ULPOWER UL390i User manual

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

Installation Manual ULPOWER UL390i UL390iS390iSA
MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 3 of 69

Installation Manual ULPOWER UL390i UL390iS390iSA
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Preface
Thank you for deciding to use a ULPower engine.
Before starting with the engine installation, read this Installation Manual carefully. The Manual will
provide you with basic information on correct engine installation, a requirement for safe engine
operation.
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.
Remarks
The figures in this Installation 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 equivalent in 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, 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, as the
manufacturer makes modifications to the engine for further development.
The engine serial number is located on the top of the crankcase.

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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.

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Safety Information
The engine should only be installed and placed into operation by persons familiar with the use of
the engine and informed with regard to possible hazards.
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.
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.
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 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- and lubrication system
releases engine manufacturer from any liability.
Unauthorized modifications of engine or aircraft will automatically exclude any liability of the
manufacturer for sequential damage.
Do not use a protective device (e.g. a fuse) essential for the engine, to protect any other circuit
Do not install unnecessary protective devices for the alternator and the regulator rectifier
Install protective caps to protect switches essential to flight safety such as ECU switch, master
switch, …

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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 ........................................................................................................9
Description of basic standard engine and accessories...................................................... 10
Engine views ....................................................................................................... 11
Technical data ....................................................................................................... 15
Dimensions of basic standard engine ( With standard propeller flange L = 55 ) ...................... 15
Weight of basic standard engine and accessories ........................................................... 15
Centre of gravity of basic standard engine................................................................... 15
Preparations for 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
Idle speed adjustment ........................................................................................... 28
Connecting the air filter ......................................................................................... 29
Throttle cable ....................................................................................................... 30
Exhaust system ...................................................................................................... 31
Dimensions of the exhaust system: ............................................................................ 31
Exhaust installation : ............................................................................................. 32
Cabin Heating:..................................................................................................... 33
Cooling system....................................................................................................... 34
Cylinder head cooling: ........................................................................................... 34
Cylinder head temperature: .................................................................................... 34
Oil cooling: ......................................................................................................... 34
Oil temperature ................................................................................................... 34
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. Double ECU & Ignition ........................................................................................ 48
Alternator & Regulator/Rectifier .............................................................................. 58
Recommended diagram .......................................................................................... 59
Starter motor ...................................................................................................... 60
Battery .............................................................................................................. 60

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Additional wiring .................................................................................................. 60
Instruments .......................................................................................................... 61
Recommended Sensors ........................................................................................... 61
Propeller drive ...................................................................................................... 65
Propeller selection................................................................................................ 68
Annex A ............................................................................................................... 69
Fuel header tank .................................................................................................. 69

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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
7 bearing crankshaft with large thrust bearing (ball bearing type)
Single central camshaft
Push rods, Tappets and Over head valves
Wet sump forced lubrication with integrated pressure regulator
Ram air cooled cylinders and 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 mm
Stroke:
74 mm
Compression Ratio:
8,16 : 1
9,1:1
Firing order:
1 –4 –5 –2 –3 –6
Direction of Rotation:
Clockwise –Pilot's view –Tractor configuration
Torque (ISA conditions):
320Nm @ 2800rpm
370Nm @ 2800 rpm
Power rating (ISA conditions):
140 hp @ 3300 rpm
(130 hp @ 2800 rpm)
160hp @ 3300 rpm
(145Hp @ 2800 rpm)
160hp @ 3200 rpm
(145 hp @ 2800 rpm)
Basic standard engine weight:
100kg (including starter motor and alternator)
100 kg
DC output:
50 Amp
Oil capacity:
4 L
Fuel (unleaded):
MOGAS with min. 95
octane rating or
AVGAS ( 95 octa = 87
mon = 97 AKI )
MOGAS with
min. 98 octane rating or AVGAS
( 98 Oct = 90MON = 94AKI )

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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 L = 55 (Standard)
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)
Only valid for the UL 390 iSA engine : engines of this type are delivered with an inverted oil system,
containing :
Gravity valve,
Gravity oil pickup tube in the sump
Gravity oil –air separator
Breather adaptor on top of the engine
Extra weight: 3,8 kg

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Engine views
Figure 1
* dimensions for standard prop flange l = 55, different prop flanges are available (see page 64)

