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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 Mark,

    I have not found a defective "soft start" module as of yet. I have came across a few of the standard ones from some local Rotax repairmen I have contacted.

    My new ign modules with the soft start did arrive and they work beautifully. They better for what they cost.

    Still working on the circuit and hoping to get a prototype board made for testing. I sent you a private email.

    Shawn
      
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  • Re: 80 HP 912UL will not start

    by » 8 years ago

    Well after a bit of pressure from some flying mates I decided to get my backside into gear and get this project going. This prototype has been tested on a test cell driving Rotax coils and 4 plugs. The unit was then placed on a motor in a aircraft and then started on this module and run for a while on it a few times. This was to guage temperatures of components. I have upgraded the critical components and the ones we know that usually fail with higher current and voltage specs. The unit is now being potted into a 3D printed case I have made and it will go on a flying aircraft for some further testing.

    The next version will have another part changed out to a better spec as it was showing some heating...not a lot mind you but to be on the safer side I have selected the best one that is available. Over the next couple of weeks I will have a couple of these updated versions running on 3 aircraft flying to see how we go. One unit will also be run at max rpm on the test cell for 24/7 for several weeks.
    IMG_4070_2016-10-27.JPG (You do not have access to download this file.)
    IMG_4071_2016-10-27.JPG (You do not have access to download this file.)
    IMG_4072_2016-10-27.JPG (You do not have access to download this file.)
      
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  • Re: 80 HP 912UL will not start

    by » 8 years ago

    Looks great Mark, keep us up to date on your progress and findings.

    Any thought of test flying a unit BEFORE you pot it? This way you could get temp readings after landing.

    I understand the potting helps with vibration but a vented case with a tiny fan might be a better option along with mounting it to the firewall rather than the top of a hot engine.

    Either way, great work!

    Shawn
      
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  • Re: 80 HP 912UL will not start

    by » 8 years ago

    Hi Shawn

    The test jig made up actually drives a set of Rotax coils and driving 4 plugs. We tested the module with this as this is how we found the heat on the FET. This is the reason for the upgraded FET again. The rest of the board is fine with heated components after running. We are pretty confident with the state of things at the moment. The current unit about to be actually flown has my first upgraded FET but the next one which will be in the test jig running 24/7 will have the latest upgrade. Then we will test that in flight as well. Every single unit will be tested for an hour or so at max RPM on the jig before being potted. This jig will also be able to test old units to see what the failures are as well

    Mark
      
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  • Re: 80 HP 912UL will not start

    by » 8 years ago

    Mark,
    Is there any chance you could email me. Conrad at conairsports dot co dot uk.
    Thanks
      
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