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ULPOWER UL390i Installation Manual

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Download this manual See also: Maintenance Manual, Operating Manual
UL39Oi
UL39OiS
UL39Oisa
Installation
Manual
MI 390A01 Revision No: 3
Date: 2014-09-15

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Summary of Contents for ULPOWER UL390i

  • Page 1 UL39Oi UL39OiS UL39Oisa Installation Manual MI 390A01 Revision No: 3 Date: 2014-09-15...
  • Page 3 ULPOWER Installation Manual UL390i UL390iS 390iSA MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 3 of 69...

  • 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 UL390i UL390iS 390iSA 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

    Testing & evaluation ..................... 35 Lubrication system ....................36 Oil Cooler ......................36 Oil/Air Separator & Breather (UL390i; UL390iS; UL390iSA) ..........38 Oil/Air Separator & Breather (UL390iSA) ..............40 Electrical system ....................41 1. Single ECU & Ignition ..................41 2.
  • Page 8 ULPOWER Installation Manual UL390i UL390iS 390iSA Additional wiring ....................60 Instruments ......................61 Recommended Sensors ................... 61 Propeller drive ...................... 65 Propeller selection ....................68 Annex A ....................... 69 Fuel header tank ....................69 MI 390A01 Revision No: 3 Date: 2014-09-15...

  • Page 9: Engine Description

    ULPOWER Installation Manual UL390i UL390iS 390iSA Engine description General Description  4 stroke, 6 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 UL390i UL390iS 390iSA 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 UL390i UL390iS 390iSA Engine views Figure 1 * dimensions for standard prop flange l = 55, different prop flanges are available (see page 64) MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 11 of 69...
  • Page 12 ULPOWER Installation Manual UL390i UL390iS 390iSA Figure 2 MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 12 of 69...
  • Page 13 ULPOWER Installation Manual UL390i UL390iS 390iSA Figure 3 MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 13 of 69...
  • Page 14 ULPOWER Installation Manual UL390i UL390iS 390iSA Figure 4 MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 14 of 69...

  • Page 15: Technical Data

    Dry weight of the basic standard engine from serial production: ......85.3 kg (188 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 UL390i UL390iS 390iSA 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...
  • Page 19 As an option we can also provide a front engine mount plate.  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 390A01 Revision No: 3...

  • 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 points 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 UL390i UL390iS 390iSA 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 ULPOWER Installation Manual UL390i UL390iS 390iSA Return line Pressure side   Connect to anti-return Connect line coming from   valve (E065001) “fuel fine filter” Picture 1 MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 23 of 69...
  • Page 24 ULPOWER Installation Manual UL390i UL390iS 390iSA Press-on kit Picture 2 Picture 3 1 fuel from tank 2 fuel return to tank 3 1/8 NPT to connect “fuel pressure sensor” – see below 4 Connect to pressure side (Picture 1) 5 Connect to return line (Picture 1) Each fuel line connecting two parts is made as follows: ...
  • Page 25 ULPOWER Installation Manual UL390i UL390iS 390iSA  Clean the fuel hoses extremely thoroughly to ensure no metal, rubber or other particles are inside before connecting all the lines. This is especially important as some of these tubes are down stream of both filters which means that the fuel injectors could be blocked by foreign particles which have not been removed properly.
  • Page 26 Installation Manual ULPOWER UL390i UL390iS 390iSA Reusable kit Picture 2 Picture 3 1 fuel from tank 2 fuel return to tank 3 1/8 NPT to connect “fuel pressure sensor” – see below 4 Connect to pressure side (Picture 1) 5 Connect to return line (Picture 1)
  • Page 27 ULPOWER Installation Manual UL390i UL390iS 390iSA 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: Connecting The Air Filter

    ULPOWER Installation Manual UL390i UL390iS 390iSA Connecting the air filter Separate, 3 parts shown in picture below are delivered with the engine. (Air filter, tube, flexible hose) Connect this parts as shown in picture below Because of the flexible hose, you can bend it the way you want. Fix the filter to the fuselage.

  • Page 30: Throttle Cable

    ULPOWER Installation Manual UL390i UL390iS 390iSA Throttle cable 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” throttle cable. This may lead to bad...

  • Page 31: Exhaust System

    ULPOWER Installation Manual UL390i UL390iS 390iSA 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:...

  • Page 32: Exhaust Installation

    ULPOWER Installation Manual UL390i UL390iS 390iSA Exhaust installation : The 6 exhaust tubes are fitted to the cylinder heads with 4 screws. Between the cylinder head and the flange is an exhaust gasket. (See Parts catalogue “Exhaust system“) Because ULP have to tighten the exhaust pipes during the final test run of your engine, the gaskets are deformed and have to be replaced.

  • Page 33: Cabin Heating

    Installation Manual UL390i UL390iS 390iSA 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 390A01 Revision No: 3 Date: 2014-09-15 Page: 33 of 69...

  • Page 34: Cooling System

    ULPOWER Installation Manual UL390i UL390iS 390iSA Cooling system Cylinder head cooling: Ram air ducts/chamber should guide the incoming air equally over the cylinders and cylinder heads. Sufficient amount of fresh air keeps the temperatures within the limits of operation. Describe ram air ducts and amount of air that should pass over the cylinders and cylinder heads.

  • Page 35: Testing & Evaluation

    ULPOWER Installation Manual UL390i UL390iS 390iSA 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 36: 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 37 “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 390A01 Revision No: 3...

