ULPOWER UL35Oi Installation Manual Download Page 10

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Installation Manual

POWER

UL350i UL350i

UL350i

UL 350i

HPS

350i

MI 350A01 Revision No: 7

Date:

2014-09-15

Page:

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



Integrated AC generator



CPU, ignition coils and electrical wiring



Fuel pump, pressure regulator and fuel lines



Exhaust system



Cooling ducts for cylinders and cylinder heads



External rectifier-regulator



Propeller flange

In addition to the basic standard engine, following items are necessary accessories:



Oil cooler and connections (depend on type of installation)



Tacho, temperature and pressure sensors, wiring (and gauges)

Summary of Contents for UL35Oi

Page 1: ...UL35Oi UL35OiF UL35OiS UL35OiHPS UL35Oisa Installation Manual MI 350A01 Revision No 7 Date 2014 09 15 ...

Page 2: ......

Page 3: ...Installation Manual ULPOWER UL350i UL350iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 3 of 60 ...

Page 4: ...n parenthesis Where precise accuracy is not required some conversions are rounded off for easier use In addition to this Installation Manual please refer to the following Operating manual Maintenance Manual Illustrated Parts Catalogue Modifications The information and components system descriptions contained in this Installation Manual are correct at the time of publication ULPower however maintai...

Page 5: ...ular 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 Attention Denotes an instruction which if not followed may severely damage the engine or other components Note Indicates supplementary information which may be needed to fully complete or understand an instruction...

Page 6: ...turer assembler or user for aircraft application Use the appropriate tooling when installing the engine Engine is delivered in dry condition without oil Before putting engine in operation it must be filled with oil according to specifications in the operating handbook Never test run the engine without a propeller or flywheel as this will inevitably cause engine damage and present a hazard of explo...

Page 7: ...tallation 16 Transport 16 State of delivery 16 Engine preservation 16 Engine suspension and position 17 Mounting Position 18 Fuel injection system 20 Air intake system 28 Air filter 28 Idle speed adjustment 28 Throttle cable 29 Exhaust system 30 Dimensions of the exhaust system 30 Exhaust installation 30 Cabin Heating 31 Cooling system 32 Cylinderhead cooling 32 Cylinder head temperature 32 Oil co...

Page 8: ...iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 8 of 60 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: ...Electric starter Electric fuel pump and pressure regulator Specifications UL350i UL350iF UL350iS UL350iHPS Displacement 3503 cc Bore 105 6 mm Stroke 100 mm Compression Ratio 8 1 8 7 1 Firing order 1 3 2 4 Direction of Rotation Clockwise Pilot s view Tractor configuration Torque ISA conditions 305Nm 2200rpm 320Nm 2400 rpm Power rating ISA conditions 120 hp 3300 rpm 116hp 2800rpm 100hp 2300 rpm 130h...

Page 10: ...ake manifold throttle and air filter Electric starter motor Integrated AC generator CPU ignition coils and electrical wiring Fuel pump pressure regulator and fuel lines Exhaust system Cooling ducts for cylinders and cylinder heads External rectifier regulator Propeller flange In addition to the basic standard engine following items are necessary accessories Oil cooler and connections depend on typ...

Page 11: ...ual ULPOWER UL350i UL350iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 11 of 60 Engine views Figure 1 dimensions for standard prop flange l 55 different prop flanges are available see page 54 ...

Page 12: ...Installation Manual ULPOWER UL350i UL350iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 12 of 60 Figure 2 ...

Page 13: ...Installation Manual ULPOWER UL350i UL350iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 13 of 60 Figure 3 ...

Page 14: ...Installation Manual ULPOWER UL350i UL350iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 14 of 60 Figure 4 ...

Page 15: ... 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 ECU wiring loom 1 6 kg 3 5 lb Exhaust bolts springs seals 3 6 kg 8 lb Electric fuel pump 0 7 kg 1 6 lb Fuel filters pre filter fine filter 0 2 kg 0 4 lb Oil Air Separator hoses 0 7 kg 1 5 lb Rectifier Regulator 0 1 kg 0 2 ...

