Motortech MIC500 Operating Manual
3
5
MIC500 –
IGNITION CONTROLLER
OPERATING MANUAL
MOTORTECH Ignition Controllers
P/N 01.10.0
0-EN | Rev. 01/201
Copyright
© Copyright 2015 MOTORTECH GmbH. All rights reserved.
Distribution and reproduction of this publication or parts thereof, regardless of the specific
purpose and form, are not permissible without express written approval by MOTORTECH.
Information contained in this publication may be changed without prior notice.
Trademarks
All trademarks and logos displayed or used in this publication are the property of the respective
entitled person.
S
TABLE OF CONTENT
1 General Information ..................................................................................................... 7
1.1 What Is the Purpose of this Operating Manual? ......................................................... 7
1.2 Who Is this Operating Manual Targeted to? ............................................................... 7
1.3 Which Symbols Are Used in the Operating Manual? ................................................... 7
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual? ........................... 8
2 Safety Instructions .................................................................................................... 10
2.1 General Safety Instructions ................................................................................... 10
2.2 Electrostatic Discharge Hazards ............................................................................. 11
2.3 Special Safety Instructions for the Device ............................................................... 11
2.4 Proper Disposal .................................................................................................... 13
3 Intended Use ............................................................................................................. 14
3.1 Functional Description .......................................................................................... 14
3.2 Applications ......................................................................................................... 14
4 Product Description ................................................................................................... 15
4.1 Product Overview .................................................................................................. 15
4.2 Technical Data...................................................................................................... 16
4.2.1 Certifications ..................................................................................................... 16
4.2.2 Mechanical Data ................................................................................................ 20
4.2.3 Warning Notices on the Device ........................................................................... 20
4.2.4 Product Identification – Labeling on the Device ................................................... 20
4.2.5 Electrical Data ................................................................................................... 21
4.2.6 Interfaces ......................................................................................................... 22
4.2.7 Requirements for External Equipment ................................................................. 22
4.2.8 Overview Drawings ............................................................................................ 23
5 Installation Instructions ............................................................................................ 26
5.1 Unpacking ............................................................................................................ 26
5.2 Determine the Installation Location of the Pickup and the Trigger Disc ..................... 26
5.3 Installation of the Ignition Controller ..................................................................... 27
6 Wiring of the Device .................................................................................................. 28
6.1 Input and Output Wiring on the Controller .............................................................. 28
6.1.1 Input and Output Connector – P/N 06.00.507, P/N 06.00.508 ............................... 29
6.1.2 Input and Output Connector – P/N 06.00.510 ....................................................... 30
6.1.3 Input and Output Connector – P/N 06.00.511 ....................................................... 32
6.1.4 Input and Output Connector – P/N 06.00.513 ....................................................... 34
6.1.5 Input and Output Connector – P/N 06.00.514 ....................................................... 36
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TABLE OF CONTENTS
6.1.6 Input and Output Connector – P/N 06.00.515-6 and -8 ......................................... 38
6.1.7 Input and Output Connector – P/N 06.00.516 ....................................................... 40
6.1.8 Input and Output Connector – P/N 06.00.517 ....................................................... 42
6.1.9 Input and Output Connector – P/N 06.00.520 ...................................................... 44
6.1.10 Input and Output Connector – P/N 06.00.525 ..................................................... 46
6.1.11 Input and Output Connector – P/N 06.00.530 ..................................................... 48
6.1.12 Input and Output Connector – P/N 06.00.550 ..................................................... 50
6.1.13 Input Wiring – Power Supply ............................................................................. 52
6.1.14 Input Wiring – 4-20 mA Input ............................................................................ 53
6.1.15 Input Wiring – Pickup ....................................................................................... 54
6.1.16 Wiring – Digital Input, Go/NoGo ........................................................................ 56
7 Functions ................................................................................................................... 57
7.1 Monitoring of Pickup Signal ................................................................................... 57
7.2 Go/NoGo ............................................................................................................. 57
7.3 Remote-Controlled Ignition Release ....................................................................... 58
7.4 Schedules A/B ..................................................................................................... 59
7.5 Timing Correction ................................................................................................. 60
7.5.1 Manual Timing Correction ................................................................................... 61
7.5.2 Analog Current Input – 4-20 mA .......................................................................... 62
7.5.3 Speed Curve ...................................................................................................... 62
7.5.4 Cylinder-to-Cylinder Alignment ........................................................................... 62
7.6 Misfire Detection .................................................................................................. 62
7.7 Ignition Energy ..................................................................................................... 63
