Universal Launch System User Guide
Contents
1. The Aerotech hybrid requires a fill valve and hose that connects to the motor s oxidizer tank Since the tanks are filled by weight you will also need a precise digital scale The fill hose assembly costs around 80 and you can expect to pay 80 150 for a suitable scale Once loaded an Aerotech hybrid is treated like a conventional motor with no special equipment needed to launch As of this writing there is only one system on the market designed for floating injector motors the Pratt Hobbies ULS Universal Launch System The ULS is offered in three Modules This modular approach allows you to buy the parts you need to fill and fire the motors you are interested in and upgrade later For floating injector motors Modules One and Two are used Module One is the Base Module which can be used to fire conventional solid fuel rocket motors Module Two is a solenoid valve assembly that attaches to the N2O supply tank and plugs into Module One It allows you to connect to the nylon fill hose fill the motor with N2O fire the igniter and dump the N20O tank in the event of a misfire The HyperTEK motor system requires the most complex ground support A basic Hypertek ground support system consists of valves regulators and fittings for the N2O and gaseous oxygen GOX tanks a high voltage system to generate the ignition arc and associated cables hoses and controllers Also required is a Fill Stem Assembly the part that contains the metal tubes t2. West Coast Hybrids Connecting the GOX HV Ignition Module gives you the capability of connecting to a HyperTEK non pyrotechnic motor system Optional 500 foot and 1000 foot cables allow you to meet the distance requirements for larger motors as listed in the NAR and Tripoli Safety Codes The ULS M1 can also be supplied with a built in battery meter that shows the voltage available from the battery or batteries when the Test button is pressed System Components ULS base unit housed in plastic casing with handle Battery Cables 2 100 foot cable standard Hand controller Bulb tester Igniter Cable Alligator clips two sets Jumper plug Safety Interlock Plug NOTE There is a compartment in the lid of the ULS M1 case The Safety Interlock Plug Alligator Clips and Bulb Tester are generally shipped in this compartment The ULS Hand Controller contains a 9v battery to activate the relays in the ULS Base Module A good battery should last through a typical flying season We recommend Duracell Ultra batteries To install the battery remove the four screws on the back plate of the Hand Controller Insert a fresh 9 volt battery into the clip and attach the battery connector Reattach the back plate with the four screws The Hand Controller also includes a Safety Interlock Plug This plug provides a removable interlock that prevents activation of the ignition circuit unless it is inserted The Safety Interlock
3. a flexible system that will accommodate every commercially available sport rocket motor solid or hybrid Tank Attachment Setting Up the GOX HV IGNITION module The GOX HV IGNITION Module has two components the GOX Regulator and the Control Module The GOX Regulator The GOX Regulator assembly attaches to an oxygen tank It controls the pressure of the gaseous oxygen GOX introduced into the motor combustion chamber Obtain a small oxygen tank from a local welding supply or hardware store We recommend renting the tanks as it usually costs less than buying them outright and you can simply return the tank for a full one when necessary Connect the tank to the Tank Attachment on the Regulator with a 12 inch crescent wrench It should be hand tight no more Open the tank valve slowly to admit oxygen into the Regulator You will see the Tank Pressure gauge rise This gauge is useful to tell you how much GOX you have left in your supply tank Listen for leaks and tighten the connector if you hear hissing The Regulator Adjustment Handle controls the pressure supplied to the output Turn it slowly clockwise until the Output Pressure gauge starts to rise At this point the GOX is being restrained by the Solenoid Valve Adjust the output pressure to the level recommended in your rocket motor s instructions usually between 60 90 pounds Listen carefully for any leaks If you hear a leak close the tank valve If it is obvious that one of
4. can move up and down in the tube The space above the injector is the oxidizer tank below it is the fuel grain A nylon hose is connected to the injector and runs out the nozzle to the oxidizer supply tank On the launch pad oxidizer flows into the motor through the nylon hose When the motor is full a special igniter positioned just under the injector is fired It burns through the nylon fill hose which releases oxidizer into the combustion chamber and starts the motor burning These motors require a launch system that can control the flow of oxidizer into the motor The larger 75mm and up Contrail Rockets motors are not strictly floating injector motors because the injector is a part of the oxidizer tank but they are filled and fired in the same way as floating injector motors The third hybrid motor system in common use is the gaseous oxygen GOX and high voltage system pioneered by HyperTEK inventor Korey Kline A HyperTEK motor consists of three parts a tank a molded plastic fuel grain and an injector bell that connects the two together On the launch pad the motor rests on a special support structure A metal tube mounted on the structure goes up through the nozzle and the fuel grain into the injector Oxidizer flows through this tube into the tank When the tank is full a second tube introduces oxygen into the combustion chamber while another mechanism generates a high voltage arc at the end of an igniter wire in the combustion chamb
