Gaspar Xicoy X45Helicopter User manual

X icoy X45Helicopter

X45TurboProp

Two Stage Gas Turbine Engines

User Manual

Version 1.1 Aug / 2020

NEW!

For 2020

X45H

X45TP

Congratulations on your purchase of these new generation Xicoy X45 two stage gas turbine engines. We
are confident you will be delighted with your purchase and  your  new  engine will give you excellent
service and maximum enjoyment to your hobby. 
The X45 eli and X45TurboProp are a new extension of a very extensive research and development
programme   by   Gaspar   Espiell   &   Xicoy   Electronica   SL  supported   by   the   latest   fluid   dynamics   and
analysis   software   to   bring   you   miniature   gas   turbine   power   units   of   unparalleled   performance   and
versatility in amazingly small packages. New electronics design and digital programming sets a new high
bar standard for this new generation of small turbine engines. 
Much of the installation and operation of these engines is common to both units so we have combined
the instruction notes to a single manual to aid currency and completeness. Where instruction is specific
to one unit it will be stated. 
This manual has been prepared to help you set up  and  safely operate your engine in your chosen
airframe. If you encounter any problems operating the engine then please consult this manual first and if
you cannot find a solution please get in touch with us. 
If your problem is with a helicopter installation or operation of your chosen helicopter then please get in
touch with your install kit supplier. 
 ere is a contents list for this manual. Left click to fast access any section.
Contents
Xicoy X45 Helicopter and X45 Turboprop, two new engines to enjoy! 4
Xicoy X45 , two stage miniature helicopter engine............................................................................................... 4
 elicopter Conversion Kits..................................................................................................................................... 4
Xicoy X45TP, two stage miniature TurboProp engine............................................................................................ 4
Features and Functions......................................................................................................................................... 5
Package Contents 6
 elicopter engine:.................................................................................................................................................. 6
TurboProp engine:................................................................................................................................................. 6
New Owners 7
Legal...................................................................................................................................................................... 7
Disclaimer.............................................................................................................................................................. 7
Warranty 8
Shipping................................................................................................................................................................. 8
Warranty conditions............................................................................................................................................... 8
Performance, weights and measures 9
Installation – X45H Helicopter engine 10
Exhaust extensions.............................................................................................................................................. 11
Fitting the clutch................................................................................................................................................... 11
Installation – X45TP TurboProp engine 13
Cooling................................................................................................................................................................. 14
Exhaust extensions.............................................................................................................................................. 14
Installing the TurboProp....................................................................................................................................... 15
Propeller Selection (TurboProp)........................................................................................................................... 16
Component Installation Notes – All versions 18
Safety Notes 22
General Notes...................................................................................................................................................... 23
ECU Battery......................................................................................................................................................... 24
 Page 2

Fuel...................................................................................................................................................................... 24
Oil........................................................................................................................................................................ 25
Engine Description 26
Engine.................................................................................................................................................................. 26
2nd Stage.............................................................................................................................................................. 26
Engine Control..................................................................................................................................................... 27
Component Description 27
ECU (Engine Control Unit)................................................................................................................................... 27
Connector board, the “ ub Lite” and “Compact  ub”..........................................................................................28
Auto Power-Off.................................................................................................................................................... 28
Ambient Sensors.................................................................................................................................................. 28
Fuel Pump........................................................................................................................................................... 29
ECU Display 30
 ub Lite data record / playback........................................................................................................................... 30
Plug-In backlit display.......................................................................................................................................... 31
Navigating Menu Screens 32
New Menu Items 37
Kero/Diesel selector............................................................................................................................................. 37
Pump min preset.................................................................................................................................................. 37
Max Power preset................................................................................................................................................ 37
Gearbox reduction............................................................................................................................................... 37
Governor constant RPM setting........................................................................................................................... 38
Propeller Overspeed Limiter................................................................................................................................ 38
Engine Installation: Electrical connections 38
Shared ECU battery............................................................................................................................................. 39
ECU Setup 40
 eli Radio Special Notes..................................................................................................................................... 40
Turboprop radio setup.......................................................................................................................................... 41
Pre-setting Radio to ECU 41
Aligning transmitter with ECU.............................................................................................................................. 42
Failsafe................................................................................................................................................................ 43
Preparing the engine for running 43
Priming/purging the fuel system........................................................................................................................... 44
Starting Notes...................................................................................................................................................... 44
Starting the engine 45
 elicopter engine running.................................................................................................................................... 45
TurboProp engine running................................................................................................................................... 46
Engine shut down procedure............................................................................................................................... 46
Adjusting the engine maximum power................................................................................................................. 47
AutoRestart function 47
What the auto-restart function does do................................................................................................................ 48
What the AutoRestart function will not do............................................................................................................ 48
Restart Disclaimer................................................................................................................................................ 49
Throttle curves (TurboProp) 50
Throttle stick position chart.................................................................................................................................. 50
Acceleration and Deceleration settings................................................................................................................ 50
ECU message codes 51
Diagnoses............................................................................................................................................................ 52
Diagnosis messages............................................................................................................................................ 52
Web site: www.xicoy.com  Email: sales@xicoy.com
See our new turbine webpage at: www.Xicoyturbines.com
 Page 3

Xicoy X45 Helicopter and X45 Turboprop, two new engines to enjoy!