8 Adjustments .............................................................................................................. 64
8.1 Ignition Control .................................................................................................... 64
8.1.1 System Requirements Ignition Control ................................................................. 64
8.1.2 Installing Ignition Control ................................................................................... 64
8.1.3 Starting Ignition Control ..................................................................................... 67
8.1.4 Menu Bar and Buttons ........................................................................................ 68
8.2 Hand-Held Programmer ........................................................................................ 69
8.2.1 RS232 Interface Adjustments ............................................................................. 69
8.2.2 Switching on the Hand-Held Programmer ............................................................ 70
8.2.3 Keys of the Control Panel .................................................................................... 71
8.3 Conventions Used in the Following ........................................................................ 72
8.4 Main View ............................................................................................................ 73
8.5 Parameterization Level ......................................................................................... 75
8.5.1 General Operation of the Parameterization Level ................................................. 75
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8.5.2 Brief Overview of Parameters ............................................................................. 78
8.5.3 Set Sequence Number ....................................................................................... 80
8.5.4 Set Reset Position ............................................................................................. 84
8.5.5 Set Overspeed ................................................................................................... 84
8.5.6 Set Security Speed ............................................................................................ 85
8.5.7 Set Misfire Rate ................................................................................................. 86
8.5.8 Activate Cylinder-to-Cylinder Alignment .............................................................. 87
8.5.9 Select Function for Digital Input .......................................................................... 87
8.5.10 Activate Potentiometer ..................................................................................... 88
8.5.11 Activate Functions for Schedules A and B ........................................................... 89
8.5.12 Set Potentiometer Limits .................................................................................. 91
8.5.13 Set Ignition Timing Limits ................................................................................. 93
8.5.14 Set Timing Offset for Schedule B ....................................................................... 95
8.5.15 Set Limits for 4-20 mA Input .............................................................................. 95
8.5.16 Set Speed Curve .............................................................................................. 97
8.5.17 Configuration Example ................................................................................... 100
8.6 Additional Functions .......................................................................................... 102
8.6.1 Set Ignition Energy .......................................................................................... 102
8.6.2 Information View ............................................................................................. 103
8.6.3 Cylinder-to-Cylinder Alignment ........................................................................ 103
8.6.4 Self Test ......................................................................................................... 105
8.6.5 Misfire Detection ............................................................................................. 107
8.7 Programming Overview ....................................................................................... 107
9 Operation ................................................................................................................ 110
9.1 Start-up .............................................................................................................. 110
9.2 Shutdown ........................................................................................................... 110
10 Errors ...................................................................................................................... 111
10.1 Possible Faults ................................................................................................... 111
10.2 Causes of Faults................................................................................................. 111
10.2.1 Overspeed ...................................................................................................... 111
10.2.2 Misfire Detection (Primary) .............................................................................. 111
10.2.3 Pickup Input Errors .......................................................................................... 112
10.2.4 Insufficient Power Supply ................................................................................ 112
10.2.5 Exiting Error Status ......................................................................................... 112
10.3 Troubleshooting and Eliminating Errors ............................................................... 113
10.3.1 Message and Error Overview ............................................................................ 113
10.3.2 Testing Supply Voltage .................................................................................... 114
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10.3.3 Testing Pickup Signal ...................................................................................... 114
10.3.4 Running a Self Test ......................................................................................... 116
10.3.5 Customer Service Information .......................................................................... 117
10.3.6 Returning Equipment for Repair / Inspection .................................................... 117
10.3.7 Instructions for Packaging the Equipment ......................................................... 118
11 Maintenance ........................................................................................................... 119
11.1 Maintenance Instructions .................................................................................... 119
11.2 Spare Parts and Accessories ............................................................................... 119
12 Index ..................................................................................................................... 120
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1 GENERAL INFORMATION
Read through this operating manual carefully before use and become familiar with the machine.