5. the fittings is loose tighten it carefully with a crescent wrench If it is not clear where the leak is coming from you can detect it by spraying a solution of soapy water on different parts of the manifold and watching for bubbles Avoid dampening the part of the Solenoid Valve that is wired to the plug The Control Module The Control Module incorporates a high voltage transformer and circuitry that switches on the transformer and the GOX Regulator valve when the ignition command is received It connects to the Basic ULS control box through the wires usually used to connect to the igniter The transformer in the Control Module puts out a very high voltage spark It can easily arc to the ground or to metal parts of your launch pad Make sure that the igniter leads are not near the ground or any metal objects NOTE DO NOT energize the Control Module unless an igniter is connected to it This can damage the high voltage transformer Plug the GOX Regulator solenoid into the Control Module Connect the battery clamps to a 12 volt battery Be careful to observe correct polarity Red goes to positive and black goes to negative Remove the alligator clips from the Igniter Cable connected to the Igniter outputs of the ULS Base Module Plug the banana plugs into the color coded connectors on the Relay Module red to red and black to black Testing the System Connect all components to an ULS Base Module as described above Open the GOX tank val
6. valve closed Liquid N20O will cause frostbite if it touches your skin a Launch Procedure Read and understand the instructions that came with your hybrid rocket motor before attempting to launch it Follow the checklist printed on the ULS Base Module faceplate First check to make sure the S afe Armed switch is in the PAD SAFE position With the rocket on the pad and secure connect the motor to the Valve Manifold Open the N2O supply tank valve Test the connection by briefly moving the Fill Test Dump Test switch to Fill The Fill valve will open and allow some N20 to flow into the motor Hold the switch open for one second or less to avoid wasting N20 Look for any loose connections Now command the dump valve open to allow any N2O in the motor to escape When you can no longer hear any venting approach the launch pad and tighten the fittings if necessary Connect the alligator clips to your igniter Make certain that the clips do not touch each other or any metal parts Check continuity by pressing the Continuity Test button Move the Safe Armed switch on the ULS faceplate to the Armed position The warning buzzer will sound Go to your launch position at least 100 feet away from the pad Clear the area check the sky for aircraft and alert all spectators When you are sure the range is safe command Fill on the hand controller Continue filling until you see liquid N2O coming from the motor vent When venting is observed rel
7. ELEers sscssevion xwv VERI RR COE aa CERT CR V E ORE R ER COD CR RC ECRIRE CR 8 POSEN me 9 Launch Proc dure iussis digress cane ete eee DE RO RR M DR CN DF A D ER 10 Misfire PrOCeUOUf es ossiixiiebXE a E RCRUM ENLEVER EAD RN E RP 10 Care and MaaitellallC6eunsecads c RE ERE VEN VAGHERAAME AOR 10 ULS Module 3 GOX HV IGNI TI ON MODULE Systeni DESCKIDUON uouiio so nuss sunu wasusSuEMEskESuRREEEKRERENESERAKEENRRERERPERRERSNEEEFEERENNAESREKSEPEEEAS 11 Redguireg TO USOT ocoesure uad RIIUDERI AQ S REANO RU IQ RU ACAODR RU UR RUNI EUER E AN RR 11 Setting Up the GOX HV IGNI TI ON module nenne nennen nnne nnn nnn 12 Th GOX Regulator issunisuusauuadsuseUekaS quA SAARE EAEE TO NEU UUVMUUN IDEE 12 The Control MOGOHIG us es EXRUA QE EROR CURRERE EVER OUPOU EE ERU ERO E CUM ER NO EUR o HET 12 Testing TNE System srira E EFadiZExERRREM apan E WEVFFEN FE VEKI FIM FE ENS 13 Setting Up for Launch sssrini cons kwuk xus ka gas vaEAREEkxwEXE SE ERE NoN ANa OAREN 13 Care and MashntelialitBin epo ERN ODIO RRRUN EE EM DN NOU MU GINE ACE ANGUS TOR RUN EL ODIUM RN N 13 BED EE OT TII e EE EEEE OE 14 More information oce ere cence nsec URRxR wee ec ceeetseneeeeeseceesseecuneusoesectesceseeeeeecesc 14 Getting Started with Hybrid Motors cccccccccccccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeneenes 14 Web NKS onn ees tees eee eee eee cece eens eence een ewe secunoessens cusneeeewe ces 16 Hybrid M
8. Plug is supplied on a convenient lanyard that can be worn around your neck The lanyard has a quick release latch to allow you to remove the Safety Interlock Plug for insertion into the Hand Controller It is your responsibility to maintain control of the Safety Interlock Plug at all times to prevent accidental ignition Setting Up the System on the Field Open up the ULS case and put it down close to the launch pad Place it in a position where it is in no danger from the motor s flame at liftoff The case must be no more than six feet from the rocket igniter to allow some slack in the cable that attaches to the igniter For 12 volt operation Plug one of the two Battery Cables into the Battery A jack on the ULS faceplate Connect the clips to your 12 volt supply battery Be certain that polarity is correct Red to Positive and Black to Negative Make sure that the clips cannot touch each other or short against any metal object I nsert the Jumper Plug into the Battery B jack on the ULS faceplate The Jumper Plug is usually kept in this position by default For 24 volt operation Plug one of the two Battery Cables into the Battery A jack on the ULS faceplate Connect the clips to one of your 12 volt supply batteries Be certain that polarity is correct Red to Positive and Black to Negative Make sure that the clips cannot touch each other or short against any metal object Plug the other Battery Cable into the Battery B jack on t
