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
MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 4 of 69
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.

Installation Manual ULPOWER UL390i UL390iS390iSA
MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 5 of 69
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.

Installation Manual ULPOWER UL390i UL390iS390iSA
MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 6 of 69
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, …

Installation Manual ULPOWER UL390i UL390iS390iSA
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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

Installation Manual ULPOWER UL390i UL390iS390iSA
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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

Installation Manual ULPOWER UL390i UL390iS390iSA
MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 9 of 69
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 )

Installation Manual ULPOWER UL390i UL390iS390iSA
MI 390A01 Revision No: 3 Date: 2014-09-15 Page: 10 of 69
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