mic500cec instalacion

MOTORTECH GmbH I Hogrevestr. 21-23 I 29223 Celle I Phone: +49 5141 9399 0 I Fax: +49 5141 9399 99www.motortech.de I [email protected]

All information is subject to change. We reserve the right to change technical information.

MIC500CEC Ignition Upgrade KitInstallation Instructions

6 Cylinder P/N 75.30.11212 Cylinder P/N 75.30.113



Page 2

02. Contents of the 6 cylinder kit ...................................................................... 3

03. Contents of the 12 cylinder kit .................................................................... 3

04. General remarks and notes on safety ........................................................ 4

05. Disassembly of the governor housing ........................................................ 5

06. Pickup installation ....................................................................................... 7

07. Trigger disc installation ............................................................................. 09

08. Assembly of the governor housing........................................................... 13

09. Ignition wiring ............................................................................................ 158 cylinder wiring diagram with Murphy gas valves ........................................................... 166 cylinder wiring diagram without Murphy gas valves ...................................................... 1712 cylinder wiring diagram with Murphy gas valves ......................................................... 1816 cylinder wiring diagram without Murphy gas valves .................................................... 19Wiring colour code ......................................................................................................... 20

10. Installation of the MIC500CEC control unit .............................................. 22

11. Final wiring ................................................................................................ 24

12. Programming ............................................................................................ 26Programming chart for 6 cylinder engines ...................................................................... 27Programming chart for 12 cylinder engines .................................................................... 28

01. Contents



Page 3

02. Contents of the 6 cylinder kit

MOTORTECH P/N Quantity Description06.00.515 1 MIC500CEC Ignition Unit64.20.047 2 Mounting Bracket06.80.072 4 Vibration Dampers75.90.014 1 Cap Screw75.90.015 1 Spring Washer75.90.037 1 Cap Screw75.90.033 1 Washer06.31.034 1 Input Harness06.20.025 1 Magnetic Disc06.60.021 1 Hall-Effect Pickup75.92.001 1 Roll Pin Magnetic disc06.31.037 1 Adaptor Harness 6 Cyl. (Option A)06.31.035 1 Output Harness 6 Cyl. (Option B)75.92.002 1 Cover Plate, Drive Housing75.92.003 1 Gasket Cover Plate06.20.027 1 Nut for Timing Disc75.92.004 1 Gasket, Governor Housing

03. Contents of the 12 cylinder kit

MOTORTECH P/N Quantity Description06.00.515 1 MIC500CEC Ignition Unit64.20.048 2 Mounting Bracket06.80.072 4 Vibration Dampers75.90.014 1 Cap Screw75.90.015 1 Spring Washer75.90.037 1 Cap Screw75.90.033 1 Washer06.31.034 1 Input Harness06.20.026 1 Magnetic Disc06.60.021 1 Hall-Effect PU75.92.001 1 Roll Pin, Magnetic Disc06.31.038 1 Adaptor Harness 12 Cyl. (Option A)06.31.036 1 Output Harness 12 Cyl. (Option B)75.92.002 1 Cover Plate, Drive Housing75.92.003 1 Gasket Cover Plate06.20.027 1 Nut for Timing Disc75.92.004 1 Gasket, Governor Housing



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04. General remarks and notes on safety

To whom is this manual addressed?

This manual is a practical instruction guide issued by the manufacturer, to all persons involvedwith the installation.

Persons who are only authorized to operate gas engines must receive proper instructions fromthe operator and must be explicitly warned about the possible dangers.

What is the purpose of this operating manual?

With the aid of this operating manual, trained personnel are in a position to perform all installa-tion work.

This manual also provides assistance to gas engine design engineers. Moreover, the manual is intended to avoid the threat of fatal injury or impaired health to the

operator or a third party, which cannot be totally ruled out as far as equipment design is con-cerned.

What must the operator pay attention to?

The operator of the equipment must ensure, that all persons concerned with the installation of the MIC500CEC ignition control system have

read and understood this manual from beginning to end. that all persons authorized to operate the gas engine have received detailed instruction and

have been warned about possible dangers.

What has to be commenced before any work?

The MIC500CEC ignition control system has been designed in compliance with state-of-the-arttechnology and is operationally safe. The equipment may pose the threat of injury or suffer dam-age, if the following safety precautions are not observed. The gas engine must only be operated bytrained and authorized personnel. Before commencing any work involving the installation, operation, resetting, matching, mainte-

nance and repair of the ignition control system, the engine must be shut off and the equipmentmust be disconnected from the power supply and safeguarded against switching on the power.