9. Universal Launch System Remote Tanking and Launching System for Sport Rocketry User Guide This is the instruction manual for all three modules of the Universal Launch System ULS Module 1 the Base Unit is capable of firing conventional solid fuel rocket motors Module 2 the Valve Manifold attaches to a nitrous oxide N2O supply tank not Supplied and allows the filling and venting of floating injector hybrid motors Module 3 the GOX HV Ignition Module connects to the Base Unit module and a gaseous oxygen GOX supply tank and allows the firing of non pyrotechnic hybrid motors Pratt Hobbies 2513 Iron Forge Road Herndon VA 20171 www pratthobbies com ULS Module 1 Base Module System Descriptio sieceeux xxxas xax xa xus EEEKESS UE RES EAR d NUUS SO RR T a DES RR drauf gu ALS M E 3 The Hand Controlli ossiexivirx eX MN CERES ERE VENCER UE AUN eserves YET NER EVER PRI KENT ERN E ENT 4 Setting Up the System on the Field cccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaes 5 LAUNCH PFOCeOHE B cawcanxist etaaidvxRwRENNESSEMEAFEEEEYYAIENIDNIEREEENVMESIS a 6 Care and Maintenall 6e aswieiwavkk EE aai VEI E KI MR VERI S RR GER WE CR RR CN ER RC CDU ERECTO ER RR 6 ULS Module 2 Valve Manifold System DescrTpLEOn iiia a saxa EUR tense xuEa asakaxsuuxaAxEasxsEEcDa Eua ERUAFERFARASEVRRR RM RK NR RER AREE 7 Setting Up the SySLOI is Leona vous uuu a eg RuEREWRT AR EA LEE KEREFRRERA VERRE RE RF RRRU REN 8 AGaD
10. ad is pushed just below the snap ring groove install the snap ring using snap ring pliers Step 5 Install Parker Press Lock Fitting into the Floating Injector The Floating Injector is denoted by an I Stamped on the top face This should be done with a deep wall socket set Make sure the injector is tightened to turn past snug To verify injector speeds and Igniter requirements please view the attached chart x m ud Me ui Ge T a Step 6 rind the included Nylon Fill Line and make sure the nylon line is cut square If it is not use a set of cutters to square off the end of the lines Once the line is cut square push the line into the Press Lock Fitting Be sure that you feel the fitting go past an O Ring seal and seat snugly onto the bottom of the fitting Once Seated give a slight pull to ensure the fitting is locked in and the fittings Teeth grab onto the line 38mm Motor Pyrodex Pellet Ignition Grain Recommendations Slow Motors 1 44 Cal 30 Grain 2 50 Cal 30 Grain 1 45 Cal 50 Grain 1 50 Cal 50 Grain 1 54 Cal 60 Grain Medium Motors 2 44 Cal 30 Grain 2 50 Cal 30 Grain 1 45 Cal 50 Grain 1 50 Cal 50 Grain 1 54 Cal 60 Grain Fast Motors 2 44Cal 30 Grain 2 50 Cal 30 Grain 1 45 Cal 50 Grain 1 50 Cal 50 Grain 1 54 Cal 60 Grain X Fast Motors 2 45 Cal 50 Grain 2 50 Cal 50 Grain Step 7 Refer to the Igniter Injector Chart t
11. ap Ring Plyers Krytox Oxygen Safe Grease Synthetic Type Grease Mobile 1 Synthetic or Similar Recommended Pyrodex Pellets Muzzle Loading Pellets Recommended and Approved Sizes are as listed in attached Chart Deep Wall Socket Set 7 16 Inch Socket for 1 8 and 3 16 Inch Injectors 1 2 Inch Socket for 1 4 Inch Injectors 9 16 Inch Socket for 5 16 Inch Injectors Good Pair of Cutters Recommended Radio Shack Coax Cable Cutters Roll of Electrical Tape Motor Assembly I nstructions d za LDCUNEEPUUTES ANR C 7 P nana Sn t d ma nm Step 1 Ensure that your motor hardware is clean and free from grease oils dirt and debris Wipe the motor components with soap and water to cut any residual grease from previous firings Make sure you have all required tools and parts for motor assembly T k N Step 2 Begin by installing all O Rings onto Nozzle Injector Baffle and Bulkhead All O rings are Dash Number 215 O Rings should be free from any cracks burns or damage 19 Step 3 Use Krytox grease on top Bulkhead O rings Smear Krytox over r the entire ur cylindrical surface of the Bulkhead This allows for an easy fit into the men case Krytox grease is available from Contrail Rockets and our Dealers de Step 4 Slide top bulkhead into the top side of the motor case The top of the motor case does not have an external groove cut into it for a thrust washer Once the bulkhe
12. d We recommend that the 12v battery should remain disconnected from the Control Module until you are set up and ready to launch This avoids accidental actuation of the GOX HV Ignition components and discharging of the battery Follow the instructions that came with your rocket motor to set up fill and fire Care and Maintenance The GOX HV Ignition components are sturdy and should not require maintenance or care beyond simple cleaning Do not expose them to water If it starts raining cover the components or disassemble the system and get it under cover If the GOX HV Ignition fails to produce an ignition spark check the fuse mounted on the faceplate A spare fuse is supplied with the new unit if you need to replace it get an FSA250V standard fuse They should be available at hardware stores automotive supply stores and Radio Shack When packing up for the day close the oxygen tank valve then command the solenoid valve open for a moment to release the pressure inside the manifold Disclaimer Pratt Hobbies certifies that it has exercised reasonable care in the design and construction of this product Since we cannot control the use of our products once sold we cannot assume responsibility for such use Our responsibility is limited to the repair and or replacement of this product at our option This product is warranted to be free from defects in materials and construction for a period of 90 days from the date of purchase Mo