Installation and start-up should not be carried out before reading and understanding this
document. Keep this manual readily available so that you can reference it as needed.
1.1 What Is the Purpose of this Operating Manual?
This manual serves as an aid for the installation and operation of the product and supports the
technical staff with all operating and maintenance tasks to be performed. Furthermore, this
manual is aimed at preventing dangers to life and health of the user and third parties.
1.2 Who Is this Operating Manual Targeted to?
The operating manual provides a code of conduct for personnel tasked with the set-up,
operation, maintenance, and repair of gas engines. A certain level of technical knowledge with
respect to the operation of gas engines and basic knowledge of electronic ignition systems are
necessary. Persons who are only authorized to operate the gas engine shall be trained by the
operating company and shall be expressly instructed concerning potential hazards.
1.3 Which Symbols Are Used in the Operating Manual?
The following symbols are used in this manual and must be observed:
Example
This symbol indicates examples, which point out necessary handling steps
and techniques. In addition, you receive additional information from the
examples, which will increase your knowledge.
Notice
This symbol indicates important notices for the user. Follow these. In
addition, this symbol is used for overviews that give you a summary of the
necessary work steps.
Warning
This symbol indicates warnings for possible risks of property damage or
risks to health. Read these warning notices carefully and take the
mentioned precautionary measures.
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1 GENERAL INFORMATION
Danger
This symbol indicates warnings for danger to life, especially due to high
voltage. Read these warning notices carefully and take the mentioned
precautionary measures.
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?
In the manual or the user interface, the following abbreviations / acronyms are used:
Abb. Term Description Explanation
ADV Advance Advanced with respect
to top dead center
ATDC After Top Dead Center After top dead center
BTDC Before Top Dead
Center
CE Conformité
Européenne
°crank-
Degree crankshaft Unit for the rotation angle of
Before top dead
center
Conformity with EU
directives
shaft
CSA Canadian Standards
Association
DC Direct Current Direct current
EMC Electromagnetic
Compatibility
LED Light Emitting Diode Light emitting diode Light emitting electronic semi-
POT Potentiometer Continuously adjustable
PWR Power Output / current Operating voltage
RET Retard Retarded with respect
to the top dead center
Indicates the direction for
timing
Mark based on EU legislation
for certain products in
conjunction with product safety
the crankshaft
Organization that defines
standards, inspects products
for safety compliance, and
issues pertinent certifications.
Compatibility of electrical or
electronic equipment items
with their surroundings
conductor
potential divider
Indicates the direction for
timing
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Abb. Term Description Explanation
RPM Revolutions Per
Minute
Revolutions per
minute
Unit for speed
TDC Top Dead Center
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2 SAFETY INSTRUCTIONS
2.1 General Safety Instructions
The following safety instructions must be followed in the area in which the device is operated.
High voltage! Danger to life!
While the engine is running, the area around the ignition system especially
holds the risk of danger due to high voltage. The following parts should
therefore not be touched or removed unless explicitly stated otherwise:
– Ignition coils and caps
– Wires of the high voltage circuit
– In- and output wiring of the ignition controller
– Pickups and their wiring
Danger to persons with pacemakers!
Electromagnetic impulses in the wiring of the ignition system may exceed
the permissible limits of pacemakers. Persons with pacemakers must
MOTORTECH equipment is manufactured as state of the art and therefore safe and reliable to
operate. Nevertheless the equipment can cause risks or damages can occur, if the following
instructions are not complied with:
– The gas engine must only be operated by trained and authorized personnel.
– Operate the equipment only within the parameters specified in the technical data.
– Use the equipment correctly and for its intended use only.
– Never apply force.
– For all work, such as installation, conversion, adaptation, maintenance, and repair, all
equipment must be disconnected from the power supply and secured against unintentional
restarting.
– Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions given while working. For maintenance of the equipment, only use
spare parts supplied by MOTORTECH. Further work must only be performed by personnel
authorized by MOTORTECH. Non-compliance with the instructions will void any warranties
for the proper function of the equipment as well as the responsibility for the validity of the
certifications.
– Safety devices must not be dismounted or disabled.
– Avoid all activities that can impair the function of the equipment.
therefore not be present in the vicinity of the ignition system being
operated. Mark the operating location of the ignition system with the
corresponding standardized warning symbol.
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– Operate the equipment only while it is in proper condition.
– Investigate all changes detected while operating the gas engine or ignition system.
– Ensure compliance with all laws, directives and regulations applicable to the operation of
your system, including such not expressly stated herein.
– If the system is not entirely tight and sealed, gas may escape and lead to an explosion
hazard. Upon completion of all assembly works, always check the system's tightness.
– Always ensure adequate ventilation of the engine compartment.
– Ensure a safe position at the gas engine.
2.2 Electrostatic Discharge Hazards
Electronic equipment is sensitive to static electricity. To protect these components from damage
caused by static electricity, special precautions must be taken to minimize or prevent
electrostatic discharge.
Observe these safety precautions while you work with the equipment or in its vicinity.
– Before performing maintenance or repair work, ensure that the static electricity inherent to
your body is discharged.
– Do not wear clothing made from synthetic materials to prevent static electricity from
building up. Your clothing should therefore be made of cotton or cotton mix materials.
– Keep plastics such as vinyl and Styrofoam materials as far away from the control system, the
modules, and the work environment as possible.
– Do not remove the circuit boards from the housing of the device.
2.3 Special Safety Instructions for the Device
Danger to life! Hazardous residual voltage!
A dangerous level of residual voltage is present in the ignition system for up
to three minutes after stopping the ignition. Do not touch any components
of the ignition kit during this time.
Explosion hazard!
When the system is powered up, do not remove any connectors unless the
system is not located in a potentially explosive atmosphere.
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2 SAFETY INSTRUCTIONS
Explosion hazard!
The replacement of parts or assemblies can impair compliance with CSA
Class I, Division 2 (Group C, D), T4.
Explosion hazard!
Never remove the equipment while the device is connected to a power
source unless the system is not located in an explosive environment.
Risk of burning!
The surfaces of the system may heat up to high temperatures.
Operational safety!
All connector screws and screw joints must be adequately tightened.
Compliance with the following tightening torques is mandatory:
– RS232 connection: 1 Nm (0.7 lb-ft)
– Connection plug 6-pole, 7-pole, 10-pole: 2.6 Nm (1.9 lb-ft)
– Connection plug 14-pole, 19-pole: 5 Nm (3.7 lb-ft)
Explosion hazard!
Never remove the cover for timing adjustment and the RS232 interface,
unless the system is not located in an explosive environment.
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Risk of damage!
Magnetic fields and heat occur when welding, which may damage or
destroy the MIC500. Therefore, pay attention to the following when
welding:
– Disconnect all electrical connections to the MIC500 prior to welding.
– Protect the MIC500 against direct contact with the welding unit and
magnetic fields, sparks and liquid metal.
2.4 Proper Disposal
After the expiration of its service life, MOTORTECH equipment can be disposed of with other
commercial waste, or it may be returned to MOTORTECH. We will ensure its environmentally
friendly disposal.
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3
INTENDED USE
3.1 Functional Description
The devices of the MIC500 series are microprocessor-controlled condenser discharge ignition
systems, which provide the ignition energy for gas engines with up to 16 cylinders.
Please note that the manufacturer is not required to implement configurations of the ignition
controller for specific engines, and that devices may be delivered without pertinent
configuration.
The ignition controllers of the MIC500 series use information supplied by the pickup to precisely
determine the correct timing for the respective outputs. An event type N+1 trigger disc serves as
transmitter.
The timing is influenced by various inputs made either automatically or manually. This can be
implemented with the installed manual potentiometer, an analog input signal (4-20 mA) or a
configurable speed curve.
