absorb oil Check the circuit and connect it again

Spark Plug yellow or weak light

change the spark plug

Reed valve

Damaged reed valve diaphragm

Replace reed valve

failure

Spark Plug

The spark plug is loose.

Tighten the spark plug

Water in fuel or fuel quality

Fuel

Poor quality, fuel storage more

Change the fuel

than 2 months

Speed

fluctuation, Lubricating Oil Poor quality of lubricating oil

Change to the original lubricating oil

voltage

fluctuation,

Drain the air from the oil inlet

smoke

The oil supply is not smooth, pipe. Open the filler cap to

there are bubbles in the yellow make the top of the fuel filter

Oil Way

oil pipe, or the oil filter in the oil close to the top of the oil level.

tank has not been replaced for Power on and drain the air. In

more than 50 hours.

some cases, tilt the fuel tank

properly.

Halo-6000 EFI Generator User Manual

The control circuit or sensor is

Control Circuit

damaged.

Contact the manufacturer.

It's time for maintenance.

Contact the manufacture.

Clean the filter element with

Air Filter

The air filter element is too dirty.

gasoline.

Insufficient Power Output

Spark Plug

The voltage

drops rapidly Battery

after take-off

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.

Low battery voltage

Before takeoff, turn the three-position-switch to "run" and wait for about 1 minute.

miscellaneous

Mechanical parts are damaged.
Tab. 3

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 hot plug. The controller will be damaged by hot plug in case of use and maintenance.

2. Controller Indicator Definition 2.1 Red indicator light: The light is not on in 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

1. throttle position

2. liquid level sensor

1. Sensor Failure

3. water temperature sensor 4. motor temperature

5. atmospheric pressure sensor

Fault light mode

---- -

Halo-6000 EFI Generator User Manual

2. ignition failure

---- ---- -

3. speed failure 4. voltage failure 5. power failure

---- on

Tab. 4

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

Halo-6000 EFI Generator User Manual

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.

Halo-6000 EFI Generator User Manual
Appendix 1List of Accessories

No.

Article

Quantity

Remark

1 Operation and maintenance manual of Halo-6000

Standard Configuration

2 Product maintenance of Halo-6000 EFI 3 Halo-6000 EFI Generator 4 Oil pump 5 Water pump

Standard Configuration

6 Water jacket

Standard Configuration

7 Water jacket cover

Standard Configuration

8 T-junction

Standard Configuration

9 Clamp(internal diameter 10~16)

Standard Configuration

10 M13 clamp (for pipe with internal diameter of 8)

Standard Configuration

11 Motor controller

Standard Configuration

12 System controller

Standard Configuration

13 PMU(for water&fuel pump)

Standard Configuration

14 12V output wire of PMU(female connector)

Standard Configuration

15 Input wire of PMU(female connector)

Standard Configuration

16 Water pipe Ø 12* outer diameter Ø16

Standard Configuration

17 Water pipe Ø 8* outer diameter Ø 12

Standard Configuration

18 Water pipe Ø 10* outer diameter Ø 14

1.5m Standard Configuration

19 Liquid level sensor 20 2*7S 12000 batteries 21 Radiator 22 Fuel tank 23 Fuel Mixer

Standard Configuration

Halo-6000 EFI Generator User Manual
Appendix 2Maintenance List

Part Name
Air Filter Assembly Oil Pump Assembly Steering
Gear Assembly

Unit Consumption
1 1
1

Spark Plug

Reed Valve 1
Assembly

Right Hand

Connecting

Rod Head

Of Steering

Gear

Position 1
Sensor

Oil Inlet 1
Pipe

Damping

Sleeve

Assembly

Cylinder 2
Block

Exhaust 2
Shim

Cylinder 2
Block Shim

Piston 2
Assembly

Piston Ring

Before Start-Up Check
Check Check

25h Check/ Replace
Check

50h Replace
Check/ Replace Check/ Replace

100h
Replace Replace Check/ Replace Check/ Replace
Check/ Replace
Replace Replace

150h 200h 300h Replace

Replace

Check/ Replace

Replace

Replace Replace Replace Replace

Piston Pin

Replace

Retaining

Ring For

Piston Pin

Assembly Of
Crankshaft 1
And Connecting
Rod

Needle

Bearing For

Connecting

Rod Small

End

Fuel 1
Injector

Upper Box

Lower Box

Deep

Groove Ball

Bearing

Halo-6000 EFI Generator User Manual Replace
Replace

Replace

Replace Replace Replace
Replace

This content is subject to change. Download the latest version from https://www.foxtechfpv.com/foxtech-halo-6000-efi-generator-for-hybrid-drone.html For everyday updates, please follow Foxtech Facebook page: https://www.facebook.com/foxtechhobby YouTube Channel: https://www.youtube.com/user/foxtechonline/featured?view_as=subscribe
©2021 FOXTECH All Rights Reserved 21

References

Halo-6000 6kw EFI water cooling generator for multicopters

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