13. ease the Fill switch Insert the Safety Interlock Plug in the Hand Controller Begin your countdown and firing sequence When you press the Ignition button you should see smoke coming from the motor nozzle Depending on the motor it may be necessary to hold the button down for two or three seconds Hold the Ignition button until ignition is confirmed When the rocket starts to move release the Ignition Button After launch remove the Safety Interlock Plug Return to the launch pad and move the Pad S afe Armed switch to the SAFE position Close the valve on the N2O supply tank Misfire Procedure If the rocket motor does not ignite release the Ignition button and remove the Safety Interlock Plug Command the Dump valve to vent the liquid N2O out of the motor Wait until the motor is empty before approaching the launch pad Move the Safe Armed switch on the ULS faceplate to the SAFE position as soon as you return to the pad Care and Maintenance Make sure the Safe Armed switch is in the SAFE position unless you are ready to launch Wrap the cables neatly and use the reusable tie wraps to secure the bundles Store all the parts inside the ULS case The ULS system requires no maintenance other than light cleaning Spare parts are available from Pratt Hobbies ULS Module 3 GOX HV IGNITION MODULE System Description The GOX HV IGNITION Module of the Modular ULS system is designed to plug into the Base Module It allows you to perform no
14. er This ignites the fuel grain which burns through straps holding the fill tube in place This allows the tube to come out of the injector releasing oxidizer into the combustion chamber The major advantage of the Hypertek system is that there are no pyrotechnic components anywhere in the system Getting Started Getting started with any of these systems means buying some ground support equipment First of all you need an N2O supply tank A 10 Ib tank is adequate for smaller motors and should cost between 150 and 250 depending on where you buy it A 20 Ib tank is recommended if you plan to fly motors of J level and above These should cost between 200 and 300 Make sure the tank is rated and tested for nitrous oxide N20 the oxidizer we use for hybrid motors While common CO 2 tanks can handle the pressure of liquid N2O they are often equipped with seals and rings that are not compatible with N2O Do not use a tank that is intended for CO 2 or for compressed air SCUBA The most common source of N20 is automotive racing hot rod stores While they are usually excellent places to get your tank filled they are often on the high end of pricing for tanks and fittings You can expect to pay 4 6 a pound to have your N20 tank filled The GOX high voltage system also requires a gaseous oxygen GOX tank These can often be rented from welding or medical companies for less money than it would cost to own a tank Check your local Yellow Pages
15. h a non petroleum based grease We recommend Mobile 1 Synthetic Grease Completely cover www pratthobbies com 25 the grain with grease before sliding the grain onto the fill line and igniter wire Step 12 Slide the Fuel grain into the motor case by pushing it down which will also push the injector assembly into position as well Wipe any excess grease off of the outside of the motor case Su T i A TN Edi Step 13 Find the graphite nozzle with O ring and give a light coat of synthetic grease You then want to slide the graphite nozzle into www pratthobbies com 26 the motor case Following the insertion of the nozzle into the motor case you will then place the nozzle washer onto the face of the nozzle Step 14 Be sure that the nozzle and nozzle washer are pressed slightly below approx 1 16 of an inch the snap ring groove Find the second snap ring and insert the snap ring into the groove to complete motor assembly You re Now Done Assembling your Contrail Rockets Hybrid Rocket Motor Venting Instructions The recommended procedure for venting Contrail Rockets Hybrid Motors is to drill the vent hole 1 8 3 16 hole in the side of the rocket prior to motor installation Next you will feed the clear vent line which is included with the reload package through the newly drilled hole and down the motor mount tube You will then connect the clear vent to the Bulkhead Vent Assembly The Vertical Press Loc
16. hat introduce N2O and GOX into the motor All of this equipment is of very high quality and will be good for years of firing The only part that can be degraded by continual use is the fill stem and the vulnerable parts are easily and cheaply replaceable Furthermore once you have the basic Hypertek system you can get inexpensive adapters to use it to fill and dump floating injector hybrids as well as fitting the Aerotech fill hose Another alternative is to add Module Three to the ULS system described in the paragraph about floating injector motors Module Three the GOX HV Ignition controls ignition of HyperTEK motors Modules One Two and Three of the M ULS will fill and fire any Hypertek rocket motor There are two sources for Fill Stem Assemblies for HyperTEK motors HyperTEK makes a sturdy steel unit that is reasonably priced and attaches easily to any large rod or rail X Rockets makes a Drop Down Launcher system that virtually guarantees successful ignition and release of the fill stem While the X Rockets system is more expensive than the basic HyperTEK fill stem assembly it should be seriously considered The X Rockets system will dramatically extend the life span of the fill stem assembly Web links For more information about hybrid motors www pratthobbies com www contrailrockets com www skyrippersystems com www hypertekhybrids com www nowhybrids com www starrocketry com www aerotech rocketry com www propulsionpolymers com w
