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80 HP 912UL will not start

in 912 / 914 Technical Questions 10 years ago

  • Re: 80 HP 912UL will not start

    by » 8 years ago

    Hi Roger

    Yes I know all about that. My day job is design and deveopment and you can make anything but the proof of the pudding comes once it gets out into the publics hands. You can do hundred of hours of intensive testing and find no issues but once it gets into production then you really find out any issues. The public are good test models for the things you never think of
      
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  • Re: 80 HP 912UL will not start

    by » 8 years ago

    https://www.youtube.com/watch?v=dBw5A1cmH2U

    Its been a little while since I have posted here. We have been flight testing the modules on several aircraft and all so far is brilliant. The test box is finished which allows the testing of original units to see if they are faulty it also of course is what we use to test each pcb after it is made and before it is potted in epoxy. Then the modules are tested again after they have been potted. The circuit board that is bare in the photo is for the original old modules that are 4 wire. Our module can be wired for the old style. This one is soon to be potted but we are waiting for the bullet style connectors to make it plug and play for the original. The attached video is testing the latest batch of units to go out on the test box. The rate is set for 5000 rpm and tests using genuine rotax coils. You can see each trigger set plus the kill switch action that is electronicaly controlled inside the ignition module
    IMG_4324.jpg (You do not have access to download this file.)
    Thank you said by: Wayne Fowler, John Walsh
      
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  • Re: 80 HP 912UL will not start

    by » 7 years ago

    Its been quite a while since I have posted here. I have made some 35 modules for people now mostly local but quite a few in NZ and all are working fine some with 120 hrs plus on them. One of the very first batch I made failed after 1 hr of use but I believe it may have been damaged by cutting and shutting wires and wrong hookup as they were trying to graft it into a system that it wasnt really wired for and all the rest of those are working fine. There have been no other failures. There are 3 versions of the units that I make required for the range and ages of the engines. The originals are what I call 4 wire which has a 4 way plug and the rest are fly leads. You slightly change the wiring format to hook them up but it is just plug and play as the correct connectors are fitted. You remove the earth bridge on the coils which leaves 2 leads from the 2 coils that are hooked directly to the modules connectors and a earth wire from the module is then bolted to the earth that the bridge was connected to. The next version made was what I call a 6 x 4 it has a 6 way and 4 way plug and one flywire then the later version of the Ducati is the 6 x 6 this has a male and female 6 wire connector. I have a box made that is injection molded glass filled nylon which is a direct replacement for the mounts. One the modules are assembled and wired they are tested on my test unit then they are filled with epoxy which is 28,000 Volts per mm insulation and once dried they are tested again.
    IMG_5380.jpg (You do not have access to download this file.)
    IMG_5378.jpg (You do not have access to download this file.)
    IMG_5377.jpg (You do not have access to download this file.)
    IMG_5376.jpg (You do not have access to download this file.)
    IMG_5375.jpg (You do not have access to download this file.)
      
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  • Re: 80 HP 912UL will not start

    by » 7 years ago

    Once again, I would just like to point out to anyone who may have jumped into this thread mid-stream, that this home-brew experimental module project is emphatically NOT approved by ROTAX.

    I'd be remiss if I didn't remind everyone about this Service Letter: http://legacy.rotaxowner.com/si_tb_info/serviceletter/sl-912i-005.pdf

    "The use of any third-party replacement kits, modifications, and non-genuine ROTAX components or accessories for ROTAX engines is NOT approved by ROTAX and very strongly discouraged..." (&etc.)
      
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  • Re: 80 HP 912UL will not start

    by » 7 years ago

    Hi Mark,
    I'm a little surprised you want to take on that kind of liability. It could be huge.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell

      
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