ULPOWER UL260 User manual

UL26o
UL35o
UL39o
UL52o
Operating
Manual
M0310: OM 260 - 520A01 Revision No: 04 Date: 2021-11-18

Operating Manual ULPOWER UL260,UL350,UL390,UL520
M0310: OM 260 - 520A01 Revision No: 04 Date: 2021-11-18 Page: 1 of 23
Preface
Thank you for choosing ULPower Aero Engines to power your aircraft.
This Manual will provide you with basic information on safe engine operations / safe flights .
We recommend to study this manual carefully , before starting the engine for the first time.
If you are unsure about the procedures mentioned in this manual, please contact a ULPower
authorised sales or service point.
We hope you will enjoy flying your ULPower-ed aircraft.
Remarks
The diagrams and other pictures in this manual show the typical construction. They may not
represent in full detail or the exact shape of the parts which have the same or similar function.
Specifications are given in the SI metric system with the USA (Imperial system) equivalent in
parenthesis. Where precise accuracy is not required, some conversions are rounded off for easier
use.
In addition to this Operating Manual, please refer to the following:
Installation Manual
Technical Data document
Installation checklist
Trouble shooting manual
Illustrated Parts Catalogue
Propeller flanges document
Maintenance Manual
Please make sure you have the latest version available of the applicable manual.
Modifications
The information and components/system descriptions contained in this Operating Manual are
correct at the time of publication. ULPower, however, maintains a policy of continuous
improvement of its products without imposing upon itself any obligation to install them on its
products previously manufactured.
ULPower reserves the right at any time to discontinue or change specifications, designs, features,
models or equipment without incurring obligation.
Please contact your dealer or check the manufacturers website (http://www.ULPower.com) for any
updates or changes concerning the engine and its manuals.
Engine serial number
On all enquiries or spare parts orders, always indicate the engine serial number. The serial number
(6 digits) can be found on top of the engine near to cylinder 2.
X
X
X
X
X
X

Operating Manual ULPOWER UL260,UL350,UL390,UL520
M0310: OM 260 - 520A01 Revision No: 04 Date: 2021-11-18 Page: 2 of 23
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.
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.

Operating Manual ULPOWER UL260,UL350,UL390,UL520
M0310: OM 260 - 520A01 Revision No: 04 Date: 2021-11-18 Page: 3 of 23
Safety information
The engine should only be installed and operated by persons familiar with the use of the engine
and informed with regard to possible hazards.
Familiarize yourself with the installation, maintenance and operational limits of your ULPower
engine. Failure to follow the instructions in these manuals can result in a serious malfunction or
loss of power in flight , with possible loss of life, injury or damage to the equipment. Limit
yourself to the operations/ maintenance mentioned in ULPower manuals. If you are uncertain
and/or in need of extra information please contact a ULPower authorized sales or service
centre.
This non certified engine is designed for possible application on aircraft used in VFR conditions
which have the capabilities of controlled gliding without engine power.
You should be aware that any engine may malfunction at any time. This could lead to a crash
landing and possible severe injury or even death. For this reason, we recommend strict
compliance with the maintenance and operation manuals and any additional information which
may be given to you by your authorized sales or service centre .
Never fly the aircraft equipped with this engine at locations, airspeeds, altitudes, or other
circumstances from which a successful no-power landing cannot be made, after sudden engine
stoppage.
Make sure you know what engine you are using. Only engines UL260iSA /UL350iSA/
UL390iSA/UL520iSA are suited for acrobatics (inverted flight, etc.).
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.
Never (test) run the engine without a propeller or flywheel as this will inevitably cause engine
damage and present a hazard of explosion.
Propeller/flywheel and its attachment with a moment of inertia in excess of the specified value
must not be used and releases engine manufacturer from any liability.
Improper engine installation and use of unsuitable piping for fuel-, cooling- ,lubricating - , intake
and exhaust system releases engine manufacturer from any liability.
Unauthorized modifications of engine, its components, ECU, etc. will automatically exclude any
liability of the manufacturer for direct, indirect and/or consequential damage.
Spare parts must meet with the requirements defined by the engine manufacturer. This is only
warranted by use of genuine ULPower spare parts and/or accessories. They are available at the
authorized ULPower distribution- and service partners.
The use of anything other than genuine ULPower spare parts and/or accessories will render any
warranty relating to this engine null and void.
Respect all government or local rules pertaining to flight operation in your flying area. Fly only
when and where conditions, topography, and airspeeds are safe.
Select and use proper and calibrated aircraft instrumentation. This instrumentation is not
included with the basic ULPower engine.
Before flight, ensure that all engine controls are operational and engine is airworthy. Make sure
all controls can be reached in case of an emergency.

Operating Manual ULPOWER UL260,UL350,UL390,UL520
M0310: OM 260 - 520A01 Revision No: 04 Date: 2021-11-18 Page: 4 of 23
Unless in a run up area, never run the engine with the propeller turning while on the ground. Do
not operate engine if bystanders are close.
In the interest of safety, the aircraft must not be left unattended while the engine is running.
Keep an engine log and respect engine and aircraft maintenance schedules. Keep the engine in
top operating condition at all times. Do not operate any aircraft which is not properly maintained
or has engine operating irregularities which have not been corrected.
To eliminate possible injury or damage, ensure any loose equipment or tools are properly secured
before starting the engine.
When in storage protect the engine, fuel, lubrication, induction and exhaust system from
contamination and exposure.
Never operate the engine without sufficient quantities of lubricating oil, fuel and cooling air.
Allow the engine to cool at idle for several minutes before turning off the engine.