17. he ULS faceplate Check the polarity on both batteries to be certain that you have Red to Positive and Black to Negative If polarity is backward on either battery the two batteries will attack each other when the Ignition command is given and the wrong part of the system will ignite This is not covered under warranty Also do not connect both sets of clamps to one battery Uncoil the 100 foot launch controller wire and insert one end into the jack marked Controller on the ULS faceplate Connect the Hand Controller to the other end To be certain that you have it connected properly press the Fill and Drain rocker switch momentarily on the hand controller and listen for the relays clicking inside the ULS when you do The Ignition button is deactivated unless the Safety Interlock is in place so you should not hear a relay click if you press the Ignition button Uncoil the 8 foot pad cable This cable has a two prong connector on one end and banana plugs on the other Plug the two prong connector into the socket on the Base Module marked lgnition Slide two alligator clips on the banana plugs at the other end The alligator clips are kept in the small parts container on the Base Module lid two extra clips are included We recommend wrapping the alligator clips and the banana plugs with electrical tape after the clips are connected to your igniter This will prevent them from shorting against each other and help keep them from being pulled out and lo
18. il Rockets LLC Reserves the right to alter the Warranty at any time at their discretion Contact Information Contrail Rockets LLC 49 N Acoma Blvd Suite 72 Lake Havasu City AZ 86403 www pratthobbies com 30
19. k Located in the Top Bulkhead Finally you feed the motor case and vent line back through and into the motor mount You will then clip off any excess vent line which sticks out of the rocket body and you are ready to fly www pratthobbies com 27 Launch Setup and Procedure In order to fire any Contrail Rockets Hybrid Motor you will need to have available a Hybrid Ground Support System We recommend the Contrail Rockets Ground Support System or the Pratt Hobbies Ground Support System For More information on Ground Support Contact your favorite hybrid vendor Pad Setup is Simple No Hybrid Motor should be operated when Nitrous Oxide Pressures are less than 550 psi or more than 900 psi It is required that you fill your Hybrid Motor from a Distance of no less than 100 Feet Manufactures of Hybrid Ground Support will be more able and willing to help assist you in the pre flight setup and procedures which go along with there equipment If you are not familiar with there equipment ask them prior to use Warnings Only Contrail Rockets Certified Reloads are to be used in Contrail Rockets Hardware The use of any other manufactures reload in Contrail Rockets Hardware will void your warranty and will also render the assembled motor non certified Never Approach a Hybrid Motor when filling or while the motor has pressurized Nitrous Oxide in it After Firing your motor it may be hot and should be handled with care Always Wear P
20. n of hybrid motors by controlling gaseous oxygen and a high voltage arc igniter Module Two the Valve Manifold is designed to connect to control circuitry built into the ULS M1 Base Block This controls two solenoid valves to allow the filling and venting of hybrid rocket motors The solenoid valves we use are made to our specifications and will not burn out in extended use like hot rod type valves Adapters and fittings are included to allow the system to connect to all commercially available hybrid rocket motors The Valve Manifold comes with connectors that fit the ULS M1 It can easily be adapted to a multi channel club launch system that provides 12 volts and at least 2 amps Simply connect one circuit to the fill valve and one to the dump valve A pressure gauge and oversize fill valve are available as options See www pratthobbies com for complete information oy 16 in l Sure Lok Adapter arie in Sure Lok ja Adapter s32in Sure Lak Adapter HyperTEK a Adapter Fitting 1 8 in Sure Lal Adapter R Setting Up the System Nitrous oxide N20 tanks are fitted with one of three different types of valves Anaesthetic or medical grade N2O tanks are not used with hybrid rocket motor systems these valves have a limited flow rate to prevent possible injury and cannot supply adequate flow to fill a hybrid motor Medical grade tanks can be recognized from their chrome plated valves The two valve type
21. n pyrotechnic ignition of hybrid rocket motors by releasing gaseous oxygen GOX into the combustion chamber while generating a high voltage spark across the ends of an igniter wire in the chamber A fuse protected high voltage transformer provides the spark Sequencer The GOX HV IGNITION Module incorporates a solid state sequencer module that optimizes the ignition sequence On ignition command the GOX valve is opened allowing gaseous oxygen to flood the motor s combustion chamber Just under one second later the transformer is energized introducing the ignition spark into the oxygen saturated motor This has been shown to provide faster and more vigorous ignition Required to Use ULS Base Module ULS M1 Valve Manifold module ULS M2 Separate 12v battery For motors that require more than 100 feet of separation between the controller and the launch pad K and above optional 500 or 1000 foot cable for the Base Module Rd as ae ae E We recommend that you set up mild leu Sutipa 3 e TEACA Pressure and test the entire ULS system ir before launch day Familiarize T R yourself thoroughly with the per PT system so you re not trying to i 3 i Adjustment Tank Pressure figure it out while you are under Handle Hose Attachment the pressure of trying to launch X something Refer to the eM x instructions that came with the P rocket motor you will be using The ULS is