  • Page 38: Oil/Air Separator & Breather (Ul390I; Ul390Is; Ul390Isa)

    When engine is completely installed and is started up for the very first time, check for leaks in the oil cooler assembly. Tighten where necessary. Oil/Air Separator & Breather (UL390i; UL390iS; UL390iSA) A breather tube is provided on the engine (picture 1). Connect this tube with provided hose to the oil /air separator.
  • Page 39 ULPOWER Installation Manual UL390i UL390iS 390iSA 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 40: Oil/Air Separator & Breather (Ul390Isa)

    ULPOWER Installation Manual UL390i UL390iS 390iSA Oil/Air Separator & Breather (UL390iSA) For the installation of the oil/air separator on the UL390iSA (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 41: Electrical System

    ULPOWER Installation Manual UL390i UL390iS 390iSA Electrical system The engine is delivered with the “ECU Wiring loom engine” installed. Wires and connecters which have to be connected during the installation are explained below The ECU and the “ECU wiring loom cockpit” are delivered separate.
  • Page 42 ULPOWER Installation Manual UL390i UL390iS 390iSA ECU Wiring loom cockpit 1. Blue shrink sleeve : Battery - / Put all 5 wires together 2. Red shrink sleeve : Battery + / Put all 6 wires together to a switch, install a fuse 20A and use a wire from minimum 2.5mm²...
  • Page 43 ULPOWER Installation Manual UL390i UL390iS 390iSA ECU Electrical Wiring Diagram for single ECU MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 43 of 69...
  • Page 44 ULPOWER Installation Manual UL390i UL390iS 390iSA Aircraft wiring UL Power propose to install the aircraft wiring as explained below. The 2 switches for the fuel pump must be connected to each other that way that it is not possible to run both pumps together. UL Power offer this pre-wired display.
  • Page 45 ULPOWER Installation Manual UL390i UL390iS 390iSA Pre-wired display (E081550). For more info, contact UL Power MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 45 of 69...
  • Page 46 ULPOWER Installation Manual UL390i UL390iS 390iSA Detailed diagram, for maintenance only MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 46 of 69...
  • Page 47 ULPOWER Installation Manual UL390i UL390iS 390iSA Connection “ECU wiring loom cockpit”, for maintenance only Signal Remark Switch off ignition 1 White/white Switch off ignition 2 White/red Switch off common White/Blue White/White Consumption pulse/litre White/red Consumption inj. pulse White/blue Common -...

  • Page 48: Double Ecu & Ignition

    ULPOWER Installation Manual UL390i UL390iS 390iSA 2. Double ECU & Ignition For safety reason we offer a completely redundant, dual channel ECU combination. In this case the engine is equipped with double oil temp sensors, double air intake temp sensors, double throttle pos sensors, double hall sensors, double wiring loom and double ECU.
  • Page 49 ULPOWER Installation Manual UL390i UL390iS 390iSA 1. Blue shrink sleeve : Battery - / Put all wires together ECU Wiring loom engine cockpit 2. Red shrink sleeve + ECU : Battery + / Put all 4 wires together 3. Red shrink sleeve + injection : Battery + / Put the 2 wires together ...
  • Page 50 ULPOWER Installation Manual UL390i UL390iS 390iSA ECU Electrical Wiring Diagram for double ECU MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 50 of 69...
  • Page 51 ULPOWER Installation Manual UL390i UL390iS 390iSA Aircraft wiring UL Power propose to install the aircraft wiring as explained below. The 2 switches for the fuel pump must be connected to each other that way that it is not possible to run both pumps together. UL Power offer this pre-wired display.
  • Page 52 ULPOWER Installation Manual UL390i UL390iS 390iSA Pre-wired display (E081565). For more info, contact UL Power MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 52 of 69...
  • Page 53 ULPOWER Installation Manual UL390i UL390iS 390iSA Detailed diagram, for maintenance only MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 53 of 69...
  • Page 54 ULPOWER Installation Manual UL390i UL390iS 390iSA Connection “ECU wiring loom cockpit”, for maintenance only Signal Remark White/White Consumption pulse/litre White/red Consumption inj. pulse White/blue Common - White/green Sensor fail White/white ECU over temperature White/red future Battery low White/blue Fuel pump relay -...
  • Page 55 UL390i UL390iS 390iSA 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 20 Amp DC current.
  • Page 56 ULPOWER Installation Manual UL390i UL390iS 390iSA 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 57 ULPOWER Installation Manual UL390i UL390iS 390iSA 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 58: Alternator & Regulator/Rectifier

    ULPOWER Installation Manual UL390i UL390iS 390iSA  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 59: Recommended Diagram

    ULPOWER Installation Manual UL390i UL390iS 390iSA 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. Optional switch can be placed on showed position if customer want to disconnect the alternator from the system.

  • Page 60: Starter Motor

    ULPOWER Installation Manual UL390i UL390iS 390iSA 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 61: Instruments

    Installation Manual ULPOWER UL390i UL390iS 390iSA 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  Fuel Pressure ...
  • Page 62 ULPOWER Installation Manual UL390i UL390iS 390iSA 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 63 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 64 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 65: 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 66 ULPOWER Installation Manual UL390i UL390iS 390iSA 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 67 ULPOWER Installation Manual UL390i UL390iS 390iSA 4. SAE VI - C – Flange : E022552 L055 / E022552 L090 / E022552 L110 = assembly 5. SAE VI - D – Flange : E022553 L055 / E022553 L090 / E022553 L110 / E022553 L035 = assembly...

  • Page 68: 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 69: Annex A

    ULPOWER Installation Manual UL390i UL390iS 390iSA Annex A Fuel header tank MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 69 of 69...

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