Page 16: ...nty is subject to the following conditions the engine must be stored in the packaging as supplied by ULPower the coverings on various openings must not be removed the engine has to be stored in a suitable dry place If the engine is stored for longer than 12 months the following tasks have to be performed every three months crank the engine by hand on attachment screw of flywheel two complete turns...

Page 17: ...h sides of the 4 holes The design of the engine mount must take into account the structural loadings while ending with 4 pins to accommodate the rubber mounts These should be tightened together with a M8x70 cap screw 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...

Page 18: ...ion No 7 Date 2014 09 15 Page 18 of 60 Mounting Position Figure 5 Mounting points As an option we can also provide a front engine mount plate 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: ...350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 19 of 60 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 ...

Page 20: ...on side of the fuel pump From the pressure side the fuel flows through a fine filter 15 micron on to the injectors which inject the right amount of fuel into the inlet manifold The remaining fuel passes through the pressure regulator and returns to the fuel tank If the aircraft is equipped with more than one fuel tank which are not connected together the return line must connect to the same fuel t...

Page 21: ... The and for the electrical connection is clearly marked Use the appropriate wiring 2 5 mm together with a 15Amp fuse A switch can be installed on the dashboard to provide electrical power to the pump allowing the pilot to manually switch the pump on off 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 E...

Page 22: ...re working A double fuel filter and bracket are included in the extra fuel pump kit Attention Be sure that all fuel lines and tank are very clean before start No pump shall be replaced for claimed defects where dirt is found into the pump due to lack of fuel tank cleaning or pump filter replacement Connecting fuel lines All fuel lines after the pump except the return line are under a constant 3bar...

Page 23: ...let over each end of the hose including the steel braid Fit the appropriate size banjo on each end all the way into the hose Eventually use a little lubricating grease saliva to ease assembly Before pressing the collet over the hose verify that hose and banjo are all the way in there is a small hole in the collet to check Turn twist the banjo eye s in the desired direction depending on the install...

Page 24: ...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 block in place are not designed to take the torque when connecting the banjo s Connect the fuel line coming from the left side of the engine cylinders 2 4 to the top hole and the return line to the bottom hole A che...

Page 25: ...ee 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 Do not over torque max 25Nm the bolts as this could cause damage to the aluminium thread in the connecting parts An M12x1 5 banjo bolt with a 1 8 NPT thread in the head is used on the exit side of the fine fuel filter to connect a fuel press...

Page 26: ...e left side of the engine cylinders 2 4 to the top hole and the return line to the bottom hole A check valve non return valve is highly recommended in the return line This is an extra safety measure in case of fire in the engine compartment If not installed fuel could run from tank to engine through a leaking fuel line even when fuel pump is switched off B Push on kit 1 1 2 3 2 Picture 1 Picture 2...

Page 27: ...n extra safety measure in case of fire in the engine compartment If not installed fuel could run from tank to engine through a leaking fuel line even when fuel pump is switched off Remark The fuel pressure regulator is integrated in the right fuel block between cylinders 1 and 3 It is connected to the inlet manifold with a cloth braided rubber tube and a small banjo in front of starter motor in or...

Page 28: ...be done while engine and master switch are switched off WARNING Take great care when adjusting throttle lever stop as the engine will be hot If the warm idle speed of the engine is unsatisfactory adjust as follows If idle speed is too low while engine is running apply throttle to the desired engine rpm Set friction to keep throttle in position and turn off engine Loosen throttle lever stop screws ...

Page 29: ...rottle cable The throttle cable may NOT go straight from engine to cockpit Or first fixing point 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 running and even engine stop NOT GOOD GOOD ...

Page 30: ...n 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 4 spare parts are in the box Procedure Unscrew the 4 M6 screws from each exhaust pipe Replace the gasket by a new one Refit the exhaust tube but DO NOT TIGHTEN the screws Af...

Page 31: ...HPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 31 of 60 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 ...