By checking the information received, the ignition controllers continuously monitor the system
status of the pickup and the correct operation of the primary ignition circuit during operation.
Depending on the severity of an error that is detected, the devices will shut down immediately or
warn the operator by a flashing LED.
To protect the engine, the ignition controllers additionally have an adjustable overspeed shutoff.
3.2 Applications
Depending on the device type, the ignition controllers of the MIC500 series are designed for
specific 2- or 4-stroke gas engines. Depending on the device type, there are between 2 to max.
16 ignition outputs available.
The ignition controllers supply the energy output required for the corresponding ignition coils of
the gas engines and can supply signals for peripheral devices. Any use other than the one
described in the operating manual shall be considered improper use and will result in the
voiding of all warranties.
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4
PRODUCT DESCRIPTION
4.1 Product Overview
The following properties of the devices from the MIC500 series differ as follows:
Device type
P/N 06.00.507 8 30 V DC 24VDC
P/N 06.00.508 8 30 V DC 24 V DC
P/N 06.00.510 16 30 V DC 24VDC
P/N 06.00.511 16 30V DC 24VDC
P/N 06.00.513 8 300 V DC 8V DC
P/N 06.00.514 16 30 V DC 8 V DC
P/N 06.00.515-6 8 (programmed on 6) 300 V DC 8VDC
P/N 06.00.515-8 8 300 V DC 8 V DC
P/N 06.00.516 16 (programmed on 12) 300 V DC 8VDC
P/N 06.00.517 16 300 V DC 8 V DC
P/N 06.00.520 8 300 V DC 24VDC
P/N 06.00.525 12 300 V DC 24 V DC
P/N 06.00.530 16 300 V DC 24VDC
P/N 06.00.550 8 30V DC 24VDC
Number of outputs
Test port /
monitor voltage
Voltage for pickup
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4 PRODUCT DESCRIPTION
4.2 Technical Data
4.2.1 Certifications
The ignition controllers of the MIC500 series with the test mark are certified as per the
following CSA standards:
CSA
– Class I, Division 2, Group C and D, T4
– CSA Std C22.2 No. 142-M1987 (Reaffirmed 2004)
– CSA Std C22.2 No. 213-M1987 (Reaffirmed 2004)
The ignition controllers of the MIC500 series are additionally certified as per the following
directives/regulations:
CE
– EMC Directive 2004/108/EC
– Limits as per DIN EN 55011:2011
– Immunity for industrial environments as per DIN EN 61000-6-2:2006-03
– Emission standard for industrial environments as per DIN EN 61000-6-4:2007-09
– Low Voltage Directive 2006/95/EC
– Low voltage switchgear – General rules as per DIN EN 60947-1:2007
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4 PRODUCT DESCRIPTION
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x
DECLARATION OF CONFORMITY
The Company:
declares that the products: Ignition controller MIC500
Intended purpose: to be used on gas-Otto-engines
complies with the provisions of the following EC Directives:
under consideration of following standards:
The marking of the product is: P/N 06.00.5x
This declaration is submitted by:
Name: Florian Virchow
MOTORTECH GmbH
Hogrevestrasse 21 - 23
29223 Celle
EMC Directive 2004/108/EC
Low Voltage Directive 2006/95/EC
DIN EN 55011-2011
DIN EN 61000-6-2-2006:03
DIN EN 61000-6-4-2007:09
DIN EN 60947-1 : 2007
Professional status: Managing Director
Celle, 13.07.2011
City, date
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legally binding signature
4 PRODUCT DESCRIPTION
4.2.2 Mechanical Data
The devices of the MIC500 series have the following mechanical characteristics:
Feature Value
Dimensions see chapter Overview Drawings on page 23
Weight 2.1 kg (4.7 lbs)
Shape of device see chapter Overview Drawings on page 23
Climatic environmental
conditions
4.2.3 Warning Notices on the Device
EXPLOSION HAZARD! Do not open cover for timing adjustment and RS232 interface unless area is
known to be non-hazardous.
WARNING! Read and understand the installation and operating manual prior to installing or
making any adjustments.