Only operate the ignition control system provided it is in perfect condition, and inform your supe-rior of any modifications which have been made to the gas engine or the ignition control system.

Ensure that you observe all the rules and regulations pertaining to your equipment, includingthose which are not explicitly stated here.

Always ensure that the engine room is properly ventilated! Ensure that you maintain a safe distance from the gas engine and the ignition control system.



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05. Disassembly of thegovernor housing

Step 1:

Remove the cover of the governordrive housing.

Attention! The gover-nor drive housing isfilled with lube oil.

Step 2:

Remove the used gasket and dis-pose it.

Note! Do NOTre-use the gasket!



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Step 3:

Remove the lock nut from accessorydrive shaft.

Step 4:

Remove the oil slinger.Lock nut and oil slinger are not re-quired any longer.



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06. Pickup installation

If your governor drive housing hasalready a pickup hole (sealed with ascrew plug) go on to Step 1b.Step 1a:

To install the pickup, drill a 9/16 holein the governor drive housing and tapto 5/8 - 18 NC.Line the drill bit up with centerline ofaccessory drive shaft and 4.10 backfrom the face of the housing.Continue at Step 2.

Attention! To preventdamaging the gover-nor drive gear whendrilling, use a 4 fluteddrill bit.

Note! Particular caremust be taken to en-sure the centerline ofthe hole is perpendicu-lar to the centerline ofthe accessory driveshaft.

Note! All metal chipsfrom drilling have to beremoved lest they willinterfere the pickupsfunction.



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Step 1b:

Remove the screw plug on the top ofthe governor drive housing.

Step 2:

Install the hall-effect pickup so that youcan see its tip inside the governordrive housing.

Attention! Do notscrew in the pickuptoo deep. Otherwise itwill be damaged whileinstalling the triggerdisc!



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07. Trigger disc installa-tion

Step 1:

Crank the engine manually to TDC(Top Dead Center) cylinder number1R (right).

Step 2:

Remove spark plug lead on cylindernumber 1R.



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Step 4:

Check the correct crank shaft posi-tion of cylinder 1R at TDC by crank-ing the engine back and forth untilpressure indicating float reacheshighest position.

Step 3:

Remove spark plug and installTop Dead Center (TDC) measuringadaptor.

This tool is available underMOTORTECH P/N 06.98.009



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Indicator float

Step 5:

Crank engine clockwise (CW) to po-sition cylinder 1R at 40 BTDC.



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Step 4:

In place of the oil slinger, install mag-netic disc (watch rotation mark ondisc) and secure with provided locknut. Align the leading edge of the firstfiring magnet (marked X) with thecenterline of the pickup.

Note! Timing disc ismarked with arrow forcorrect rotation.

Step 5:

Torque the timing disc lock nut to150-160 ft.lb. (203-217 Nm)



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08. Assembly of the gov-ernor housing

Step 1:

Adjust the gap of the pickup andmagnet disc to .040.060 0.010

Attention! Contactbetween pickup anddisc can cause failureof these componentsand loss of ignition!

Step 2:

Clean the surface of the governordrive housing to allow for proper in-stallation of new gasket.



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Step 4:

Install the governor drive cover.

Step 3:

Apply sealing compound to the gov-ernor drive cover.Stick the new gasket to the cover.



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09. Ignition wiring

There are two options for wiring avail-able:

A Adaptor harness6 Cylinder P/N 06.31.037

12 Cylinder P/N 06.31.038

The ignition kit includes an adaptorharness that allows to continue theuse of the old ignition coil wiring.Connect the old existing harness tothe one end of the adaptor harnessand the other end to the MIC500CECunit.

B New wiring harness6 Cylinder P/N 06.31.035

12 Cylinder P/N 06.31.036

If the existing wiring harness is wornout a new wiring is recommended.Remove all old wiring and wire theengine according to attached wiringdiagrams.