Xicoy X45H, two stage miniature helicopter engine

This new power unit from the Xicoy stable is a miniature 2stage gas turbine helicopter drive unit to power

0.90cu in (15cc) size pod and boom size R/C helicopters. The unit features a miniature gas turbine

engine producing up to 3.5kw/4.7hp driving a 2nd stage turbine linked to a gearbox just like standard full

size practice. This offers a powerful, smooth and vibration free powerplant that can run on regular

kerosene. The sound is totally different from any piston engine, being smooth and steady with a gentle

rush of expanding air to provide a unique driving system unlike any other.

The unit is designed to interchange comfortably with standard 0.90 glow heli engines with considerably

more power available. Standard mountings, shaft attachments, fan and clutch parts may be reused with

minimal modification. The output rpm range matches closely with the benefit of a much higher reserve

torque and broader power curve making it easy match to any similar airframe.

The engine and gearbox unit is extremely small and light and easy to install and operate. It uses the

latest digital control with many additional safety functions developed specifically for this application. The

unit features a built-in constant head speed governor function eliminating fiddly pitch curve programming.

The unit is aimed at experienced helicopter fliers and is equally suited to sport and scale applications

with that unmistakeable scale turbine sound.

Helicopter Conversion Kits

Conversion kits are becoming available to convert standard glow engine airframes such as the Align 90

size “T-Rex700/800” or GoGlow 690 type R/C helicopter to this new power unit and we recommend this

route. (see the Xicoyturbines.com webpage for details of kits and supported airframes and brands).

Conversion kits alleviate the requirement to adapt components and airframe and install this unique gas

turbine power unit as all have already been resolved and included. Step by step instructions plus access

to help and support from like minded helicopter people greatly simplify the process. Installation becomes

a straight forward assembly task similar to assembly of the helicopter itself.

Xicoy X45TP, two stage miniature TurboProp engine

Xicoy are delighted to offer the X45TP, another 2 stage X45 TurboProp development utilising the 2stage

drive developed for the X45Heli. This unit benefits from very small size and light weight with a high

power output up to 5kw/6.7hp, equivalent to many 50cc piston engines making it ideal to power most

planes up to 2.5m/98” wingspan.

We have introduced this power plant complete with a sturdy mounting enabling it to easily fit standard

firewalls of airframes intended for bulkhead mounted 30 to 60cc petrol (gas) engines. A growing list of

airframe suggestions suited to the engine will be shown in the www.Xicoyturbines.com website.

The Xicoy 45TP is available in two reduction ratings, High and Low:

•High is for swinging large props at lower rpms for high wing Pilatus PT6 glider tug type

applications.

•Low is for fast flying sport “Tucano” or PC21 type models with limited ground clearance.

Depending on your planned airframe simply select the reduction rating for the propeller you plan to use.

Choice is if you plan to fly light and fast, or heavy and slow, a bit like the KV value for electric motors.

The gearboxes have been optimised to match each application and can be modified to opposite ratio by

replacing two of the gears, which can be done by customer. This enables us to optimise the performance

of the unit to the power curve of the 2nd stage and maximise your enjoyment of the unit.

Page 4

Features and Functions

•Tiny 60mm case 2 stage engine developing up to 5kw of shaft power

•Very low installed weight and bulk

•eli gearbox outline and shaft matches standard 90 size heli glow engine

•Turboprop version comes complete with bulkhead mounting

•Turboprop option of two reduction ratios: i = circa 6k and Lo = circa 8k

•2nd stage rpm feedback to ECU for constant speed governor function (heli)

•Gearbox over-speed protection function

•Gearbox output rpm and temperature included in telemetry feedback

•Accommodates wide presettable range of helicopter reduction ratios

•Peak power user presettable

•Valves and ECU installed on-engine

•Internal kero burner and thermocouple for clean exterior

•Compatible with diesel and kerosene

•Incredible start to idle of less than 25secs

•Fast spoolup to flight rpms

•Automatic cooldown after run, even with receiver power turned off

•Automatic battery disconnection after cooldown

•Brushless high speed starter

•Tiny intelligent brushless fuel pump

•igh speed digital control of all components

•Gearbox uses lubrication from engine, no separate oil required

•Choice of display options, on and off board and Bluetooth Android/iPhone

•Telemetry options available for most modern transmitters

New options and features are being added from time to time,

keep watching on: www.Xicoyturbines.com for details

Page 5

Package Contents

Helicopter engine:

Engine unit inc fod screen

Fuel pump

ub Lite + colour display + 300mm signal cable, OR / Compact ub

Engine cable 250mm

Battery cable

Servo type cable 300mm x 2

Aluminium filter

4mm tubing, 1mtr

USB memory card with instruction manual

TurboProp engine:

Engine unit inc mounting and fod screen

Fuel pump

ub Lite + colour display + 300mm signal cable, OR / Compact ub

Engine cable 500mm

Battery cable

Servo type cable 300mm x 2

Aluminium filter

4mm tubing, 1mtr

USB memory card with instruction manual

Page 6

New Owners

If you sell or pass on this engine to a 2nd or subsequent owner please also pass on this Users

Manual or its link, so they can enjoy a safe and fulfilling ownership too.

The Xicoy Electronica SL responsibility is limited exclusively to the repair of the engine and

accessories which are outlined in the conditions of warranty.

Before unpacking the engine, please read through these notes and agree to the conditions of

warranty.

Customer satisfaction is important to Xicoy Electronica. Technical support is readily available

through your local dealer and via email:

Xicoy Electronica SL, Plaça Pere Llauger Nau 18, 08360, Canet de Mar, Barcelona, Spain

Web site: www.xicoy.com Email: sales@xicoy.com

See our new turbine webpage at: www.Xicoyturbines.com

Legal

The engine design and contents of this User Manual are copyright Xicoy Electronica SL, Canet

de Mar, Barcelona, Spain. All rights are reserved.

This User manual, pictures and data are the property of Xicoy Electronica SL and cannot be

used or reproduced in any way with written permission from Xicoy Electronica SL.

Disclaimer

This engine is a very sophisticated piece of machinery. Great care should be taken at all times

when using the engine. It should only be operated installed in an airframe and by those with

appropriate skills and knowledge to do so. The engine is not a toy. Incorrect operation or misuse

can cause damage to property and serious bodily harm to operators, spectators or animals.

Xicoy Electronica SL accepts no liability any damage which may occur.

Xicoy Electronica SL assumes no responsibility for any errors contained in this document and is

not liable for any damages resulting from such errors.

It is forbidden to use this engine outside radio control applications, especially those that

power vehicles to carry people

Page 7

Warranty

The warranty duration for this Xicoy X45 or X45TP engine is two years from date of completed

purchase, or 25 running hours, whichever comes first.

•Warranty is valid solely for the original 1st owner and is non-transferable upon resale.

•Warranty includes all supplied parts and is limited to manufacturing defects only.

•Shipment costs forth and back, including packing and relevant customs fees are not covered by

the warranty, and will be at owners expense.

Damage or defective operation covered under warranty terms will be repaired and tested at no cost to

original owner (other than shipping expenses). Repairs not covered under the terms of warranty will be

carried out by Xicoy Electronica SL or their appointed agent after agreement of costs.

Shipping

Before returning the engine or ancilliary equipment for service or repair, please contact first your local

dealer or Xicoy Electronica SL Central Office to agree action and costs.

Do not ship before contacting Xicoy Electronica first

Shipping anything from outside the EU

without appropriate documentation will introduce delay and costs at customs borders

Warranty conditions

Please do not disassemble this engine or accessories (gearbox, pump etc) unless with express consent

from Xicoy Electronica SL. You will breach your warranty agreement and will find it an unfamiliar

sophisticated and precision assembly which you may not be able to reassemble without considerable

difficulty and specialist equipment. Simply slackening the compressor nut on the engine will lose the

delicate balance condition of rotor without which the engine may not run without sustaining damage to

the rotating assembly.

This warranty is voided if any one or more of the following conditions apply. In such a case Xicoy

Electronica SL will accept no responsibility for any damage or other consequence caused by engine

operation:

1. The product has been subject to operation using incorrect fuel, oil or fuel/oil mix.

2. The product is, or appears to be crash damaged, the fuel pump is blocked due to particle

ingestion, electronics or pump-drive are flooded with fuel or water ingress, connection leads are

cut or show loss of insulation and/or short circuit or reverse polarity on battery or engine cable

connection.

3. Unauthorized maintenance and/or modifications have been made to any part of the product;

including unlocking of the ECU and changing any of the manufacturers settings, or any items

supplied has or appears to have been disassembled.

4. Parts show damage by ingestion or entanglement of foreign object (wires or pipes, sand, grit and

small abrasive particles, water or fluids, dry powder from extinguisher).

5. The engine has or appears to have been operated incorrectly or not in accordance to this

operators manual.

6. The product has been or appears to have been misused, neglected or inadequately maintained.

7. The engine or fuel pump has or appears to have suffered damage or blockages in the fuel

system due to being run with unfiltered or contaminated fuel.

