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ULPOWER UL35Oi Installation Manual

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UL35Oi
UL35OiF
UL35OiS
UL35OiHPS
UL35Oisa
Installation
Manual
MI 350A01 Revision No: 7
Date: 2014-09-15

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Summary of Contents for ULPOWER UL35Oi

  • Page 1 UL35Oi UL35OiF UL35OiS UL35OiHPS UL35Oisa Installation Manual MI 350A01 Revision No: 7 Date: 2014-09-15...
  • Page 3 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA MI 350A01 Revision No: 7 Date: 2014-09-15 Page: 3 of 60...

  • Page 4: Preface

    If any passages of the Manual are not completely understood or in case of questions, please contact the manufacturer or an authorised dealer. We hope you will have much pleasure and satisfaction flying your aircraft powered by a ULPower engine.

  • Page 5: Repeating Symbols

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Repeating symbols This manual uses the following symbols to emphasize particular information. These indications are important and must be respected.  WARNING Identifies an instruction which, if not followed, may cause serious injury including the possibility of death.

  • Page 6: Safety Information

    It should be clear that the choice, selection and use of this particular engine on any aircraft is at the sole discretion and responsibility of the aircraft manufacturer, assembler and owner/user. ULPower makes no warranty or representation on the suitability of its engine's use on any particular aircraft. Furthermore, ULPower makes no warranty or representation of this engine's suitability with any other part, component or system which may be selected by the aircraft manufacturer, assembler or user for aircraft application.

  • Page 7: Table Of Contents

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Table of contents Preface ........................4 Remarks ....................... 4 Modifications ......................4 Engine serial number ....................4 Repeating symbols ....................5 Safety Information ....................6 Table of contents .....................7 Engine description ....................9 General Description ....................9 Specifications ......................
  • Page 8 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Starter motor ...................... 51 Battery ......................51 Additional wiring ....................51 Instruments ......................52 Recommended Sensors ................... 52 Propeller drive ...................... 56 Propeller selection ....................59 Annex A ....................... 60 Fuel header tank ....................60...

  • Page 9: Engine Description

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Engine description General Description  4 stroke, 4 cylinder, horizontally opposed  Electronic spark ignition (variable timing)  Electronic multipoint fuel injection (pressure and temperature compensated)  Electronic RPM limiter  Direct propeller drive ...

  • Page 10: Description Of Basic Standard Engine And Accessories

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Description of basic standard engine and accessories The basic standard engine consists of the following:  Engine assembly  Injectors and spark plugs  Intake manifold, throttle and air filter  Electric starter motor ...

  • Page 11: Engine Views

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Engine views Figure 1 * dimensions for standard prop flange l = 55, different prop flanges are available (see page 54) MI 350A01 Revision No: 7 Date: 2014-09-15 Page: 11 of 60...
  • Page 12 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Figure 2 MI 350A01 Revision No: 7 Date: 2014-09-15 Page: 12 of 60...
  • Page 13 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Figure 3 MI 350A01 Revision No: 7 Date: 2014-09-15 Page: 13 of 60...
  • Page 14 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Figure 4 MI 350A01 Revision No: 7 Date: 2014-09-15 Page: 14 of 60...

  • Page 15: Technical Data

    Dry weight of the basic standard engine from serial production: ....... 66,1 kg (145,73 lb) The total operational weight depends on the accessories installed. Typical accessories provided by ULPower have the following weight:  Ignition Coils & leads: ................3,0 kg (6,6 lb) ...

  • Page 16: Preparations For Engine Installation

    Engine preservation The engine is preserved at ULPower, thus warranting proper protection against corrosion for at least 12 months after date of delivery from ULPower. This warranty is subject to the following conditions: ...

  • Page 17: Engine Suspension And Position

    (8.8 steel/Din 912) and lock nut between two flanges with the correct pretension (45mm distance)(Torque to 25Nm). We suggest the steel Engine Mount Pin (1) and aluminium Engine Mount Washer (2) to be dimensioned as below. This two parts are available as an option from ULPower if needed.

  • Page 18: Mounting Position

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Mounting Position Figure 5: Mounting points Y-axis Z-axis attachment point 1 -125 mm 95 mm attachment point 2 125 mm 95 mm attachment point 3 -125 mm 165 mm attachment point 4 125 mm 165 mm As an option we can also provide a front engine mount plate.
  • Page 19 UL350iF UL350iS 350iHPS 350iSA  WARNING : The engine installation must be ground run tested before first flight. Prefabricated parts to weld to your frame are available as an option from ULPower if needed. MI 350A01 Revision No: 7 Date: 2014-09-15...

