OpenPPG v3.1 and v3.2 Manual
This is an open source document. Everyone is free to add and edit it. If you would like to edit what someone else wrote, please so by clicking the edit icon on this post.
Nothing in this document should be taken as fact (we all make mistakes). This is meant to pool the community’s knowledge in one place, so that Paul can use it as a starting off point for the official manual, which will be published on OpenPPG.com
Table of Contents
- Parts list / diagram
- How to assemble
- Battery installation
- Battery charging
- Harness installation
- Pre-flight check
- Controller operation
- Suggested maintenance
- Video resources
1 - Specs
Thrust: 160 lbs. This should be enough for pilots weighing up to ???
Weight (no batteries or harness): 20 lbs
Peak power use: 300 amps, 48 volts
Cruise power use: ??
Flight time: 10-12 minutes for each set of 2 bonka batteries
Dimensions when ready to fly:
Dimensions when folded up:
Propeller Spec? At least list a known-good config?
2 - Parts list / diagram
- Bottom plates cf (2)
- Inside legs cf (2) (need pic to show difference)
- Outside legs cf (2)
- Arms cf (8)
- Front motor plates cf (4)
- Rear motor plates cf (4)
- Gooseneck bars (2)
- 20mm Standoffs
- 35mm Standoffs
- N3 Bolts (Are these a standard somewhere that google makes hard to find? How many are needed? Why use two different sizes? Is there a minimum strength the standard guarantees?)
- N4 Bolts
cf - carbon fiber part
m - Metal part (I don’t see this on anything … does it apply to the bolts? The standoffs?)
- Motors (4) – two of which are clockwise, two counterclockwise, so that torque cancels out.
- Motor controllers (ESCs) (4)
- Batteries (2 or 4 typ) XT150 type connectors
3 - How to assemble
- Narrow nose pliers
- Wire cutters
- Utility knife
- N3 Allen key (inch/mm ??) (a second key is helpful)
- N4 Allen key (driver is helpful)
- Socket (sizes?) and ratchet driver
- Soldering Iron (35Watt)
- Electrical tape and/or Heat shrink (sizes ?)
- 60/40 Solder (Assuming this means 60/40 Sn-Pb … Is the type important? Did you intentionally avoid 63/37 (used for electrical work?) or the various lead-free options (may be bad for aerospace?) … or is 60/40 just the default that was good enough?)
- Thread Locker adhesive (sug. Loctite Red 271)
The frame structure is assembled from paired carbon plates which are bolted together using standoffs between the plates and bolts from each side into the standoffs. The parts key together at the edges and thus lock together.
Assemble lower frame and legs
- Assemble one leg using an inner and an outer leg piece, nine 20mm standoffs and 18 N3 bolts.
- Assemble a second leg per step 1 using remaining inner and outer leg pieces. Be sure to assemble it as a mirror to the first so a left and a right leg are created.
Assemble arms and motors
Assemble gooseneck bars
Nothing about the backplates … are they part of the Wiring assembly?
Probably should also list the sequence for netting and controller.
Instructions for assembling the kit can be found in this video demonstration.
One possible layout for motor rotation:
This has diagonally opposite motors spinning in the same direction, so that motor torque will be balanced both vertically and horizontally.
OpenPPG can be folded up for easier transport. To make it flight ready:
- Lock arms and baseplate with hinges
- Attached hoop pieces with plastic spacers to arms
- Secure netting (?)
4 - Battery installation
Suggested batteries: https://openppg.com/shop/batteries/bonka-22000mah-6s-lipo-battery/
OpenPPG operates at between 40-60 volts. Batteries must be installed in series to obtain 48 volts. Additional batteries must be installed in parallel. For the suggested bonkas, that means you must always use an even number of batteries (to get the voltage right), with additional pairs being added in parallel to increase duration and reduce overheating. When using batteries in parallel, ensure that all batteries are charged to within 1 volt of each other. If there is a significant difference in charge then one battery could charge another at high currents, which can lead to a fire.