Page 32: ... C 356 F Max continuous 160 C 320 F Min 50 C 125 F Oil cooling Depending on the aircraft installation and climatic conditions it can be necessary to use an oil cooler The oil cooler should be placed in fresh airflow For further information we refer to the lubrication system description Oil temperature Max 120 C 248 F Min 50 C 122 F Normal 80 100 C 175 212 F Helicopter configuration For helicopter ...

Page 33: ...h water For Cylinder head air pressure connect one side of the tube to a static port inside the ram air duct and the other side of the tube inside the cowl near the outlet For the pressure drop across the oil cooler plumb one side of the tube against the front of the cooler and fix the other side of the tube inside the cowl near the outlet For the cylinder head cooling and oil cooling there have t...

Page 34: ...d be connected The integrated thermostat shut of the oil flow to the oil cooler until the oil temperature reach 80 C 176 F This is necessary to warm up the engine quickly in winter time Connecting oil filter sandwich plate Insert the male adaptor bits 3 together with a copper sealing ring 4 into the oil filter sandwich plate with integrated thermostat 5 and gently tighten A torque of max 25Nm shou...

Page 35: ... otherwise could cause cracks and leakage 2 brackets are included in the oil cooler kit to fix the cooler in front of the engine see picture below Bend the brackets the way you want Remove 4 bolts on the corner of the oil sump and fix the brackets with the same bolts as shown in the picture Of course it s allowed to fix the cooler on any other place but be sure that there is enough air flow over t...

Page 36: ...50i UL350iS UL350iF UL 350iHPS A breather tube is provided on the engine picture 1 Connect this tube with provided hose to the oil air separator An oil return tube is also provided on the engine picture 2 Connect this tube with the provided hose to the return side of the oil air separator The breather on an engine is necessary to prevent any pressure build up inside the engine casing due to normal...

Page 37: ...coming from between the cylinders goes straight into the oil air separator and the hose returning to the oil sump follows a nice line going downwards to the sump There should be no bucket bend in the hoses enabling oil to stay in the hose Be sure to keep the return line to the oil sump away from the exhaust eventually use some shielding If for any reason or after a time period specified in the mai...

Page 38: ...2014 09 15 Page 38 of 60 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: ...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 White red Check light Pin No 27 5 Battery Pin No 23 Battery Pin No 1 Connect to dashboard switches 6 Ground for each ignition coil connect to switch The standard length of the wiring loom is 500 mm This means that if you want ...

Page 40: ...Throttle Position Sensor Hall Sensor RPM Hall Sensor Sync RPM 2 pulse rev 0 12V Engine ECU O N O FF Power Supply Battery Power Supply Battery 3 13 Engine M ount Plate 37 34 35 36 Ignition 1 0N O FF Ignition 2 0N O FF 42 43 17 3 2 S 1 ECU Connector 18 14 5 6 7 Fuse 15A Fuse 15A 87 30 85 86 G round Battery 1 1 2 s 2 s 3 3 8 12 20 white 24 27 Fuel consum ption white green Checklight white red G round...

Page 41: ... Sensors 1 RPM pulse 2 pulse rev Hall Sensor 1 2S Hall Sensor 4 2S Throttle Position Sensor 1 Throttle Position Sensor 3 Air Tem p O il Tem p Throttle Position Sensor 2S PC connector PC connector PC connector Battery Ignition Coils 2 Injectors Air Tem p O il Tem p Ignition Coil 1 1S Ignition Coil 1 3S Ignition Coil 2 1S Ignition Coil 2 3S O ptional Relay for Fuel Pum p provides ground to relay Hal...

Page 42: ... 10 or pin 33 and connects the other side to the ground When both switches are in the position ignition off connecting to ground the software in the ECU stops immediately the fuel injection Output fuel pump relay Use the white colour wire to activate the fuel pump relay ground Use a 15Amp fuse for this fuel pump relay Output RPM Use the white blue colour wire Output check light Use the white red c...

Page 43: ...e wiring loom and double ECU B1 B4 A4 A1 A6 A7 A5 B5 B6 A8 B7 B3 B8 B2 A2 A3 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 White red check light Pin No 27 ...