  • Page 20: Fuel Injection System

    A complete fuel connection kit can optionally be obtained from ULPower. We would like to draw your attention to a few point before installing/connecting the fuel system: ...
  • Page 21 Alternately a relay switch (see picture on the right - obtainable from ULPower as an option) can be placed between the pump and Engine Control Unit (ECU), allowing the ECU to determine when the pump should start and stop.
  • Page 22 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Optionally a second fuel pump can be installed as a backup. Ideally fuel should be drawn from tank through a second output on the tank, otherwise a T-Joint ø12x12x12 is placed between the tank and each pre-filter and is connected with the same hose and clamps.
  • Page 23 Installation Manual ULPOWER UL350i UL350iF UL350iS 350iHPS 350iSA Press-on kit Picture 1 Picture 2 Picture 3 1 fuel from tank 2 fuel return to tank 3 1/8 NPT to connect “fuel pressure sensor” – see below Each fuel line connecting two parts is made as follows: ...
  • Page 24 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Use a copper sealing ring on both sides of a banjo and tighten with banjo bolt or hex cap nut. Do not over-torque (max. 25Nm) the bolts as this could cause damage to the aluminium thread in the connecting parts.
  • Page 25 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA A. Reusable kit Picture 1 Picture 2 Picture 3 1 fuel from tank 2 fuel return to tank 3 1/8 NPT to connect “fuel pressure sensor” – see below Follow the instructions below to fix hoses and fittings: Use a copper sealing ring on both sides of a banjo and tighten with banjo bolt or hex cap nut.
  • Page 26 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA When tightening the banjo bolts that connect to the engine, use a spanner to hold the injector block in place (see image on the left). The two screws on the other side holding the injector...
  • Page 27 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Use a copper sealing ring on both sides of a banjo and tighten with banjo bolt or hex cap nut. Do not over-torque (max. 25Nm) the bolts as this could cause damage to the aluminium thread in the connecting parts.

  • Page 28: Air Intake System

    Air filter Only ULPower approved air filters may be used. These air filters can be purchased by ULPower. Idle speed adjustment The throttle lever stop (1) is factory set to a position that should correspond to a warm engine idle speed of approx.

  • Page 29: Throttle Cable

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Throttle cable The throttle cable may NOT go straight from engine to cockpit. ( Or first fixing point ) NOT GOOD GOOD Reason Because the engine moves against the firewall (because of rubber mounts) while running, the throttle position keeps on changing in case of “straight”...

  • Page 30: Exhaust System

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Exhaust system Unless otherwise agreed, the motor will be delivered with the UL power exhaust system. The system is designed to reduce the noise to an acceptable level without loosing power. Dimensions of the exhaust system: Exhaust installation : The 4 exhaust tubes are fitted to the cylinder heads with 4 screws.

  • Page 31: Cabin Heating

    Installation muffler brackets : Cabin Heating: As an option we can also provide a cabin heating unit. For more information, see website accessories/parts, illustrated parts catalogue or contact ULPower. MI 350A01 Revision No: 7 Date: 2014-09-15 Page: 31 of 60...

  • Page 32: Cooling System

    The air flow generated by this fan blows into the ram air boxes. Additional weight of this system is ca. 4 kilo. For more information, contact ULPower. MI 350A01 Revision No: 7...

  • Page 33: Testing & Evaluation

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Testing & evaluation For new installations the pressure drop across both Ram air ducts must be checked. The following is a guide to evaluating an engine installation to see if it meets minimum cooling requirements.

  • Page 34: Lubrication System

    Oil Cooler Depending on the aircraft and climatic conditions, an optional oil cooler will be necessary. A complete oil cooler kit is available from ULPower. The oil cooler can be connected on the interfaces of the sandwich plate with integrated thermostat which is situated at the front left side of the engine.
  • Page 35 “accessories/kits section). In any case: one straight, one 45°, one 90° and one 150° fitting are provided with the oil cooler kit. If necessary (for ease of installation) different angles can be obtained from ULPower upon request. Available angles: MI 350A01 Revision No: 7...

  • Page 36: Oil/Air Separator & Breather (Ul350I; Ul350Is; Ul350If;Ul 350Ihps)

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA 0° 45° 90° 120° 150° 180° Instruction to fix the reusable hoses and fittings: see page 23 Instruction to fix the push-on hoses and fittings: see page 24 Connecting oil lines Connect oil lines to the sandwich plate and the oil cooler. There is no particular in/out direction on the cooler so you are free to connect them in the most suitable way.
  • Page 37 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA The oil/air separator bottle is connected as follows: Connect to tube leaving aircraft Connect to tube coming from engine Connect to tube returning to oil sump The oil/air separator bottle can be mounted onto the firewall and must stay in its upward position as shown above.

  • Page 38: Oil/Air Separator & Breather (Ul350Isa)

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Oil/Air Separator & Breather (UL350iSA) For the installation of the oil/air separator on the UL260iSA (aerobatic), with the gravity valve and all oil lines, follow the instructions below. It is important that the gravity valve and the oil/air separator are mounted exactly vertically !

  • Page 39: Electrical System

    1. Single ECU & Ignition 1. Connect to ECU 2. PC Connector for programming by ULPower 3. Ground for cable shielding 4. White/blue: RPM pulse (2 pulses/rev. 0-12V)(Pin No. 9) White: To optional Fuel Pump Relay(Pin No. 25) White/green: Fuel consumption (Pin No.24)
  • Page 40 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA ECU Electrical Wiring Diagram F u e l P um p R e la y F u e l P um p F u s e 1 5 A P o w e r S u p p ly...
  • Page 41 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA ECU Connector – Wiring: B a tte ry (g ro u n d ) F u e l c o n s u m p tio n O p tio n a l R e la y fo r F u e l P u m p...