Operating Manual ULPOWER UL260,UL350,UL390,UL520
M0310: OM 260 - 520A01 Revision No: 04 Date: 2021-11-18 Page: 5 of 23
Table of contents
Preface ..................................................................................................................1
Remarks...............................................................................................................1
Modifications.........................................................................................................1
Engine serial number ...............................................................................................1
Repeating symbols ..................................................................................................2
Safety information....................................................................................................3
Table of contents .....................................................................................................5
Description of systems...............................................................................................7
Lubricant system ....................................................................................................7
Fuel system ..........................................................................................................7
Electronic Engine Management system..........................................................................7
Cooling system.......................................................................................................8
Warning lights .........................................................................................................9
Check light ...........................................................................................................9
Battery low...........................................................................................................9
General operating limits .......................................................................................... 10
Running in .......................................................................................................... 10
Performance (in ISA - International standard atmosphere - conditions) ............................... 11
Acceleration ....................................................................................................... 11
Deviation from bank angle ...................................................................................... 11
Oil level............................................................................................................. 11
Operation limits ................................................................................................... 12
*Electrical power ................................................................................................. 13
**Manifold air temperature ...................................................................................... 13
***Rail fuel pressure ............................................................................................... 13
+Oil pressure ....................................................................................................... 14
++EGT ................................................................................................................ 14
+++Cylinder head temperature................................................................................... 14
++++Turbo pressure................................................................................................. 14
Operating media .................................................................................................... 15
Fuel.................................................................................................................. 15
Lubricants .......................................................................................................... 15
Standard operation ................................................................................................. 16
Daily/Pre-flight checks........................................................................................... 16
Engine start ........................................................................................................ 16
Prior to take-off................................................................................................... 17
Warming up period:............................................................................................ 17
Idle speed:....................................................................................................... 17
Throttle response: ............................................................................................. 17
Ignition test: .................................................................................................... 17
Take-off and cruise ............................................................................................... 17
Engine shut-down ................................................................................................. 18
Engine storage ..................................................................................................... 18
Abnormal operation ................................................................................................ 19
Abnormal running on ignition check ........................................................................... 19
Sudden engine stop ............................................................................................... 19
Reaching maximum engine speed .............................................................................. 19
Exceeding of max. admissible cylinder head temperature ................................................ 20
Exceeding of max. admissible oil temperature .............................................................. 20
Oil pressure below minimum.................................................................................... 20

Operating Manual ULPOWER UL260,UL350,UL390,UL520
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Exceeding of max. admissible oil pressure ................................................................... 20
Relative fuel pressure deviates from normal ................................................................ 21
Derivation of turbo pressure (if applicable).................................................................. 21
Single CHT and/or EGT drop .................................................................................... 21
Knocking ............................................................................................................ 21
Low battery voltage .............................................................................................. 22
Prop Strike ......................................................................................................... 22
Revision ............................................................................................................... 23

Operating Manual ULPOWER UL260,UL350,UL390,UL520
M0310: OM 260 - 520A01 Revision No: 04 Date: 2021-11-18 Page: 7 of 23
Description of systems
Lubricant system
The high volume oil pump, with integrated pressure release valve, takes up oil through a coarse
filter on the oil pick up tube which is located in the wet oil sump.
An impressive amount of pressurized oil is pumped through the mandatory oil cooler (not included
as standard with the engine) and oil filter before it enters the main oil gallery where it lubricates
the essential parts of the engine. Excessive oil accumulates back into the oil sump.
Fuel system
Fuel from the tanks is guided through a coarse filter before reaching the electrical fuel pump. This
high volume fuel pump (120l/h or 32USgal/h) creates a pressurized fuel flow and pumps fuel
through a fuel fine filter towards the injectors and the integrated fuel pressure regulator.
Afterwards excessive fuel is returned to the fuel tank.
Electronic Engine Management system
All ULPower engines are equipped with an electronic injection and ignition system.
The ECU automatically sets the fuel mixture and ignition timing (multiple times per second!). As a
result, in the cockpit, there is no choke, no primer, no carb heat, and no mixture, just a single lever
: the throttle. It will even fine tune the fuel flow to compensate for changes in barometric pressure
as well as inlet air temperature in the inlet manifold/airbox. The fuel mixture and ignition timing is
controlled for operations up to 18.000 ft.
With timing corrections to avoid detonation and a built-in rev-limiter,(3.300rpm on most naturally
aspirated engines or 2.700 RPM on turbo engines) the ECU not only ensures efficient power to fuel
consumption at any given operating condition.
Note: The engine is managed electronically, consequently, the engine cannot run without a
working electrical system.
The UL 260 / UL350 engine and fuel pump use maximum continuous 15 Amps
1
to operate.
The UL 390 / UL520 engine and fuel pump use maximum continuous 21 Amps1to operate.
Note: The UL260/UL350 engine comes standard with an integrated AC generator with external
rectifier/regulator that can supply up to 30 Amps. The UL390/UL520 generator can supply
up to 50 Amps. This should be sufficient to charge the battery while the standard engine is
operating and other electrical aircraft systems are in use. Electrical system should be
monitored to ensure sufficient electrical power is available to maintain battery charge at
all times. In the event of alternator failure, in cockpit non-essential electrical systems
should be switched off to maximize engine operation time whilst seeking an immediate
landing site.
1
Operation : one pump, dual ignition, single ECU, 3300 RPM ,13.5V

Operating Manual ULPOWER UL260,UL350,UL390,UL520
M0310: OM 260 - 520A01 Revision No: 04 Date: 2021-11-18 Page: 8 of 23
Cooling system
All engines are air and oil cooled. Installing the ram air ducts that come with the engine, is
mandatory. See installation manual for more info on this subject
The installation of an oil cooler is mandatory as the oil is not only used to lubricate but also to cool
the engine. See installation manual for more info on this subject.