Page 44: ...Installation Manual ULPOWER UL350i UL350iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 44 of 60 ECU Electrical Wiring Diagram ...

Page 45: ... the wiring loom to protect it when installed Also take care that no water can come into the connector along the wiring loom The picture below shows the acceptable A and not acceptable NA installation of the ECU box and wiring loom A NA A A NA Mount the Ignition coils on the firewall or the engine mount on a flat surface We advise not to mount them right beside the ECU to avoid any possible electr...

Page 46: ...350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 46 of 60 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: ...th a couple of turns Make sure the lead is fixed tightly and it cannot be pulled out by a small force The ignition coil cover clicks onto the ignition coil Make sure you get the correct leads going to the correct spark plugs The other side of the lead is screwed in the spark plug cover Cut the lead to the requested length Do not strip the plastic but screw the spark plug cover into it Do not forge...

Page 48: ...ou are able to fly another 40 45 minutes with a good and full charged battery Note while starting the engine in cold weather the voltage can drop temporal under 12V and generate a warning signal When the alternator work properly the warning signal must disappear after 10 20 sec while running at 1500 Rpm or higher Do not install unnecessary protective devices for the alternator and the regulator re...

Page 49: ... and once the battery is again fully charged and its voltage reaches a certain fixed value the thyristors in the shunt regulator actually short the generator windings to ground dump the load in a pulsating like fashion which generates heat in the regulators components and which must be dissipated by its outside surfaces to the surrounding environment to prevent the regulator rectifier from overhea...

Page 50: ...4 09 15 Page 50 of 60 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 51: ...late both connections to prevent short circuit by touching with a metal object and making contact with the engine ground Ground to starter motor and solenoid is provided via engine block Ground cable is attached to engine mount plate with an M6 bolt see image above right Cable thickness should be at least 16mm 5AWG or smaller Battery In a standard installation there has to be one battery of 12V 18...

Page 52: ...emperature Oil pressure and temperature are both important figures to monitor and should be kept within operating limits at all times Therefore an oil pressure sensor and oil temperature sensor should be installed on the engine and analogue or digital gauges installed on the aircraft s dashboard Make sure sensors and gauges are compatible and properly calibrated Recommended specifications for oil ...

Page 53: ...ng disc in such a manner that a nice straight end is obtained Unscrew the socket screw 4 of the oil pressure sensor fitting 6 Be careful not to loose the brass cone 5 that sits inside Before removing the tape slide the socket screw over the hose including the stainless steel braid Remove the tape Open the stainless steel braid towards the outside to free the end of the inner plastic tube As shown ...

Page 54: ...he oil can t leak of the engine Fuel Pressure Recommended specifications for fuel pressure sensor range 0 5 bar 0 80 psi thread 1 8 NPT CHT Ideally all 4 CHTs should be measured Alternately at least 2 CHTs the hottest one on each side of the engine most probably CYL3 and CYL4 in a tractor configuration should be monitored and kept within limits CHT Bayonet style probes by ULPower are recommended S...

Page 55: ... into the cylinder Measuring one EGT can only tell you that that specific cylinder is running properly or not It might be wrong to conclude that what you measure is representative for all cylinders No holes are predrilled in the exhaust so you are free to choose the type you prefer probes with clamps or thread however we recommend to use the ULPower EGT probes See accessories kits Usually temperat...

Page 56: ...lt is locked with a special locking washer A large ball bearing is used as thrust bearing which is held in position by two disc springs and a spacer ring This assembly allows engine to be used in either tractor or pusher configuration Engine turns clockwise when seen from cockpit in tractor configuration The propeller must be carefully selected to match the airframe and the engine characteristics ...

Page 57: ...R UL350i UL350iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 57 of 60 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: ...i UL350iF UL350iS UL 350iHPS 350iSA MI 350A01 Revision No 7 Date 2014 09 15 Page 58 of 60 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 59: ...oden propeller is recommended to absorb engine vibrations However a few composite propellers have been used with no known problems up to date WARNING 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...

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

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