  • Page 42: Connecting The Ecu To The Cockpit

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Connecting the ECU to the Cockpit Power supply  Install a switch (ECU on/off)  Connect the power supply (battery ”+”) to one side of the switch. Use a cable of min. 2,5 mm²...

  • Page 43: Double Ecu & Ignition

    A1-A8: connections ECU1 B1-B8: connections ECU2 1. Connect to ECU 2. PC Connector for programming by ULPower or to “UL Check” program 3. Ground for cable shielding 4. White/blue: RPM pulse (2 pulses/rev. 0-12V)(Pin No. 9) White: To optional Fuel Pump Relay(Pin No. 25) White/green: Fuel consumption (Pin No.24)
  • Page 44 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA ECU Electrical Wiring Diagram MI 350A01 Revision No: 7 Date: 2014-09-15 Page: 44 of 60...
  • Page 45 UL350iF UL350iS 350iHPS 350iSA ULPower advise to use “positive lock” connectors for all electrical connections to ensure that connection not become loose because of vibrations. Make sure ECU and Ignition switches are of adequate quality and are designed for at least 15 Amp DC current.
  • Page 46 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Connect connectors on wiring loom as shown below to any of the two coils. Make up the ignition leads according to the length needed. The necessary parts (covers, clamps and lead) are provided with the engine.
  • Page 47 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA The provided copper clamps are used on one end of each lead and screw into the ignition coil cover. Strip only a few millimetres of the outer plastic of the ignition lead to unveil the inner core. It is advisable to solder the copper clamp onto the lead for good contact.

  • Page 48: Alternator & Regulator/Rectifier

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA  Attention: First start after installation / maintenance.  Start the engine with only coil 1 (and ECU 1 in case of redundancy ) When the engine run very well, stop the engine and start again with only coil 2 (and ECU 2 ...
  • Page 49 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Connect regulator/rectifier to the battery and the 3 yellow electrical wires (3) (which are usually grouped together in a protective sheath) E xte n s ion o f ye llo w w ire s...

  • Page 50: Recommended Diagram

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Recommended diagram We advise to install a capacitor 68.000 µF (ULP n° E053010) parallel on the battery to ensure power to the +12V bus in case of open contact in the battery.

  • Page 51: Starter Motor

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Starter motor The electric starter engine (1) is mounted on the top of the engine and drives the ring gear (2) at the back of the engine. The motor is activated by engaging the starter button (the master switch has to be on) which...

  • Page 52: Instruments

    Installation Manual ULPOWER UL350i UL350iF UL350iS 350iHPS 350iSA Instruments Recommended Sensors In order to operate the engine within the specified limits of the operating handbook, operator should at least monitor following parameters:   Oil Pressure  Oil Temperature ...
  • Page 53 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Oil Pressure The oil pressure sensor should not be directly screwed into the engine block, and is therefore connected by means of a flexible pressure line in order to avoid sensor failure due to engine vibrations.
  • Page 54 CYL3 and CYL4 in a tractor configuration) should be monitored and kept within limits. CHT Bayonet style probes by ULPower are recommended. See accessories/kits. Bayonet adaptor (3/8"UNF) is integrated. Each cylinder head has a pre-drilled hole close to the exhaust port to monitor CHT.
  • Page 55 Although one cannot do much (apart from changing the throttle) on the ULPower engine to influence the EGT, monitoring all EGTs will provide the pilot with an immediate indication that things might not be normal.

  • Page 56: Propeller Drive

    6 propeller drive lugs are provided with the engine. These are made to have a tight fit in the propeller flange holes. ULPower offers different types of propeller flanges. 1. Standard Flange...
  • Page 57 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA 2. SAE I - F – Flange : E022550 L055 / E022550 L090 / E022550 L110 = assembly 3. SAE VI - B – Flange : E022551 L055 / E022551 L090 / E022551 L110 = assembly...
  • Page 58 ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA 4. SAE VI - C – Flange : E022552 L055 / E022552 L090 / E022552 L110 = assembly SAE VI - D – Flange : E022553 L055 / E022553 L090 / E022553 L110 / E022553 L035 = assembly...

  • Page 59: Propeller Selection

    Never use the engine without a propeller. Damage will occur in this state. In case of using a ‘constant speed propeller”, only an electrically commanded propeller can be used. ULPower can optionally deliver a bracket to mount the electrical contacts. Part n° E022007 Install the bracket as show in the picture.

  • Page 60: Page: 7 Of

    ULPOWER Installation Manual UL350i UL350iF UL350iS 350iHPS 350iSA Annex A Fuel header tank MI 350A01 Revision No: 7 Date: 2014-09-15 Page: 60 of 60...

This manual is also suitable for:

Ul35oifUl35oisUl35oihpsUl35oisa

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