Batteries may be attached to frame using a large strap: [More PICs NEEDED]
Or with a DIY box: [PIC NEEDED]
Or with a DIY 3D printed rails: https://community.openppg.com/t/paul-b-braedin-b-gliderpilot-glydrfreak-flights-build-modifications/559/112?u=jrsimple
5 - Battery charging
How to charge:
Always inspect your batteries for dents, tears, or other damage before each use.
What is balance charging?
Balance Charging is a technology/technique that regulates the charging of each cell in a battery. This helps prevent overcharging of some cells, as well as fully charging others, yielding benefits to battery life, output and safety. It operates similarly during discharge cycles as well.
What NOT to do when charging:
- Do NOT overcharge! This may cause fire.
- Do NOT leave your batteries charging unsupervised.
6 - Harness installation
7 - Preflight Checks
- Propeller arms locked open
- Cage and netting secure
- Batteries securely attached to frame
- Battery connections in correct setup (parallel & series) and connections secure and away from props
- Harness secure and no loose straps
- Turn on power switch
8 - Controller operation
To arm the motors for flight:
Batch 2: Double click the solid red button. You will then hear a tone confirming the system is armed.
Batch 3: Hold top button while double-pressing side button. Throttle will vibrate and sound arm tone to confirm
Batch 4: Double click top button. You will then hear a tone and feel vibration confirming the system is armed.
To disarm/turn off:
Batch 2: Double click the solid red button. You will then hear a tone confirming the system is disarmed.
Batch 3: Hold top button while double-pressing side button. Throttle will vibrate and sound disarm tone to confirm
Batch 4: Double click top button. You will then hear a tone and feel vibration confirming the system is disarmed.
9 - Flight
Monitor your LiPo battery voltage during flight. Land before your batteries get down to 3.4 volts per cell (40.8v for a 12s pack) or your batteries can accumulate permanent damage. Warning: Highly discharged batteries can become dangerous to charge, due to low internal resistance.
10 - Suggested maintenance
11 - Warnings
When flying with only 2 bonka batteries, batteries may overheat. It is suggested to fly with a minimum of 4 bonka batteries (or equivalent).
When flying with 2 batteries it drains a lot of current (amps) from the two packs. Flying with 4 batteries will drain at half the rate from each pack, resulting in less heat generated at the battery pack level and the connections.
12 - Video Resources
Please add links to all OpenPPG related videos below.
|OpenPPG youtube channel||https://www.youtube.com/channel/UCJc7CgstP0amq8ke_rxAe5Q|
|PDWhite youtube channel||https://www.youtube.com/channel/UCwA2hdZzT2WmgsKxowHUSNQ|
|14 Jan 2019||Pauls Battery Charging setup||https://youtu.be/ufZHTRZBxtk|
|14 Jan 2019||Throttle v2 overview||https://youtu.be/vI1dPY_5OTI|
|13 Jan 2019||Pre-built quick setup guide v3.2||https://youtu.be/VT9rrX6FJoY|
|22 Jun 2018||OpenPPG 22 v3.1 Build Video (part 1)||https://www.youtube.com/watch?v=kEDDKatQQ3E|
|OpenPPG 22 v3.1 Build Video (part 2)||Not released yet|
|10 Aug 2018||Two Electric PPG Air to Air (OpenPPG 22 v3.2)||https://www.youtube.com/watch?v=iOWObMjmRvg|
|22 May 2018||OpenPPG 22 Fun Flying and Update||https://www.youtube.com/watch?v=aSm94tQ0qDU|
|30 Mar 2018||Batch Two Update- Open Source Electric PPG||https://www.youtube.com/watch?v=TEXIIIgmMHM|
|22 Feb 2018||OpenPPG DIY Electric Paramotor Update||https://www.youtube.com/watch?v=mj4-kNLtI3g|
|18 Jan 2018||DIY Electric Paramotor Project Update (Vid #3)||https://www.youtube.com/watch?v=LsQhtP4wmHw|
|26 Dec 2017||Electric Paramotor Project DIY Frame Breakdown (Vid #2)||https://www.youtube.com/watch?v=3tbF83QRtgI|
|10 Dec 2017||Electric Paramotor Project DIY (Vid #1)||https://www.youtube.com/watch?v=IvmQbtxeKuE|