Page 16

8 cylinder wiring diagram with Murphy gas valves



Page 17

6 cylinder wiring diagram without Murphy gas valves



Page 18

12 cylinder wiring diagram with Murphy gas valves



Page 19

16 cylinder wiring diagram without Murphy gas valves



Page 20

Wiring colour code

Colour Output CylinderRed ............ A ............ 1st Cylinder to fireYellow ........ B ............ 2nd Cylinder to fireGreen ......... C ............ 3rd Cylinder to fireBrown ........ D ............ 4th Cylinder to fireBlue ........... E ............ 5th Cylinder to fireOrange ....... F ............. 6th Cylinder to firePurple ........ K ............ 7th Cylinder to fireGrey ........... L ............. 8th Cylinder to firePink ........... M ............ 9th Cylinder to fireWhite / ....... N .......... 10th Cylinder to fireRedWhite / ....... P ...........11th Cylinder to fireYellowWhite / ....... R .......... 12th Cylinder to fireGreenWhite / ....... S .......... 13th Cylinder to fireOrangeWhite / ....... T ........... 14th Cylinder to fireBlueWhite / ....... U .......... 15th Cylinder to fireBlackWhite / ....... V .......... 16th Cylinder to firePurpleBlack ......... J ................. Ground leadNot wired ... H ................ Monitor lead



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It is recommended to use a wire pro-tection hose when installing the igni-tion wiring

Attention! Before cut-ting wire double checkwire colour code withappropriate number ofcylinder.



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10. Installation of theMIC500CECcontrol unit

Attention! It is recom-mended to install thecontrol unit on loca-tions off the engineto prevent damagesfrom temperature andvibrations.

If the control unit installationon engine is preferred please pro-ceed as follows.

Step 1:

Mount the ignition controller on thebrackets by use of vibration damp-ers.

Step 2:

Install the ground strap.

Attention! If you donot install the groundstrap it may result inrisk of life by high volt-age and the damageof equipment.



Page 23

Step 3:

Mount the brackets on the engine us-ing the existing threaded holes.

MIC500CEC unit installed.



Page 24

11. Final wiring

Step 1:

Connect the pickup lead of the inputconnector to the hall-effect pickup.

Attention! Do notbundle ignition wiringand pickup wiring to-gether. Maintain aminimum separationof 1 (25 mm).



Page 25

Step 2:

Connect the pickup lead assemblyand the ignition harness to theMIC500CEC with its provided mili-tary style plugs.

Step 3:

Remove magneto and install coverplate with above shown gasket.



Page 26

12. Programming

Read attached ignition manual care-fully.Program the controller according tothe attached programming chart.

Attention! Incorrectlyprogrammed ignitionmay result in risk of lifeand the damage ofequipment.



Page 27

Programming chart for 6 cylinder engines

(1) firing pattern = sequence-no. 21 (6 Cylinder) (2) reset position BTDC nominal: 40 BTDC actual: (3) overspeed 1350 RPM (4) security speed (max. starting speed) 400 RPM (5) misfire rate 15 (6) cyl-to-cyl-timing enabled disabled

ON/OFF ignition (7) contact I/P D STOP

A/B 2-potentiometer operation

(8) potentiometer function enabled disabled (9) speed curve potentiometer A enabled disabled (10) 4 20 mA in A enabled disabled (11) speed curve potentiometer B enabled disabled (12) 4 20 mA in B enabled disabled (13) potentiometer max. angle stop left (C(CCW): ADV BTDC: 30 ADV (14) potentiometer max. angle stop right (CW)(CW): ADV BTDC: 15 ADV (15) most advanced timing point for potentiometer AA: ADV BTDC: 30 ADV (16) most retarded timing point for potentiometer AA: ADV BTDC: 15 ADV

additional functions:

[Shift] + [E] energy (15 % - 100 %): 80% [Shift] + [H] operating hours / software rev. op. hours: software rev.:

[Shift] + [C]: cylinder cylinder adjustment ignition output: A B C D E F K L M N P R S T U V

firing order

change (+) ADV (-) RET

[Shift] + S self test [Shift] + M misfirings / sec [Shift] + R reset error



Page 28

Programming chart for 12 cylinder engines

(1) firing pattern = sequence-no. 39 (12 Cylinder) (2) reset position BTDC nominal: 40 BTDC actual: (3) overspeed 1350 RPM (4) security speed (max. starting speed) 400 RPM (5) misfire rate 15 (6) cyl-to-cyl-timing enabled disabled

ON/OFF ignition (7) contact I/P D STOP

A/B 2-potentiometer operation

(8) potentiometer function enabled disabled (9) speed curve potentiometer A enabled disabled (10) 4 20 mA in A enabled disabled (11) speed curve potentiometer B enabled disabled (12) 4 20 mA in B enabled disabled (13) potentiometer max. angle stop left (C(CCW): ADV BTDC: 30 ADV (14) potentiometer max. angle stop right (CW)(CW): ADV BTDC: 15 ADV (15) most advanced timing point for potentiometer AA: ADV BTDC: 30 ADV (16) most retarded timing point for potentiometer AA: ADV BTDC: 15 ADV

additional functions:

[Shift] + [E] energy (15 % - 100 %): 80% [Shift] + [H] operating hours / software rev. op. hours: software rev.:

[Shift] + [C]: cylinder cylinder adjustment ignition output: A B C D E F K L M N P R S T U V

firing order

change (+) ADV (-) RET

[Shift] + S self test [Shift] + M misfirings / sec [Shift] + R reset error



Page 29

(1) Sequence-Number ............................ See pages 28 and 29.(2) Reset BTDC ...................................... Position in degrees of trigger disc basic setting.

Trigger pin / hole A is opposite to pickup.(3) Overspeed ........................................ Over speed value. When reached, ignition will shut

down.(4) Security Speed .................................. The speed that controls the operation of contact A.

Contact A enables or disables the primary outputs.The Security Speed determines whether the enginespeed must go to zero after contact A is closed (toground) or if the primary outputs can be enabledwith the engine stopping.If the ignition is firing andthe speed goes above the security speed if contactA is closed, it is necessary to wait for 0 RPM beforethe primary outputs will be enabled. If the speedstays below the security speed, and contact A goesfrom closed to open, the primary outputs will beenabled and the ignition will start firing again.

(5) MIS / SEC ......................................... Max. allowed misfiring rate. When exceeded,ignition will shut down.

(6) cyl to cyl enable.................................. enables cyl-to-cyl-timingcyl to cyl disable ................................. disables cyl-to-cyl-timing

(7) contact I/P for stop .......................... contact switch lead D of 10-pin connector activatedfor ON/OFF of ignition.

contact I/P for A/B ........................... activated for operation with 2 timing schedules(8) Pot timing enable ............................ potentiometer function activated

Pot timing disable ........................... potentiometer function deactivated(9) speed curve in A in A - enable ......... speed curve for timing curve A activated

speed curve in A not in A - disable ... speed curve for timing curve A deactivated(10) 4 20 mA in A in A - enable............. 4 20 mA analog for timing curve A activated

4 20 mA in A not in A - disable ...... 4 20 mA analog for timing curve A deactivated(11) speed curve in B in B - enable ........ speed curve for timing curve B activated

speed curve in B not in B - disable .. speed curve for timing curve B deactivated(12) 4 20 mA in B in B - enable ............ 4 20 mA analog for timing curve B activated

4 20 mA in B not in B - disable ..... 4 20 mA analog for timing curve B deactivated(13) Pot CCW xx.xx ADV .......................... Potentiometer, max. angle at max. CCW position

ADV BTDC .................................... RET most retarded (0.00)



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(14) Pot CW xx.xx ADV ............................. Potentiometer min. angle at max. CW positionADV BTDC .................................... RET most retarded (0.00)

(15) max ADV A: ....................................... most advanced timing point for timing curve A (max.limit to advance)

(16) max RET A: ....................................... most retarded timing point for timing curve A (max.limit of retard)

(17) max ADV B: ....................................... most advanced timing point for timing curve B (max.limit to advance)

(18) max RET B: ....................................... most retarded timing point for timing curve B (max.limit of retard)

(19) Offset ................................................. only for 2-point adjustment to program a secondcurve B (see 6.3.1)

(20) 4 mA timing ....................................... adjustment of timing point given by analog singal(input signal: 4 mA)ADV = x degree advanced from potentiometersettingRET = x degree retarded from potentiometersetting

(21) 20 mA timing ..................................... adjustment of timing point given by analog singal(input signal: 20 mA)ADV = x degree advanced from potentiometersettingRET = x degree retarded from potentiometersetting

(22) speed points # ................................... number of speed points, required for speed curve(max. 5 points possible)

(23) BP 1 .................................................. speed point 1: - new speed = engine speed- angle = retard angle

BP 2 .................................................. speed point 2: - new speed = engine speed- angle = retard angle

BP3 ................................................... speed point 3: - new speed = engine speed- angle = retard angle

BP4 ................................................... speed point 4: - new speed = engine speed- angle = retard angle

BP5 ................................................... speed point 5: - new speed = new engine speed- angle = retard angle

(24) End / Start .......................................... ESC quit programming mode

mic500cec instalacion

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