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80 HP 912UL will not start

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1 year 3 months ago #14677 by Roger Lee
Roger Lee replied the topic: 80 HP 912UL will not start
Just like anything new a few may be good, but until you get hundreds out there with thousands of hours all data is preliminary. I'm not saying these are bad by any means just it needs more time and volume testing. Like many other things, parts may be good until an owner gets them. :)

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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1 year 3 months ago #14679 by Mark Kyle
Mark Kyle replied the topic: 80 HP 912UL will not start
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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1 year 1 month ago #15019 by Mark Kyle
Mark Kyle replied the topic: 80 HP 912UL will not start


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

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2 months 1 day ago #17843 by Mark Kyle
Mark Kyle replied the topic: 80 HP 912UL will not start
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.

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2 months 16 hours ago - 2 months 16 hours ago #17844 by RotaxOwner Admin
RotaxOwner Admin replied the topic: 80 HP 912UL will not start
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: 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.)
Last Edit: 2 months 16 hours ago by RotaxOwner Admin.

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2 months 10 hours ago #17847 by Roger Lee
Roger Lee replied the topic: 80 HP 912UL will not start
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)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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2 months 9 hours ago #17850 by Mark Kyle
Mark Kyle replied the topic: 80 HP 912UL will not start
Hi Roger

This project was initially done as a favour for a few friends here in OZ with crook modules in older aircraft that were homebuilt. The modules are supplied on the basis that they are for experimental use only and are NOT to used on any "certified" engines. Over this side of the planet we are no where near litigious as you guys in the USA are. I do cover myself though with a agreement on supply of any module but the key is they are NOT to be used for any certified engine or aircraft eg LSA. The original intention was this. Its no different here than having a homebuilt aircraft and you use a tyre tube from a auto parts supplier instead of a certified aircraft tyre tube. I have had a lot of messages from people about this project so thought I would relate the experience so far. In the end you take the responsibility for any decision you make once you are informed of the facts. Anything after that decision you make ends up being your responsibility. As a side note to this we are working on a ignition monitor at the moment which will monitor by no direct physical connection to your ignition system a instrument which will be able to tell you the health of your ignition firing pulses. On the dash you will have a series of dual Leds that will be either green or red when in operation. If a module is weak you will see the green turning red or if you have a dead set of coils or a plug etc you will see it is not working. This could happen during a flight and you usually wont know until next time you are flying when you go to check your mags. This system will work on any engine not necessarily a Rotax
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2 months 7 hours ago #17855 by Roger Lee
Roger Lee replied the topic: 80 HP 912UL will not start
Hi Mark,
An owner might sign something, but places like the US say you can't sign away your rights or a spouse or friend if injured would make you fair game. Just be careful it's a litigious society.

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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2 months 6 hours ago #17856 by Mark Kyle
Mark Kyle replied the topic: 80 HP 912UL will not start
Hi Roger

I totally understand and thats why I havent done anything from the USA. Not so bad here though. Then again its the same as say using a viking or aeromomentum engine in a homebuilt aircraft. They are not certified and yet there are plenty flying and I have not heard of any legal issues...yet for them. We are still reasonably lucky here with the legal side its there...there are still plenty of ambulance chasers here in OZ but its a lot more difficult for them. Signing a document of your intentions still carries some weight. The modules of course you can have 1 fail and you still have another the odds of both failing at the same time would be akin to winning the lotto. This is another reason for developing the ignition monitor. It wont matter what engine you have t will monitor the ignition to the plugs and if there is a issue you will know in real time and adjust what you are doing. Divert to another location or get more height etc until you get back and fix the problem.

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