EXPLOSION HAZARD! Do not disconnect while circuit is live unless area is known to be nonhazardous. For wiring details please refer to the operating manual.
CAUTION! Do not pressure wash this ignition module. Damage to electronic components may
result.
4.2.4 Product Identification – Labeling on the Device
The necessary numbers for unique product identification are on the device:
– P/N: Product number of the ignition controller
– S/N: Serial number of the ignition controller
-40°C to +70°C (-40°F to +158°F)
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4.2.5 Electrical Data
The devices of the MIC500 series have the following electrical characteristics:
Feature Value
Power consumption 60 W with 24 V
Power supply 18 V DC to 30 V DC
Required current Peak current 20 A
External fuse 6 A, slow blow
Number of ignition
outputs
Output voltage and
output energy
Output connector Depending on device type (see Input and Output Wiring on the
Electrical Data for Inputs and Outputs
The inputs and outputs of the MIC500 ignition controllers have the following electrical data:
Inputs and outputs Values
4-20 mA input Auxiliary voltage: Corresponds to supply voltage of the MIC500
Digital input Impedance: 10 kΩ
Go/NoGo output Switching capacity: 100 mA
Signal LED An LED to display operating mode and errors
Pickup input Impedance: 10 k
Continuous current 5 A
Depending on device type 8, 12 or 16 outputs (see Product
Overview on page 15)
Max. 180 mJ with 300 V
The output energy is adjustable from 15 % to 100 %.
Controller on page 28)
Open: 0 V to 0.8 V
Closed: 2.8 V to 30 V
Open collector output
Darlington-Transistor design
Voltage applied: 18 V DC to 30 V DC
Peak/steady current: max. 0.45 A DC
Output power: max. 2.4 W
Power supply for inductive pickups is based on the input voltage
e. g. 24 V DC with an input voltage of 24 V DC (see Product
Overview on page 15).
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4 PRODUCT DESCRIPTION
Inputs and outputs Values
Ignition coil outputs Output voltage: Max. 300 V
Output energy: Max. 180 mJ
Test ports /
monitor voltage
4.2.6 Interfaces
RS232
– VT100-Terminal
– Baud rate: 9,600, data bits: 8, stop bit: 1, parity: none
– Plug connection: D-SUB, 9-pole
– Maximum lead length: 5 m
4.2.7 Requirements for External Equipment
External equipment shall fulfill the input and output specifications of the MIC500.
Depending on device type (see Product Overviewon page 15)
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4.2.8 Overview Drawings
P/N 06.00.507, P/N 06.00.508:
P/N 06.00.511, P/N 06.00.520, P/N 06.00.525, P/N 06.00.530, P/N 06.00.550:
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4 PRODUCT DESCRIPTION
P/N 06.00.513, P/N 06.00.514, P/N 06.00.515-6 and -8, P/N 06.00.516, P/N 06.00.517:
All device types:
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Device Components
Pos. Labeling Description Function
Timing adjustment potentiometer Potentiometer for manual timing
Status Status LED LED for displaying operating mode and
Inputs and Outputs Based on Device Type
The connections for the input and output wiring vary between the device types. For detailed
information, see section Input and Output Wiring on the Controller on page 28.
Pos. Connection position Function
Left side of device Input and output connection, 23-pole (depending on device
Left front Input and output connection, 6-, 7-, or 10-pole (depending on
Right front Input and output connection, 10-, 14-, or 19-pole (depending
Right side of device Input connection, 10-pole (depending on device type)
RS232 connection Connection of the ignition controller to a
computer or a hand-held programmer for
configuration and status monitoring (see
Adjustments on page 64).
adjustment (see Manual Timing Correction
on page 61).
error conditions (see Message and Error
Overview on page 113)
type)
device type)
on device type)
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5
INSTALLATION INSTRUCTIONS
5.1 Unpacking
Unpack the device, taking care not to damage it, and ensure that the operating manual is always
stored with the ignition controller and is easily accessible. Check the contents for completeness
and verify that the device type meets your application requirements.