22. ny ice formed by leaking N2O or any metal parts that have been chilled by leaking N20 Position the nitrous oxide N2O supply tank so that the pressure tubing from the motor can easily reach the fitting on the valves Plug the Fill valve the one closest to the tank into the connectors marked FILL on the Base Module faceplate Plug the dump valve the one on the end of the T fitting that opens to the atmosphere into the connectors marked Dump on the Base Module faceplate Adapters The ULS Valve Manifold includes a set of adapters intended to connect to all commercially available hybrid rocket motors These adapters screw into the outlet side of the Tee Fitting on the Manifold Select an adapter that is the appropriate size for the motor you plan to use The Sure Lok connectors are PTC push to connect fittings for various sizes of nylon 4 tubing These are used with RATT Works Propulsion Polymers Sky Ripper Contrail Rockets and West Coast E Hybrids motors See the table below for the appropriate Ms size F p a The tapered brass fitting shown above installed in the ad Tee Fitting connects to a stainless steel hose that connects to a HyperTEK fill stem assembly 75mm i ww Contrail Rockets motors fill through two hoses To set up for a 7bmm Contrail motor screw the tee fitting provided in the adapter bag to the output of the tee on the Valve Manifold and insert the appropriate size PTC connecto
23. o find out which size and number of Pyrodex Pellets is recommended for ignition Verify that you have the correct size and number of Pyrodex Pellets for your reload and then slide the igniter wire through the center hole of the pellet Bend the resistor to the side of the powder pellet as shown Step 8 Place the Igniter assembly next to the top of the Injector Face Put the Resistor approximately 90 Degrees away from the fill tube Refer to Picture x 7 2 E LI L k i lt hc s amp V P r ss 3 he aie Er 1 E k a A ei vM b j 7 a 1 FE gt w lt M ia da Step 9 After aligning the igniter into position use electrical tape to tape the igniter to the fill line 2 wraps of electrical tape over the entire igniter grain is recommended This holds the heat of the Black Powder Pellets close to the Nylon Line www pratthobbies com 24 Step 10 Now that the Injector and Igniter assembly is put together you will be greasing the Injector Assemble with Krytox Grease just as you did with the top bulkhead Once the Injector is greased you will slide the assembly into the motor tube Be sure to not slide the injector up to far as you will use the grain to push the injector up the rest of the way into the case Step 11 Find the included Fuel Grain which came with the reload package Grease the outside of this grain wit
24. occasioned by seller s negligence or based on strict product liability or principles of indemnity or contribution Contrail Rockets Neither assumes nor authorizes any person to assume for it any liability in connection with the use of any product or data Contrail Rockets LLC Ensures that reasonable care during the design and manufacture process Because we can not control the use or storage of our products Contrail Rockets can not be held responsible for any personal injury or property damage resulting from the handling use or storage of its products The Purchaser assumes and accepts all liabilities and risks associated by the handling or use of Contrail Rockets Products By Purchasing a Contrail Rocket LLC product you are hereby acknowledging the above disclaimer and agreeing to not hold Contrail Rockets LLC its owners employees stock holders partners or subcontractors for any harm or blame caused by the use of our product caused by the purchaser and or end user www pratthobbies com 29 Warranty Our Products are Warranted for a time period of one year from the date of original purchase The warranty expressed by Contrail Rockets LLC covers defects in material or workmanship There shall be no expressed or implied warranty which covers any item damaged through the use of a Contrail Rocket Motor This includes the motor hardware electronics and any other items which suffer from the misuse neglect caused by the user Contra
25. otor Instructions ULS Module 1 Base Module System Description The ULS Base Module is a rocket ignition system powered by one or two external 12 volt batteies The Base Module is designed to put more power into an igniter than other launch systems The battery is close to the launch pad and only has eight feet of heavy gauge wire between it and the igniter The control relays are powered by a 9v battery in the Hand Controller Effectively all of the high current 12 volt battery s power goes straight to the igniter The continuity sensing circuit is transistorized and will not set off sensitive igniters like flashbulbs or electric matches Pressing the Continuity Test button lights an ultrabright LED if the igniter circuit is complete A buzzer sounds when the unit is set to Pad Armed 12 volt operation is sufficient for most Black Powder and APCP composite propellant solid rocket motors as well as most common hybrid motors 24 volt operation is required for the older igniters supplied with Contrail Rockets hybrid motors 24 volt operation is also very useful for cluster ignition or custom made high current igniters Control circuitry built into the ULS will allow the filling and venting of hybrid rocket motors when combined with other modules When you are ready for hybrids you can add the Valve Manifold Module and a N2O supply tank to fire floating injector motors like RATT Works Propulsion Polymers Sky Ripper Contrail Rockets and