8. The engine and/or accessories show damage by physical contact with a corrosive substance

through operation or storage.

For further Information and updates on the X45H and X45TP engine and available

Xicoy Electronica help and support check our new dedicated turbine webpage at

www Xicoyturbines com

Page 8

Performance, weights and measures

X45Heli X45 TurboProp

Nominal power at sea level 3.5kw / 4.7hp 5kw/6.7hp

Idle shaft rpm 4,000rpm 1200 (low 11.1:1 ratio)

1000 (high 13.5:1 ratio)

Nominal max shaft rpm 20,000rpm (limited) 8krpm low ratio/6krpm high ratio

Governor RPM range Rotor 800-2,400RPM Propeller RPM Limiter >4k RPM

Torque at max rpm 1.5Nm (13 lb ins) 6.25Nm (55.3 lb ins) (low ratio)

8.33Nm (71.2 lb ins) (high ratio)

EGT at max power 350-450C 550 - 700´C

Fuel consumption at max power 100ml/min / 3.4oz/min 150ml/min / 5oz per min

Restart capability Off and manual Off, manual & automatic

Fuel Kerosene or diesel Kerosene or diesel

Oil mix required 4%, see text for breakdown 4%, see text for breakdown

Overall length: 280mm/11” 320mm/12.6”

Width across exhausts: 120mm/4.75” 120mm/4.75”

Width main body: 60mm / 2.35” 72mm / 2.83” (mounting)

Firewall to rear of prop distance n/a 160mm / 6.3”

Gearbox output shaft: Clutch portion 9.5mm / 3/8”, Dia 10mm plain portion, threaded

threaded 5/16” UNF M8x1.25 internally for M8 cap bolt

Gearbox mounting holes: 4 off dia 4.1mm 4 off dia 5mm, W86-90mm x 50mm

W52mm x 25mm (0.2”, 2” x 3.38-3.54”)

(0.164”, 2.05” x 0.98”) Firewall cutout required:

W72mm x 70mm (2.83”x 2.75”)

Unit weight bare 1170g/41oz 1470g/51.7oz (inc mounting)

Ancilliaries + Compact ub 70g/2.5oz 70g/2.5oz

ub Lite + display 86g/3oz 86g/3oz

ub Lite, no display 62g/2.2oz 62g/2.2oz

Airborne weight 1232g – 1261g 1532g - 1556g (inc mounting)

43.3oz – 44.3oz 53.9oz – 54.7oz (inc mounting)

Suitable ECU battery: 2S Lipo, min cap 1200mAh (recommended)

3S LiFe, min cap 1500mAh

Page 9

Installation – X45H Helicopter engine

Please read through the section on Safety as there are many

areas to consider that may differ from those pertaining to

other forms of helicopter power plant.

elicopters have a special form of vibration due to

assymetrical gyrations of the rotor head. We recommend

using a locking compound on any critical screws likely to

loosen in service. Use only blue type as the green type can

be impossible to loosen later. If you need to return your unit

for service, please remove clutch and fan assembly and any

mountings.

The unit is designed to operate with the output shaft uppermost. A side and plan view can be

downloaded from www.Xicoyturbines.com. Use the link to check for other sizes of mounting and views to

suit specific airframes as they become available.

NOTE To accommodate the housing expanding with temperature, the top bearing next to the fan is

allowed to slide against a strong internal load spring. Please note therefore that on installation, you need

to ensure there is no downward pressure on the output shaft which could overcome the spring and

cause the gears to bind which causes noise and excessive and rapid gear wear.

Use the standard clutch Retain and use the clutch supplied for the piston engine for the airframe. It

enables the engine to start and run to idle without powering the rotors. It also provides a valuable

slipping point in event of rotor being overloaded or forcibly stopped in a crash, or the helicopter being

blown over by strong gust of wind.

Keep gearbox cool The gearbox unit must be cooled in operation. Being connected to a gas turbine

producing up to 100kw of heat energy per second, it will otherwise quickly overheat in use. In operation

the fan drive will absorb some 500w which the engine can manage easily. If you planned to use a small

electric fan for the same purpose you will have to find an equivalent 500w of power to run it.

Use the standard fan The standard fan included with glow engine helicopters is suitable if used with

supplied shroud which can be trimmed to clear any areas of contact and direct the cooling flow

downwards onto the centre of the exhaust and gearbox. With an effective cooling setup the gearbox

temperature should seldom exceed 50C in operation, though may climb to 80C or more when engine is

stopped due to heat soak from the hot 2nd stage.

You can see if the fan is effective enough if the exhaust begins to turn a darker brown shade. Aim to

keep at least 6mm of shroud clearance to any hot surface. Consider the possibility that the fan shroud

may need to be fitted 1st, before the fan and clutch assembly.

Page 10

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