Scope of Supply
The scope of supply of the MIC500 ignition controllers consists of the following components:
– Ignition controller MIC500
– Installation set incl. four vibration dampers
– Ground strap
– Storage device (USB flash drive or CD-ROM) with software for configuring the ignition
controller
– RS232 interface cable for connecting the ignition controller with a PC/laptop or hand-held
programmer
– Operating manual
5.2 Determine the Installation Location of the Pickup and the Trigger Disc
Depending on engine type and application, the position of the pickup must be specified. All
angle reference information is based on:
TDC 1st cylinder / Compression cycle
The installation location for the pickup must have adequate mechanical strength and must not
exceed the specified temperature ranges. The pickup is designed for its appropriate use only,
multiple use of the pickup signal is not permissible. The N+1 triggering can be carried out via the
crankshaft or the camshaft. Ensure good accessibility to facilitate the calibration of the pickup.
Comply with the pertinent regulations for the wire routing.
The precise position of the pickup is shown in the example in chapter Input Wiring – Pickup on
page 54.
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5.3 Installation of the Ignition Controller
Risk of damage!
The device must not be installed directly on or at the engine, as vibration
and heat may cause damage to electronic components.
The installation of the MIC500 ignition controller is implemented on a fixed bracket or a wall
near the engine. Always use the included vibration dampers and the ground strap. The
installation location of the device must be selected so that the distance to the pickup installed
on the engine ensures a reliable signal transmission to the ignition controller, and so that there
is adequate space for maintenance and repair work. Also ensure adequate space for the
connection wiring. The mechanical specifications must be complied with. The ground strap
serves to ground the ignition controller and must be used accordingly. Ensure a flawless
electrical connection for this purpose.
Installation locations where strong vibrations or ambient temperatures of below -40 °C (-40 °F)
or above +70 °C (+158 °F) are present are not permissible and result in the warranty being
voided.
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6 WIRING OF THE DEVICE
6.1 Input and Output Wiring on the Controller
Operational safety!
All connector screws and screw joints must be adequately tightened.
Compliance with the following tightening torques is mandatory:
– RS232 connection: 1 Nm (0.7 lb-ft)
– Connection plug 6-pole, 7-pole, 10-pole: 2.6 Nm (1.9 lb-ft)
– Connection plug 14-pole, 19-pole: 5 Nm (3.7 lb-ft)
Operational safety!
Never connect more than one output to each ignition coil, as the output
boards can otherwise be damaged!
Assignment of the wire colors
Take the assignment of the wire colors of the wiring harness for the input
and output wiring from the wiring plan enclosed with the wiring harness.
Protection when using wiring rails
Every wiring rail on the engine block should be grounded to avoid
disruptions in the device caused by secondary current in the ignition coils.
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6.1.1 Input and Output Connector – P/N 06.00.507, P/N 06.00.508
Input and output connector: left side of device, 23-pole, connector
Pin Pin assignment
1 Ignition output D
2 Ignition output C
3 Ignition output B
4 Ignition output A
5 Switch Go/NoGo
6 Not used
7 (+) 4-20 mA
8 Pickup signal
9 Ignition output E
10 Ground
11 Measuring lead (1:10)
12 (-) Supply voltage
13 (+) Supply voltage
14 Supply voltage pickup (24 V DC)
15 (-) 4-20 mA
16 Ignition output F
17 Ignition output K
18 Ignition output L
19 Digital input (Switch A/B or Switch Start/Stop)
20 Not used
21 Not used
22 4-20 mA PWR
23 Pickup ground
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6 WIRING OF THE DEVICE
6.1.2 Input and Output Connector – P/N 06.00.510
Input connector: left front, 6-pole, socket
Pole Pole assignment
A Pickup signal
B Supply voltage pickup (24 V DC)
C Pickup ground
D Switch Go/NoGo
E (+) Supply voltage
F (-) Supply voltage
right side of device, 10-pole, socket
Pole Pole assignment
A Not used
B Not used
C (+) 4-20 mA
D Digital input (Switch A/B or Switch Start/Stop)
E (-) 4-20 mA
F 4-20 mA PWR
G Not used
30 Rev. 01/2015
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