26. re information There are several excellent sources for more information on the World Wide Web We try to include good background information and links to other sources on our catalog Web site www pratthobbies com You will find links to each of the commercial hybrid motor manufacturers on our home page We also sponsor a Yahoo discussion group at http groups yahoo com hybridrocketmotors Getting Started with Hybrid Motors This is a copy of an article posted on our web site to provide a quick overview of the commercially available hybrid motor systems Three hybrid systems There are three distinct types of hybrid rocket motors presently certified and on the market Each requires different support equipment although there is some commonality The simplest is the Aerotech system where the oxidizer tank is attached to a conventional reloadable motor casing The tank is loaded before it is attached and installed in the rocket A pyrovalve releases the oxidizer into the combustion chamber when the igniter is fired The second is the floating injector design used by RATT Works Propulsion Polymers SkyRipper and Contrail Rockets motors This is sometimes called the U C Valve for Urbanski and Colburn two experimenters who apparently came up with the idea independently at about the same time In this kind of motor the casing is a single tube with closures on each end The inside of the tube is divided into two sections by the injector which
27. rotective Eyewear Gloves and Clothing when working with Hybrid Motors or Ground Support Always follow the Tripoli Safety Code as well as the NFPA Safety Code for Mid and High Power Rocketry Not heeding these warnings could result in injury of yourself or others www pratthobbies com 28 Disposal and Cleanup If for any reason you need to return or dispose of your reload please contact Contrail Rockets LLC for information on how to return the item Appropriate shipping and handling as well as packaging requirements may be necessary Any used items should be disposed of in the proper trash receptacle Safety and First Aid Contrail Rockets Hybrid Motor Reloads will not burn without the presence of a High Temp Heat Source and strong oxidizer If for some reason any part of a reload is ingested induce vomiting and seek medical attention Disclaimer Contrail Rockets LLC specifically disclaims any warranties with respect to any and all products sold or distributed by it the safety or suitability thereof or the result obtained whether express or implied including without limitation any implied warranty of merchantability of fitness for a particular purpose and or any other warranty Buyers and users assume all risk responsibility and liability whatsoever for any and all injuries including death losses or damages to persons or property including consequential damages arising from the use of any product or data whether or not
28. rs into the holes of the tee 4 RATT Works H and Sky Ripper 29mm and 38mm RATT Works 54mm RATT Works K and L Note Contrail 38mm motors require one fitting as do all the other brands Contrail 75mm motors fill through two tubes so a tee and two each of the appropriate size fitting are included Sure Lok connectors will hold the tube when it is pushed ALL the way into the connector There is a point of resistance half way in that can fool you into thinking that the tube is fully inserted If you can tug the tube out of the connector it was not fully inserted Make sure that the tubing is cut cleanly and square on the end that you insert You should be able to give the tube a brisk tug without loosening it when it is fully inserted If you have a piece of tubing that just won t stay in place try cutting off an inch of it and inserting the freshly cut end To remove tubing from the Sure Lok pull the green ring back toward the body of the connector with your thumb and forefinger This releases a ring of barbs inside the connector that are holding the tube in place allowing you to slide it out Practice this until you get the feel of it Testing Test the connections by commanding the Fill and Dump valves open momentarily either with the Hand Controller or with the Fill Test Dump Test switch on the ULS Base Module faceplate The solenoid valves make a loud click when opened NOTE Perform this test with the N20O supply tank
29. s that can be used with rocket motors are designated CGA 326 and CGA 660 These numbers are usually stamped into the valve The ULS Valve Manifold comes equipped with a nipple and nut to fit a CGA 326 tank valve CGA 660 fittings are available as an option Note Industrial grade and racing grade N20O include an additive that produces a strong unpleasant smell usually butyl mercaptan or sulfur dioxide This is done to make it impossible to use the denatured N2O as a recreational drug allowing hobbyists to buy it without restriction It also functions as a way of detecting leaks the same as the leak check compounds usually added to natural gas Connect the ULS Valve Manifold to your supply tank with a suitable wrench The nut does not have to be tightened too hard Position the Valve Manifold so that the outlet of the Dump valve is pointing down If you need to dump the N20 in a motor on the pad it will vent through this outlet at a high rate of speed Just like a rocket this will cause an opposite force and it can knock your N2O tank over possibly damaging the valve assembly Open the tank valve and listen for leaks If you hear hissing close the tank valve and wait for the hissing to stop then tighten the tank nut If hissing continues examine other parts of the manifold that may need tightening Note Liquid N2O has a temperature of minus 65 degrees and can cause frostbite if it touches your skin Be very careful not to touch a