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Figure 2

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Figure 3

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Figure 4

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Technical data
Dimensions of basic standard engine ( With standard propeller flange L = 55 )
pos. (+)
neg. (-)
total 
max. dimension in x-axis
92.5 mm (3,641 inch)
630 mm (24,803 inch)
722.5 mm (28,444 inch)
max. dimension in y-axis
327 mm (14,488 inch)
327 mm (14,488 inch)
654 mm (28,976 inch)
max. dimension in z-axis
182 mm (7,165 inch)
290 mm (11,417 inch)
472 mm (18,582 inch)
Weight of basic standard engine and accessories
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)
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 lb)
Rubber engine mounts:.............................................................................0.3 kg (0,7 lb)
Optional Oil Cooler:................................................................................... 1 kg (2,2 lb)
4 L engine lubricating oil:..........................................................................3.5 kg (7,7 lb)
Possible fully operational engine weight: ..................................................... 100 kg (220.4 lb)
Gravity valve, oil air separator and hoses: ................................................... 3.8 kg (8,37 lb)
Possible fully operational engine weight for the UL390 ISA:..............................103.8kg (228.8 lb)
Centre of gravity of basic standard engine
centre of gravity in x-axis
-245.0 mm (-9,645” inch)
centre of gravity in y-axis
0 mm (-0,0” inch)
centre of gravity in z-axis
-21 mm (-0.826” inch)
.

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Preparations for engine installation
Transport
The engine is to be lifted by putting straps under the base of the cylinder heads on both sides of the
engine (see pictures below).
WARNING : Don’t lift the engine by the aluminium oil return tubes under the cylinders.
State of delivery
the engine will be delivered/shipped in a plywood crate with galvanised steel profiles and wooden
runners.
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:
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 anticlockwise
(viewed alternator side). See figure 3.
inspect for corrosion (e.g. prop shaft). At detection of corrosion, send the engine to the
overhauler without delay.
repack engine into original packaging and seal properly.
WARNING : The engine must not be put into service during preservation.
WARNING : The maximum storage period is limited to 24 months!
Preservation for periods longer than 24 months is only possible after a written
permission of ULPower. Should the situation arise, send the engine for inspection to
ULPower.

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Engine suspension and position
The UL390 engine has 4 mounting points situated at the back of the engine. 8 Rubber Mounts
are provided with the engine; to be assembled on both 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) to be dimensioned as below. This two parts are available as an option from ULPower if
needed.
(2)
(1)

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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

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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.

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Fuel injection system
Accessories such as an electric fuel pump together with a pre-filter and fine fuel filter are provided
in the basic package and the fuel pressure regulator is integrated in the engine assembly. 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:
Use appropriate fuel lines and connections as the fuel injection system requires a constant 3bar
fuel pressure.
A fuel injection system requires a return line of adequate dimensions. Large quantities
(120 litres/hour = 31 USgal/h) of fresh fuel circulate through the fuel system of which only little is
used and the remainder needs to return to the fuel tank.
We strongly encourage the use of a fuel pressure sensor and gauge to verify fuel system is
working correctly. Too much/little fuel pressure can influence the fuel mixture, possibly causing
sudden stoppage or damage to the engine as a result.
Overview
The fuel is drawn from the fuel tank, through a pre-filter (100 micron), to the suction 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 tank of which fuel is drawn from.
There are 2 possibilities:
install a 3 way duplex fuel selector valve which allows for 2 fuel lines to
be switched simultaneously and has the provision to return the fuel to
the same tank from which it is drawn. However never switch the
selection to the “lock” position!
install a small separate (± 2.5 lt / 0.7 USgal) header tank from which the
fuel is drawn and also returned, while it is gravity fed from the separate
fuel tanks. For ULP header tank, sea annex A
For ease of explanation we presume the fuel system is connected to a single tank.
Attention:In any case, do NEVER shut of the return line from the engine to the tank! This
return line must always stay open.
Installing Pre-filter and Fuel Pump
The fuel pump (1) should be placed as close as possible to the fuel tank (3) as it is much more
powerful on the pressure side than on the suction side. The pre-filter (2) is placed between fuel
tank and pump to protect the fuel pump from being damaged by any foreign particles.