ULPOWER UL390i Installation Manual Download

Page: 1 / 69

39Oi

Installation

Manual

MI 390A01 Revision No: 3

Date: 2014-09-15

Summary of Contents for UL390i

Page 1: ...UL39Oi UL39OiS UL39Oisa Installation Manual MI 390A01 Revision No 3 Date 2014 09 15...

Page 2: ......

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

Page 4: ...sis 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 Ill...

Page 5: ...ation 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 ins...

Page 6: ...bler 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...

Page 7: ...or engine installation 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 Id...

Page 8: ...al ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 8 of 69 Additional wiring 60 Instruments 61 Recommended Sensors 61 Propeller drive 65 Propeller selection 68 Annex A 69 Fu...

Page 9: ...nd cylinder heads Integrated AC generator external rectifier regulator Electric starter Electric fuel pump and pressure regulator Specifications UL390i UL390iS UL390iSA Displacement 3888cc Bore 105 6...

Page 10: ...ure regulator and fuel lines Exhaust system Cooling ducts for cylinders and cylinder heads External rectifier regulator Propeller flange L 55 Standard In addition to the basic standard engine followin...

Page 11: ...tion Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 11 of 69 Engine views Figure 1 dimensions for standard prop flange l 55 different prop flanges are available see...

Page 12: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 12 of 69 Figure 2...

Page 13: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 13 of 69 Figure 3...

Page 14: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 14 of 69 Figure 4...

Page 15: ...cessories 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...

Page 16: ...owing 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 engi...

Page 17: ...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...

Page 18: ...0iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 18 of 69 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 1...

Page 19: ...n No 3 Date 2014 09 15 Page 19 of 69 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 we...

Page 20: ...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...

Page 21: ...or 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...

Page 22: ...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 defect...

Page 23: ...ion Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 23 of 69 Return line Connect to anti return valve E065001 Pressure side Connect line coming from fuel fine filter...

Page 24: ...g disc in such a manner that a straight end is obtained Use compressed air to blow all particles of rubber and metal out of the inside of the hose Remove the tape and slide a collet over each end of t...

Page 25: ...ers which means that the fuel injectors could be blocked by foreign particles which have not been removed properly Use a copper sealing ring on both sides of a banjo and tighten with banjo bolt or hex...

Page 26: ...2014 09 15 Page 26 of 69 B 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...

Page 27: ...et manifold with a cloth braided rubber tube and a small banjo in front of starter motor in order to regulate fuel pressure 3 bar above inlet manifold pressure Regularly check for wear particularly on...

Page 28: ...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 f...

Page 29: ...low 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 fuselag...

Page 30: ...ate 2014 09 15 Page 30 of 69 Throttle cable Reason Because the engine moves against the firewall because of rubber mounts while running the throttle position keeps on changing in case of straight thro...

Page 31: ...4 09 15 Page 31 of 69 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 loos...

Page 32: ...during the final test run of your engine the gaskets are deformed and have to be replaced 6 spare parts are in the box Procedure Unscrew the 4 M6 screws from each exhaust pipe Replace the gasket by a...

Page 33: ...UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 33 of 69 Cabin Heating As an option we can also provide a cabin heating unit For more information see website accessories parts illustrated...

Page 34: ...mits of operation Describe ram air ducts and amount of air that should pass over the cylinders and cylinder heads Cylinder head temperature Max 180 C 356 F Max continuous 160 C 320 F Min 50 C 125 F Oi...

Page 35: ...ter 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...

Page 36: ...ted 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 san...

Page 37: ...mpers so that it is less subject to vibrations which otherwise could cause cracks and leakage 3 brackets and 4 silent blocks are included in the oil cooler kit to fix the cooler in front of the engine...

Page 38: ...390iS UL390iSA 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 thi...

Page 39: ...m 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 enab...

Page 40: ...Page 40 of 69 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...

Page 41: ...ECU and the ECU wiring loom cockpit are delivered separate 1 Single ECU Ignition 1 Connect to ECU 2 Ground for cable shielding 3 PC Connector UL check or aux box 4 Connect to coil 1 5 Ground 6 Connect...

Page 42: ...wires white white RPM signal 2 pulses rev 0 12V white blue Fuel consumption Injector puls Output is a duty cycle 100 is equal to 72l Hr white red fuel consumption pulses litre 72l Hr 170Hz 170 pulses...

Page 43: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 43 of 69 ECU Electrical Wiring Diagram for single ECU...

Page 44: ...14 09 15 Page 44 of 69 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 possi...

Page 45: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 45 of 69 Pre wired display E081550 For more info contact UL Power...

Page 46: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 46 of 69 Detailed diagram for maintenance only...

Page 47: ...n 8 20 Sensor fail Y White white 9 20 ECU over temperature Z White red future 10 20 Battery low G White blue 11 20 Fuel pump relay J White blue 12 20 Fuel pump relay e White white 13 20 Health h White...

Page 48: ...ble air intake temp sensors double throttle pos sensors double hall sensors double wiring loom and double ECU The engine is delivered with 2 x ECU wiring loom engine installed Picture 1 Wires and conn...

Page 49: ...onsumption Injector pulse Output is a duty cycle 100 is equal to 72l Hr white red fuel consumption pulses litre 70l Hr 170Hz 170 pulses sec 6 Yellow shrink sleeve 4 wires white green Common white red...

Page 50: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 50 of 69 ECU Electrical Wiring Diagram for double ECU...

Page 51: ...14 09 15 Page 51 of 69 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 possi...

Page 52: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 52 of 69 Pre wired display E081565 For more info contact UL Power...

Page 53: ...Installation Manual ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 53 of 69 Detailed diagram for maintenance only...

Page 54: ...ure Z White red future 10 20 Battery low G White blue 11 20 Fuel pump relay J White blue 12 20 Fuel pump relay e White white 13 20 Health h White red 14 20 Engine data TX232 B White blue 15 20 Engine...

Page 55: ...n time Mount the ECU unit in a place where temperatures do not reach over 65 C preferably on the cabin side of the firewall Take great care when putting the wiring loom through the firewall not to dam...

Page 56: ...390A01 Revision No 3 Date 2014 09 15 Page 56 of 69 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 part...

Page 57: ...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 correc...

Page 58: ...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...

Page 59: ...ge 59 of 69 Recommended diagram We advise to install a capacitor 68 000 F ULP n E053010 parallel on the battery to ensure power to the 12V bus in case of open contact in the battery Optional switch ca...

Page 60: ...onnections 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...

Page 61: ...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 instal...

Page 62: ...isc 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...

Page 63: ...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...

Page 64: ...ylinder 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...

Page 65: ...d 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...

Page 66: ...al ULPOWER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 66 of 69 2 SAE I F Flange E022550 L055 E022550 L090 E022550 L110 assembly 3 SAE VI B Flange E022551 L055 E022551 L090 E022...

Page 67: ...WER UL390i UL390iS 390iSA MI 390A01 Revision No 3 Date 2014 09 15 Page 67 of 69 4 SAE VI C Flange E022552 L055 E022552 L090 E022552 L110 assembly 5 SAE VI D Flange E022553 L055 E022553 L090 E022553 L1...

Page 68: ...ver 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 prope...

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

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