30. st by a high power rocket motor that lifts off before the igniter wire burns away Testing A 12V Bulb Tester is included with the ULS This takes the place of an igniter in tests and also allows you to test the solenoid control circuits After setting up the system see above connect the Bulb Tester to the igniter clips and go through the launch procedure The bulb will light when you press the Fire button You can use the pad cable and Bulb Tester to test the Fill and Dump outputs by plugging the cable into either the Fill or Dump socket and moving the rocker switch on the Hand Controller Launch Procedure Follow the checklist printed on the ULS Base Module faceplate Make sure the Base Module is switched to PAD SAFE Connect the alligator clips to your igniter Make certain that the clips do not touch each other or any metal parts We recommend wrapping each clip with electrical tape Press the CONTINUITY TEST button The LED will illuminate if the circuit through the igniter is complete Note The Continuity Test circuit only functions when the switch is in the PAD SAFE position Move the switch on the ULS faceplate to the PAD ARMED position The warning buzzer will sound Go to your launch position at least 50 feet away from the pad Clear the area check the sky for aircraft and alert all spectators Insert the Safety Interlock Plug in the Hand Controller Begin your countdown and firing sequence After launch immediatel
31. ve and adjust the regulator to a level of 80 pounds Close the GOX tank valve Prepare a short length of 24 gauge igniter wire see the instruction manual that comes with HyperTEK or Propulsion Polymers motors for details Suspend the cut end of this wire in a position where it is easily visible and away from any metal or flammable objects Insert the Safety Interlock Plug into the Base Module Hand Controller and press the I gnition button You will hear a pulse of gaseous oxygen coming from the Regulator output as it releases the GOX that was admitted when the valve was opened One second later you will see an electrical arc across the end of the igniter wire When you have verified that these two events have happened release the Ignition button The system is ready for use Setting Up for Launch Set up and test the ULS Base Module module and the Valve Manifold module as described above Set up and organize the components at the launch pad Connect the output of the GOX regulator to the GOX inlet on your fill stem assembly with a hose with 4AN fittings not supplied We recommend laying the GOX supply tank flat on the ground to avoid damage if it should fall over Position the Control Module in such a way that the clips cannot touch the ground or any part of the launch pad The voltage from the transformer in the Control Module can arc to the ground instead of going through the wire if you are not careful to make sure it has no path to groun
32. ww rattworks net www x rockets com Hybrid Motor Instructions Thanks to the kind permission of the folks at Sky Ripper and Contrail Rockets we are reproducing some of their instructions as an appendix to this manual Please note that these may not be the latest or current versions of the instructions you should always check the instructions that came with the parts you ordered rather than relying on these These copies are presented here for informational purposes so you can gain a basic understanding of the workings of these motors before you buy them Always check the manufacturers Web sites see the previous section or contact us at info pratihobbies com for the latest versions and information on these products Contrail Rockets 38mm Hybrid Rocket Motor Reload Instruction Manual Congratulations on your purchase of a Contrail Rockets 38mm Hybrid Reload The supplied motor reloads have been designed to operate in Contrail Rockets Hardware only Before you begin assembly of this reload please read through this manual and familiarize yourself with the steps If you have any questions please contact Contrail Rockets I ncluded With this Reload Package is Quantit Item Name Press Lock Injectors User Selected At Time of Purchase gniters Nylon Fill Lines User Selected At Time of Purchase 3 O Rings Size 215 1 1 8 Inch Vent Line Clear Instruction Manual Not Included With this Reload Package is Sn
33. y remove the Safety Interlock Plug from the Hand Controller Return to the launch pad and move the Pad Safe Armed switch to the PAD SAFE position The warning buzzer operates all the time that the switch is in the PAD ARMED position to remind you to safe the system after launch Misfire Procedure If the rocket motor does not ignite remove the Safety Interlock Plug and wait at least 60 seconds before approaching the launch pad Move the Safe Armed switch on the ULS faceplate to the PAD SAFE position as soon as you return to the pad Care and Maintenance Make sure the Pad Safe Pad Armed switch is in the PAD SAFE position unless you are ready to launch Wrap the cables neatly and use the reusable tie wraps to secure the bundles Store all the parts inside the Base Module case The ULS system requires no maintenance other than light cleaning The alligator clips are easily replaceable You can order more clips from us when you need them or get them at an electronics store System Description The ULS Universal Launching System is a modular rocket launch control system powered by one or two external 12 volt batteries It consists of yjtrr Modules Module One is the ULS Base Module which contains control circuitry and the 12 volt battery Module Two is the Valve Manifold which connects to a nitrous oxide N2O supply tank and allows filling and venting of hybrid motors Module Three is the GOX HV Ignition which allows non pyrotechnic ignitio
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